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
6. Check installation that all bolts are torqued properly and that there is not interference with
brake lines or cables, electrical wires, fuel lines, exhaust pipes or any other chassis or suspension related component throughout the suspension travel. Reattach shock absorbers to axle
brackets and tighten bolts to factory specification.
6299 ( R-6299) 02/26/2010
559-734-7451 800-367-5480 FAX 559-734-7460
Part B Leveling Valve Installation
Subtract 1” from
reference dimension
7. Reference the ride height from step (1) and subtract 1” from this measurement. Adjust
frame height to the new measurement and place frame on jack stands. This will allow
the vehicle to have a level attitude as Dodge built in rake to accommodate compression
of the coil spring under load. The air suspension will hold ride height regardless of
load. IMPORTANT- You must reduce the rear ride height 1” to prevent the leveling
valve linkage from contacting the bed.
Remove 2 bolts
8. Remove 2 bolts from differential cover as shown. Attach leveling valve axle bracket
as shown using 5/16” X 1-1/4” bolts. Place qty (4) 5/16” washers between differential
cover and bracket at each bolt location to make bracket sit square. Torque to 10-12 ft-lb.
6299 ( R-6299) 02/26/2010
559-734-7451 800-367-5480 FAX 559-734-7460
Inlet/Exhaust Port Delivery Port
9. Prepare leveling valve for installation. The inlet and exhaust ports have a
screen across the base of the port while the delivery ports to the air springs have a
hole. See photos. Attach fittings to leveling valve as shown below. Torque fittings to 7-8 ft-lb. Do not over tighten.
1/4” tube –1/4” MPT
elbow (fitting may have
plastic elbow)
1/4” tube—1/4” MPT
connector
6299 ( R-6299) 02/26/2010
Assemble leveling valve
with long studs at top of
valve.
Locate slotted holes for valve
as shown. Clamp bracket to
frame forinitial installation.
DO NOT DRILL ANY
HOLES AT THIS TIME.
Center lever arm on
valve with 11/64” drill
10. Attach leveling valve to bracket as shown using 1/4” nylon locknuts and
washers. Tighten to 7 ft-lb. Attach leveling valve linkage pins to valve and axle
bracket in orientation shown. Make sure that the axle bracket and linkage pin
will not interfere with brake lines. Relocate brake lines as required. Tighten nuts
to 8-10 ft-lb. Assemble linkage as shown in photos and clamp leveling valve
bracket to frame crossmember in location shown so that linkage geometry
matches photo. DO NOT drill mounting holes at this time. Center leveling
valve by inserting a 11/64” drill bit through hole in arm and body of leveling
valve. When satisfied with linkage geometry, REMOVE drill bit.
Attach leveling valve to
bracket using long studs
at top of valve.
Linkage to be angled as
shown for initial layout.
Link must be attached as
shown for initial layout.
6299 ( R-6299) 02/26/2010
11. IMPORTANT– BEFORE DRILLING ANY MOUNTING HOLES IN
CROSSMEMBER, remove jack stands and lower frame so that the weight of the
vehicle is on the bump stops. CHECK POSITION OF LEVELING VALVE SO
THAT IT CLEARS AXLE ASSEMBLY AND BRAKE LINES. It will be a close
fit but there should be at least 1/2” of clearance. Relocate brake lines if required.
Also check that the leveling valve arm will not contact the floor of the vehicle or
any other components—evaporative canister, vent tube, exhaust pipe, etc. After
verifying clearances proceed to step 12—DO NOT DRILL HOLES AT THIS
TIME.
Leveling Valve Clearances with vehicle on bump stops
Check position of leveling valve
so that at least 1/2” clearance is
maintained to axle and brake lines.
Maintain at least 1” clearance
to vehicle floor when weight
of vehicle is on bump stops.
Leveling Valve clearance must be checked with weight of vehicle
on bump stops before drilling any mounting holes.
6299 ( R-6299) 02/26/2010
Leveling valve orientation at full extension
Minimum 20 deg Angle between linkage
and lever arm maintained at full extension
Good Installation—Leveling
valve will work correctly
Lever arm and linkage point at
each other at full extension
which will result in damage to
lever arm, valve and linkage.
Correct by moving leveling
valve toward passenger side
frame rail until minimum angle
Bad Installation—Leveling
valve will not work correctly
12. Reconnect shock absorbers to axle brackets and torque bolts to 60-70 ft-lb. IMPORTANT— Raise vehicle frame until the wheels come off the ground and support frame on
jack stands. Note orientation of leveling valve linkage. The leveling valve arm and link
must NOT be in line when the suspension is at full extension or the valve will not operate
properly. Ensure there is at least a 20 degree angle between the lever arm and linkage at
full extension . The leveling valve can be moved toward the passenger side frame rail to
increase this angle. The leveling valve MUST be RECHECKED at compression and nominal ride height if the leveling valve is moved to ensure that the arm and linkage will not
contact the vehicle or any of its components.
13. When satisfied with position of leveling valve and linkage has been checked for
proper operation and clearance, mark hole
location to attach leveling valve bracket to
crossmember. Drill (2) 1/4” holes and
install (2) 5/16” self tapping bolts to attach
bracket to crossmember. Torque bolts to
10 ft-lb
6299 ( R-6299) 02/26/2010
559-734-7451 800-367-5480 FAX 559-734-7460
Part C Compressor Installation
Air Filter
14. Prepare the compressor for mounting by HAND-TIGHTENING the air filter
into the port on the compressor. If necessary, adapters are provided with the
compressor to connect nylon hose from the tank to the compressor hose. Do
not remove the braided hose or check valve from the compressor. If the vehi-
cle will be operated in a manner where the compressor may draw in water,
the air filter should be remotely mounted in the cab with components included with compressor.
Blowoff Valve
3/8” Tube X 1/4”
MPT Connector
Reducer
1/4” Street Tee
Drain Valve
Relay
15. Prepare air tank as shown. Apply pipe sealant or Teflon tape to all fittings
before tightening. .
6299 ( R-6299) 02/26/2010
559-734-7451 800-367-5480 FAX 559-734-7460
Compressor hose installed to tank. Do not
tighten check valve.
16. Mount compressor to mounting plate
using fasteners supplied with compressor
as shown in photo. Connect compressor
mounting plate to the passenger side frame
rail using two of the supplied U-bolts
washers and locknuts. Mount tank to tank
bracket as shown using 3/8 x 1-1/4 bolts
and mount to frame using supplied U-bolt.
Torque nuts on U-bolts to 30-35 ft-lb.
Torque bolts to 20-25 ft-lb. Connect compressor hose to tank fitting as shown
above. Take care to tighten only the specified fitting to avoid damaging check valve
6299 ( R-6299) 02/26/2010
559-734-7451 800-367-5480 FAX 559-734-7460
Plumbing and Wiring Diagram
6299 ( R-6299) 02/26/2010
559-734-7451 800-367-5480 FAX 559-734-7460
17. Route 12 ga and 16 ga electrical wires from compressor to engine compartment along driver’s side frame rail. Make sure to fasten wires securely to existing
wire harness. Follow plumbing and wiring diagram for connection of leveling valve,
compressor, and relay. Take care when routing air and electrical lines that they will
not be crimped or chafed during installation or use. Deviation from the electrical diagram and failure to use an inline fuse holder (supplied) will void warranty. DO NOT
install fuse in inline fuse holder until all connections and circuits are verified to be completed correctly.
From air tank
To Air Springs
18. Connect air springs to leveling valve as shown. Tie strap hoses as required to avoid contact with exhaust and chafing on frame.
6299 ( R-6299) 02/26/2010
559-734-7451 800-367-5480 FAX 559-734-7460
28. After all connections have been verified, install fuse in inline fuse holder, apply park
brake and start engine with shifter in park or neutral. Due to the amperage draw of the
compressor, failure to turn engine on during initial startup may drain the battery enough to
require a jump start.
29. Test system by adding air to air springs. Disconnect linkage from arm and rotate arm
up to fill air springs. Check all connections with soapy water for leaks. After the integrity of the system is verified, reconnect linkage to valve. A MINIMUM OF 5-10 PSI
MUST BE MAINTAINED IN AIR SPRINGS AFTER INSTALLATION FOR WARRANTY TO BE VALID. FAILURE TO KEEP MINIMUM PRESSURE IN AIR
SPRINGS WILL VOID WARRANTY.
30. Recheck all components and test drive vehicle. Re-check all components for mounting and proper torque. Check clearance to all vehicle components including suspension
components, exhaust pipe, brake lines, fuel lines, hoses, etc. Re-check installation on a
regular basis afterward. The air tank MUST be drained at least every couple of weeks to
prevent condensation buildup, FAILURE TO REGULARLY DRAIN AIR TANK WILL
VOID WARRANTY.
6299 ( R-6299) 02/26/2010
Loading...