Hellwig Air 6307 User Manual

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INSTALLATION INSTRUCTIONS

6307Air Spring Kit

2007+ Toyota Tundra 2WD & 4WD

Thank you for purchasing a quality Hellwig

Product.

PLEASE READ THIS INSTRUCTION SHEET
COMPLETELY BEFORE STARTINGYOUR
INSTALLATION

IMPORTANT NOTES

DO NOT INFLATE AIR SPRINGASSEMBLY UNLESS IT HAS BEEN

PROPERLY INSTALLED ON VEHICLE.

DO NOT INFLATE AIR SPRINGS OVER 100 PSI

AMINIMUM OF 5-10 PSI MUST BE MAINTAINED IN AIR SPRINGS
AFTER INSTALLATION FOR WARRANTY TO BE VALID. FAILURE TO
KEEPMINIMUM PRESSURE INAIR SPRINGS WILLVOID WARRANTY.

THIS UNIT IS DESIGNED TO INCREASE THE LEVELLOAD CARRYING
CAPACITY OFYOURVEHICLE. 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 DAMAGETO YOUR VEHICLEAND PROPERTY.

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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 ANY HOLES, ENSURE THAT ALL ELECTRICAL WIRES, FUEL LINES,
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 THE GAS TANK,
FUEL LINES, BRAKE LINES, EXHAUST PIPE, ETC. EXISTS, STOP YOUR INSTALLATION AND
CALL HELLWIG PRODUCTS FOR TECHNICAL HELP.

IF WHEELS ARE REMOVED FOR INSTALLATION OF KIT, CHECK MANUFACTURERS
SPECIFICATIONS FOR PROPER LUG NUT TORQUE BEFORE REINSTALLING WHEELS.

WHEN CUTTING AIR BRAKE TUBING A SQUARE CUT IS REQUIRED OR LEAKAGE MAY
RESULT.

1. Park vehicle securely and set parking
brake and chock wheels. Prepare vehicle
for mounting air springs by removing
ABS cable from its mounting points as
shown in photos

Cut tie strap at
this location.

Pry open clip to remove cable
from clips in these locations. .

Cut tie strap at
this location.

Pry open clip to remove ca­ble from clip.

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Crimp cable into bracket.

2. Reattach ABS Cable to upper bracket as shown in photos and crimp cable to bracket.

Attach mounting bracket
with offset to front of vehicle

3. Remove ABS bracket from axle and attach relocation bracket to axle with
the offset in the bracket towards the front of vehicle. Torque bolt to 10 ft-lb.
Attach ABS axle braket to relocation bracket as shown in photo with 5/16” bolt
and locknut. Torque to 10 ft-lb.

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Rear View

Tie strap cable
to bracket at
this location.

View under driver side spring

Front View

Crimp cable to
bracket at these

Gently pull cable
through isolator to
allow adequate slack
in cable.

4. Attach ABS cable to axle bracket as
shown in photos. It may be necessary to
gently pull the cable through the rubber
isolators on bracket, at the top of axle,
and under the driver side spring to allow
enough slack in cable to properly attach
cable to bracket. Crimp tie strap cable to
bracket as shown in photos.

Gently pull cable through
isolator to allow adequate
slack in cable.

5. Remove bolt attaching emergency
brake bracket to axle on both the driver
and passenger side to allow installation of
U-bolts at a later step.

Remove bolt attaching emergency
brake bracket.

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Passenger Side

Finger on tab
must be located
on forward side
of axle.

Install tab behind flange
on axle bracket.

6. Attach tab to axle bracket as shown using the 3/8 X 1” bolts, small washers,
and locknuts. Torque bolts to 25 ft-lb. The finger on the tab must be located so
that it is on the forward side of the axle. This will result in the driver and pas­senger assemblies having the tab oriented in opposite directions. The tab must
be installed on the back side of the axle bracket flange to allow proper clearance
to the welded ABS cable mounting tabs on the axle.

7. Install air fittings into air springs
and torque to 20 ft-lb.

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8. Attach air spring to axle bracket assembly using the 3/8” flanged locknuts.
Leave loose for adjustment later. Orient fitting in air spring so that it points for­ward when installed on vehicle.

This side toward wheel

Attach air spring to plate us­ing countersunkhole.

Long End to front of vehicle

Short End to rear of vehicle

Washer must be facing up.

Front of Vehicle (Pass Side Shown)

9. Prepare frame bracket for installation on air spring assembly. There is a left and a
right frame bracket. The washer that is welded to the bracket is assembled facing up.

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10. Attach frame bracket and
heat shield to air spring assem­bly using the 3/8” flat head cap
screw. Orient frame bracket as
shown in photo so that the long
end points forward and the
washer is facing up. (Passenger
side shown—heat shield is not
installed on driver side)

Forward

11. Insert air spring assembly between

Center slots on
rivets.

frame rail and axle as shown so that slots
in frame bracket are centered on rivets of
bump stop bracket on frame rail. Insert
carriage bolts into slots in axle bracket as
shown.

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3/8 X 7” Bolt
Note Orientation

U-Bolt

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12. Attach outboard holes in frame
bracket to slotted holes in crossbars
using 3/8 X 7” bolts washers and
locknuts and slide crossbars over
the top of the frame rail with the
threaded hole facing inboard.
( Note orientation of bolts.) Attach
inboard holes in frame bracket to

3/8 X 6-1/2” Bolt

threaded hole in crossbar using 3/8
X 6-1/2” bolts. Position frame
bracket and tighten bolts to 25 ft-lb.

ABS Cable

Tie Strap

Axle Strap

Air Spring Studs

13. Install U-bolt around axle pad and insert legs of U-bolt through tabs in axle
bracket as shown. Attach U-bolt with 3/8” locknuts and washers. Attach axle strap
to carriage bolts using 3/8” locknuts and washers. Tighten U-bolts and carriage bolts
until tabs bend slightly. Make sure not to pinch the ABS cable. Tie strap ABS cable
to leg of U-bolt and shown. Align air spring and tighten locknuts on air spring studs
to 20 ft-lb. Reattach emergency brake cable brackets and tighten bolt to 7-10 ft-lb.

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14. Complete passenger and driver’s side installation of air spring assembly.

15. Cut air brake lines to length and connect air lines to fittings by pushing the air line into
the air fittings as far as possible. WHEN CUTTING AIR BRAKE TUBING, ASQUARE

CUT IS REQUIRED AND THE HOSE END MUST NOT BE DEFORMED OR LEAK­AGE MAY RESULT. IF DEFORMATION OF THE HOSE END OCCURS, THE
HOSE END MUST BE REWORKED SO THAT IT IS ROUND. Engagement of the

sealing O-ring will be felt when the air line has been inserted properly into the fitting. Fittings
may be disconnected if required by pushing down on the outer ring while pulling firmly on
the air line. Route air lines away from exhaust pipes or any other sources of heat and ensure
that the air lines are protected from sharp edges.

Shielding

Tie Strap air line to emer­gency brake cable frame
bracket. Lines can be

Tie Strap

Shielding

routed as required after
this point.

16. Route air lines as shown along the emergency brake cables. Lines MUST be
routed as shown with shielding and tie straps installed on air lines as shown. Fail­ure to install air lines as shown will result in excessive flexing of air lines and po­tential leaks. Air lines can be routed as required after being tie strapped to the
emergency brake cable frame bracket.

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17. Check your installation to ensure
that all fasteners are tight and that the
assembly and all fasteners clear brake
and fuel lines, emergency brake ca­bles, fuel tanks, wiring harnesses, etc.

18.Select a location for the air inflation valves. The location can be on the bumper or body
of the vehicle where an air chuck can be used to inflate the air springs. Select a location
where the valve will not be damaged or interfere with the operation of other compo­nents.

19.Inflate air springs to 40 psi and check for leaks. A soapy water solution can be used to
find slow leaks.

20.When satisfied with integrity of the system, adjust air pressure to desired level. The air
springs can be inflated to any level between 10 and 100 psi. DO NOT run the air
springs empty or warranty will be void. MINIMUM air spring pressure is 5 psi. Failure
to keep air in the air springs will void the warranty. For best RIDE use only enough air
pressure as required to level the vehicle. If a firmer ride is desired, more pressure can be
used.

21.Check air pressure in the system regularly to ensure system performance and mainte­nance of warranty. Just like tires, the air pressure in the system will vary due to tem­perature changes. For your air spring system to function properly it must be checked on
a regular basis.

ATTENTION INSTALLER: BE SURE THATTHE CUSTOMER RECEIVES

THIS INSTRUCTION SHEET, ALL IMORTANT NOTE CARDS AND THE WAR­RANTY FORM.

6307 ( R-6307 ) 12/06/07