Hellwig Pro Series Standard User Manual

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

INSTALLA TION INSTRUCTIONS

Thank you for purchasing a quality Hellwig Product.

PLEASE READ THIS INSTRUCTION SHEET COMPLETELY BEFORE STARTING YOUR INSTALLATIONPROCEDURES.

2” max adjustment

Leaf Stack

Hat Section

Straight U-bolt

2” max adjustment

Main Leaf

Second Leaf

Crossbars

Main Spring

Offset U-bolts

Leaf Tip

TORQUE TABLE

BOLT SIZE: 3/8” = 20-30 ft. lbs. – 7/16” = 35-45 ft. lbs. – ½” = 50-70 ft. lbs. – 9/16” = 70-90 ft. lbs

SAFETY: PARK YOUR VEHICLE ON A FLAT LEVEL SURFACE, SET THE PARKING AND CHOCK THE FRONT TIRES.
NOTE: THIS KIT INCLUDES LOCKNUTS WHICH REQUIRE TIGHTENING WITH A WRENCH AFETR BEING STARTED BY

HAND.

NOTE: IF YOUR VEHICLE IS EQUIPPED WITH A BRAKE FLUID PROPORTIONING VALVE ON THE REAR AXLE READ

INSERT (R-362)

IMPORTANT NOTE: IF YOUR VEHICLE IS EQUIPED WITH A FACTORY CONTACT OVER LOAD IT MUST BE REMOVED

BEFORE INSTALLING THE NEW HELPER SPRINGS.

IMPORTANT NOTE: HELLWIG HELPER SPRINGS ARE DESIGNED TO INCREASE THE “LEVEL LOAD” CARRYING

CAPACITY OF YOUR VEHICLE. NEVER LOAD THE VEHICLE THAT THIS UNIT IS INSTALLED ON BEYOND THE
MANUFACTURER’S MAXIMUM GROSS VEHICLE WEIGHT RATING.

1. Raise the rear of the vehicle by the frame so that the rear tires are just slightly contacting the floor. Be sure to
block the front tires and use Jack Stands to support the vehicle by the frame.

2. Lay out the spring leaves into two (2) sets. Each will consist of a main leaf with u-bolt cups and a second leaf
without cups. Lay the leaves so that the long ends are all in the same direction. Stack the leaves so that the
main leaf is on top. The long end of the spring stack must be installed toward the rear of the vehicle and the
short end toward the front.

3. Place the spring stack on top of the main spring with the long end toward the rear of the vehicle.

4. Place the U-bolts with the straight legs in the cups at the ends of the spring. Loosely install the crossbars using
the hardware provided.

5. Adjust the crossbar s on the end of the springs so that the adjacent leaf tip will not make contact with the
crossbar when the spring is deflected. It may be necessary to move the spring stack fore or aft for best
alignment.

6. Install the offset U-bolts with the offset toward the axle as shown in the diagram. The U-bolt should be
fastened as close to the hat section as possible. If you are working on 2-1/2” wide springs position the
outboard U-bolt leg against the outboard edge of the main spring to maximize brake hose, caliper, and backing
plate clearance. The U-bolts may also be installed with the legs pointing up and crossba rs on top of spring to
provide additional clearance if required. Install the crossbar with the washers and nuts to connect to the main
spring. Torque the nuts to 65 ft-lb and double nut.

008 ( R-008 ) 11/27/05

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

7. Adjust the U-bolts at the end to desired preload. The minimum tension adjustment is having enough tension on
the end U-bolts so that they do not loosen or rattle and move when the vehicle is driven over rough or bumpy
surfaces. Maximum adjustment is when the leaf cups have been deflected two (2) inches from their free state.
DO NOT EXCEED THE MAXIMUM ADJUSTMENT OF 2 INCHES.

8. When adjustment is complete, double nut to lock in adjustment.

9. Lower vehicle to the ground and check your installation for clearance on all undercarriage components; wires,
fuel, brake, and air conditioning lines. Test drive the vehicle and recheck your installation, adjust as needed.
Recheck on a monthly basis thereafter.

IMPORTANT NOTE: CHECK YOUR INSTALLATION. ARE ALL NUTS AND BOLTS SECURELY

TIGHTENED AND DOUBLE NUTTED WHERE PROVIDED? BOUNCE THE VEHICLE CHECKING
FOR CLEARANCE ON ALL UNDERCARRAIGE COMPONENTS, MUFFLERS, GAS FILLER PIPES,
BRAKE LINES, EMERGENCY BRAKE CABLE, AIR CONDITIONING LINES, RUBBER BOTTOMING
PADS, ETC.

IMPORT ANT NOTES, WARNINGS AND TIPS

Before attempting the installation of any Hellwig Accessory Spring , be sure and identify the vehicle to which the
accessory spring will be installed as either being or not being equipped with height sensing brake fluid proportioning
valve. If a vehicle is equipped with the brake fluid proportioning valve on the rear axle, it is recommended that any
Hellwig Full Time Accessory Spring NOT be installed. Only the Progressive Rate Accessor y Springs are to be in­stalled on these vehicles. Some of the vehicles manufacturers (FORD, GM, DODGE) have recommended an adjust­ment or modification of the brake system. If the vehicles height or weight requirements have been changed due to the
suspension modifications or unusual load situations, contact your local dealer for correct adjustment after installation.

If you have any questions about the application, please contact Hellwig Products Company.

ATTENTION INSTALLER: BE SURE THAT THE CUSTOMER RECEIVES THIS INSTRUCTION SHEET,

ALL IMORTANT NOTE CARDS AND THE WARRANTY FORM

008 ( R-008 ) 11/27/05