Hellwig Air 6299 User Manual

559-734-7451 800-367-5480 FAX [phone]

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 [phone]

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