Hellwig Air 6290 User Manual

559-734-7451 800-367-5480 FAX 559-734-7460
INSTALLATION INSTRUCTIONS
6090Air Suspension Kit (pat. pending)
1999-2006 Tahoe, Suburban, Avalanche, Yukon
Thank you for purchasing a quality Hellwig Product.
PLEASE READ THIS INSTRUCTION SHEET COMPLETELYBEFORE STARTING
YOUR INSTALLATION
IMPORTANT NOTES
IF EQUIPPED WITH FACTORY PREMIUM RIDE OR AUTOLEVELSUSPENSION, CONTACT HELLWIG PRODUCTS CO. FOR FURTHER INSTRUCTIONS.
DO NOT INFLATE ANYAIR SPRINGASSEMBLY UNLESS IT HAS BEEN
PROPERLY INSTALLED ON VEHICLE.
DO NOT INFLATE AIR SPRINGS OVER 100 PSI
AMINIMUM OF 5-10 PSI MUSTBE MAINTAINED INAIR SPRINGS AFTER INSTALLATION FOR WARRANTYTO BE VALID. FAILURE TO KEEPMINIMUM PRESSURE INAIR SPRINGS WILLVOID WARRANTY.
THIS UNIT IS DESIGNED TO INCREASE THE LEVEL LOAD CARRYING CAPACITY OF YOUR VEHICLE. NEVER LOAD THE VEHICLE THIS UNIT IS INSTALLED ON BEYOND THE MANUFACTURER’S MAXIMUM GROSS VEHICLE WEIGHT RATING.
OVERINFLATIONAND IMPROPER USE MAY RESULT IN PERSONAL INJURYAND/OR DAMAGE TO YOUR VEHICLEAND PROPERTY.
6090 ( R-6090) 03/09/07
559-734-7451 800-367-5480 FAX 559-734-7460
BEFORE STARTINGYOUR PROJECT
WHEN LIFTING A VEHICLE WITH A JACK, BE SURE TO SET THE PARKING BRAKE AND USE SAFETY STANDS. ENSURE THAT THE INSTALLATION OF COMPONENTS WILL NOT CRUSH OR DAMAGE FUEL AND BRAKE
LINES OR ELECTRICAL HARNESSES. BEFORE DRILLING ANYHOLES, ENSURE THAT ALL ELECTRICAL WIRES, FUELLINES, BRAKE LINES, BRAKE
HOSES AND ANY OTHER COMPONENTS ARE MOVED OR PROTECTED TO AVOID DAMAGE FROM DRILLING ANY HOLES .
DO NOT ATTEMPT ANY MODIFICATIONS TO THE VEHICLE OTHER THAN THOSE OUTLINED IN THIS INSTRUCTION SHEET. IF ANY INTERFERENCE WITH THEGAS TANK, FUEL LINES, BRAKE LINES, EXHAUST PIPE, ETC. EXISTS, STOP YOUR INSTALLATIONAND CALL HELLWIG PRODUCTS FOR TECHNICAL HELP.
IF WHEELS ARE REMOVED FOR INSTALLATIONOF KIT, CHECK MANUFACTURERS SPECIFICATIONS FOR PROPER LUG NUT TORQUE BEFORE REINSTALLING WHEELS.
WHEN CUTTING AIRBRAKE TUBING, A SQUARE CUT IS REQUIRED AND THE HOSE END MUST NOT BE DEFORMED OR LEAKAGEMAY RESULT. IF DEFORMATION OF THE HOSE END OCCURS, THE HOSE END MUST BE REWORKED SO THAT IT IS ROUND.
ENGAGEMENTOF THE SEALING O-RING WILL BE FELT WHEN THE AIR LINE HAS BEEN INSERTED PROPERLY INTO THE FITTING. FITTINGS MAY BE DISCONNECTED IF REQUIREDBY PUSHING DOWN ON THE OUTER RING WHILE PULLING FIRMLY ON THE AIR LINE.
ROUTE AIRLINES AWAY FROM EXHAUST PIPES OR ANY OTHER SOURCESOF HEAT AND ENSURE THAT THE AIR LINES ARE PROTECTED FROM SHARP EDGES.
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PartA Air Spring Installation
Measure this distance
1. Prepare vehicle for installation by chocking front tires and setting emergency brake. Before starting installation, measure the distance from the top of rear wheel to fender lip as shown. This is the original ride height of the vehicle. Write this measurement down as this will be used to set the height of the air springs later in the installation.
2. For ease of installation, posi­tion the rear wheels on automo­tive ramps. Ensure vehicle is secure and disconnect shock absorbers from rear axle. Raise
Remove insulators from frame and axle
vehicle frame until coil springs are unloaded. Support frame with jack stands and remove coil springs and insulators from vehicle. Do not remove bump stops from frame.
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7/16UNF x 2-1/4 Bolt
Push Nut Clip
3/8 UNF Nut
Driver Side
1/2 MPT x 3/8 Hose fitting
This side of bracket faces inboard
3. Prepare driver side air spring assembly by installing 1/2” MPT x 3/8 push to connect fitting into air spring. Torque to 25-30 ft-lb. The driver side frame bracket has a full circle cut out for the air fitting instead of a cut-out on the edge. Attach frame bracket to air spring with 3/8” UNF nuts. Torque to 20 ft-lb. Place 7/16­20x2-1/4” bolt through hole in frame bracket and retain with push nut clip. Push nut can be installed on bolt by pushing on clip with a deep well socket while holding head of bolt in place.
7/16UNF x 2-1/4 Bolt
Push Nut Clip
This side of bracket faces inboard
Passenger Side
3/8 UNF Nuts
1/2 MPT x 3/8 Hose fitting
Heat Shields
4. Prepare passenger side air spring assembly by installing 1/2” MPT x 3/8 push to connect fitting into air spring. Torque to 25-30 ft-lb. The passenger side frame bracket has a cut-out on the edge of the bracket for the air fit­ting. Place two (2) heat shields on top of air spring as shown and attach frame bracket to air spring with 3/8” UNF nuts. Torque to 20 ft-lb. Place 7/16-20x2-1/4” bolt through hole in frame bracket and retain with push nut clip. Push nut can be installed on bolt by pushing on clip with a deep well socket while holding head of bolt in place.
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This end inboard This end inboard
3/8-16 x 1” Bolt
3/8-16 x 1-3/4” Bolt Install 1­1/4” spacer tube between bracket and air spring
3/8-16 x 1” Bolt
Driver Side
Passenger Side
5. Attach axle bracket to air spring as shown. The reinforcement braces are to be installed over the coil seat on the axle. Note that the bracket is installed so that the braces are under the air spring. The section of the axle bracket without braces will be installed so that it faces inboard toward the center of the axle. There are differences in how the brackets attach to the air spring for the driver and passenger assemblies. On the passenger side assembly attach the 3/8-16 x 1-3/4” bolt and 1-1/4” spacer to air spring and axle bracket as shown. Then at­tach 3/8-16 x 1” bolt to air spring through middle hole of axle bracket as shown. Snug bolts but do not tighten to allow for adjustment. On the driver side assem­bly attach the axle bracket to the air spring using the slotted holes as shown us­ing 3/8-16 x1” bolts. Snug bolts but do not tighten to allow for adjustment.
Passenger Side
3/8-16 x 1-3/4” Bolt Install 1-1/4” spacer tube between bracket and air
Coil spring seat—install bracket so that reinforcement braces center bracket on seat.
6090 ( R-6090) 03/09/07
Place frame bracket over coil spring seat
6. Compress air spring assembly and install between axle and frame. Place brackets over coil spring seats so that the cut-out in the frame bracket and the reinforcements in the axle bracket fit over the raised lip of the seat. Adjust axle brackets so that air springs sit square and tighten bolts to 20 ft-lb. Heat shields may need to be bent slightly to clear exhaust pipe.
Nut and lock washer
Frame Washer
7. To aid assembly of brackets to frame, lower frame of vehicle slightly so that the air spring assembly holds itself in place between the axle and frame. While lowering frame, DO NOT get under vehicle or place hands between axle and frame. Place frame on jack stands before continuing work. Attach frame bracket by placing frame bracket over coil spring seat so that the cut-out in the frame bracket fits over the raised lip of the seat. Place frame washer over bolt and attach bracket with 7/16”nut and lock washer. Tighten 7/16” bolt to 35-40 ft-lb. Due to the close quarters of the body and frame it is advised to hold the nut in place with a wrench and tighten the bolt head. To gain additional clearance to tighten the nut, the plastic inner fender wells can be unbolted.
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Slotted hole
8a. 1999– early 2006 models—Driver side panhard axle bracket has a large slotted hole to insert bolt through as shown. Place 3/8-16x2-3/4” bolts through slotted holes in axle bracket as shown and attach qty 2 axle straps per side to axle using washers and 3/8” locknuts. Tighten nuts until legs of axle straps bend slightly. Relocate brake lines so that they do not interfere with axle brackets, bolts, straps and air springs.
Thick washers
8b. Late 2006 models - Driver side panhard axle bracket does not have a large slotted hole. Place 3/8-16x2-3/4” bolts through slotted holes in axle bracket as shown and attach qty 2 axle straps to passenger side axle bracket using washers and 3/8” locknuts. Attach 1 axle strap to outboard side of axle bracket only as shown for early models. Place qty (2) 1/4” thick wash­ers between axle bracket and panhard axle bracket as shown. Shim axle bracket with addi­tional flat washers until bracket is parallel with axle. Insert 3/8-16 x 1-1/2 bolt and tighten locknut to 20 ft-lb. Tighten nuts on axle straps until legs of axle straps bend slightly. Relo­cate brake lines so that they do not interfere with axle brackets, bolts, straps and air springs.
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