Hellwig Air 6299 User Manual

559-734-7451 800-367-5480 FAX 559-734-7460
INSTALLATION INSTRUCTIONS
6299Air Suspension Kit (pat. pending)
2009+ Dodge 1500 Pickup with Rear Coil Springs
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 SPRINGASSEMBLYUNLESS 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.
6299 ( R-6299) 02/26/2010
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.
6299 ( R-6299) 02/26/2010
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.
6299 ( R-6299) 02/26/2010
Place frame bracket over coil spring seat
Place retainer plate on top of frame so that axle bracket can be retained by 1/2” bolt
Attach frame bracket to re­tainer plate with 1/2x2-1/2” bolt through hole in bracket and engage threaded hole in plate.
3. Place retaining plate on top of rail as shown. Locate frame bracket on coil spring seat as shown with the notch pointing outboard. Insert 1/2 x 2-1/2 UNC bolt through hole in frame bracket and tighten into threads in frame plate. Align bracket to be square with the frame and axle and tighten bolt to 35 ft-lb.
6299 ( R-6299) 02/26/2010
3/8 x 2 Flat head cap screw and spacer. Torque to 20 ft-lb.
Passenger Side Shown Driver Side Opposite
Install air spring to axle bracket as shown so that fit­tings will point out­board when in­stalled on vehicle.
Install bracket on air spring so that notch is located on forward in board side when installed on axle.
3/8 x 3/4 bolt and washer. Torque to 20 ft-lb.
4. Assemble air spring to axle bracket as shown. Make sure to orient axle bracket so that the notch will clear brackets welded to axle assembly. Install fittings in air spring and torque to 20 ft-lb.
6299 ( R-6299) 02/26/2010
Drill 13/32” (.406) hole in bump stop flange for 3/8” bolt.
5. Install air spring assembly on axle as shown. Insert studs in air spring through holes in frame bracket and attach air spring using 3/8” fine thread nuts. Torque to 20 ft-lb. Insert car­riage bolts into outer slotted holes and attach strap to axle with 3/8” washers and locknuts. Leave loose for adjustment later. Align air spring and mark hole for 13/32” (.406) hole to be drilled in axle bump stop flange as shown. Attach axle bracket to flange using 3/8 X 1” bolt, washers and locknut. Tighten bolt to 20-25 ft-lb. Tighten carriage bolts to 20 ft-lb.
6299 ( R-6299) 02/26/2010
Loading...
+ 11 hidden pages