Hellwig 6110 User manual

INSTALLATION INSTRUCTIONS
6110 Air Spring Kit
Ford F150 2/4WD
Thank you for purchasing a quality Hellwig Product.
PLEASE READ THIS INSTRUCTION SHEET COMPLETELY BEFORE STARTING
YOUR INSTALLATION
IMPORTANT NOTES
DO NOT INFLATE ANY AIR SPRING ASSEMBLY UNLESS IT HAS BEEN
PROPERLY INSTALLED ON VEHICLE.
DO NOT INFLATE AIR SPRINGS OVER 50 PSI.
LOADS REQUIRING OVER 50 PSI WILL EXCEED THE GVW AND
DESIGN LIMITS OF THE VEHICLE AND MAY RESULT IN PERSONAL
INJURY AND/OR DAMAGE TO YOUR VEHICLE AND PROPERTY.
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.
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.

BEFORE STARTING YOUR 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 AND THE HOSE END
MUST NOT BE DEFORMED OR LEAKAGE MAY RESULT.
1. Park vehicle securely and set parking brake and chock wheels. Remove
factory bump stops from vehicle by removing nuts from studs using a
13mm socket.
Bump Stop
DO NOT INFLATE AIR SPRINGS OVER 50 PSI

3. Install fitting in port of air spring. Torque fitting to approximately 20 ft-lb.
2. Install frame adapter on frame using M10-1.5 flat head cap screw. Align bracket
so that the inboard holes are evenly spaced from the inside wall of the frame rail.
Torque to 25 ft-lb.
M10-1.5 Flat head cap
screw. Torque to 25 ft-lb
4. Install threaded studs into
frame adapter with countersunk
holes oriented as shown. Apply
loc-tite supplied in kit to threaded
studs before installation.
3/8” X 1-1/2” threaded stud
3/8” X 1” threaded stud
4
DO NOT INFLATE AIR SPRINGS OVER 50 PSI

5
5. Attach frame adapter to air spring as shown with 3/8” x 3/4” flat head cap
screws. Install heat shields as shown to passenger side assembly before attaching
bracket. Torque bolts to 20 ft-lb.
Passenger Side
3/8” flat head cap screws
Install heat shields as
shown on passenger
side only.
DO NOT INFLATE AIR SPRINGS OVER 50 PSI

6. Attach axle bracket to air spring as shown with 3/8” x 1” bolts and washers.
3/8” x 1” bolt
7. Disconnect brake hose bracket
from axle by removing vent tube
fitting from axle. Reconnect vent
tube fitting without brake bracket.
Brake bracket will be attached to
a new bracket later.
Vent Tube—Remove and re-
attach w/o brake bracket
DO NOT INFLATE AIR SPRINGS OVER 50 PSI

8. Install air spring assembly between frame and axle as shown. Insert threaded studs
into mating holes in frame bracket. Attach assembly with 3/8” flange nut on outboard
(3/8” x 1” ) stud first. Install frame reinforcement over inboard (3/8” x 1-1/2”) studs
as shown. Make sure frame reinforcement is squarely positioned against inboard wall
of frame rail. Tighten flange nuts to 20-25 ft-lb.
Flanged lock nut Frame Reinforcement
Flange Nut
Threaded Stud
Saddle Lock Nut
9. Attach air spring assembly to
axle with 3/8” threaded studs
as shown in photo. Insert
threaded studs into threaded
holes in axle bracket. Lock
studs to bracket with flange
nut. Attach saddle to axle us-
ing locknuts. Torque nuts to
20-25 ft-lb. Saddle will flex
as it is tightened to fit secure-
ly against axle.
DO NOT INFLATE AIR SPRINGS OVER 50 PSI

10. Attach brake relocation bracket to driver’s side air spring assembly using 3/8” x
1-1/4” bolts and locknuts. Attach brake hose bracket to relocation bracket as
shown with 3/8” x 1” bolt and locknut. Tighten bolts to 20-25 ft-lb. Reposition
brake lines as required to avoid any contact with shock absorber. Note location of
brake hoses, electrical lines or any other component that may contact air spring as-
sembly and reposition as required.
11. 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, wir-
ing harnesses, etc. Make sure
that heat shields are posi-
tioned for maximum protec-
tion of air spring.
Relocation Bracket Relocation Bracket
DO NOT INFLATE AIR SPRINGS OVER 50 PSI

10. Complete passenger and driver’s side installation of air spring assembly.
11.Select a location for the air inflation valves. The location can be on the bump-
er 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.
12.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. A length of heat shielding is provided
to protect the air line as it exits the passenger side air spring.
13. Inflate air springs to 40 psi and check for leaks. A soapy water solution can
be used to find slow leaks.
14.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 50 psi. DO NOT
run the air springs empty or warranty will be void. MINIMUM air spring pres-
sure 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.
15.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.
Maintenance and Inspection:
Your Hellwig Suspension Product is built to last. However, as with all vehicle systems, it requires routine
inspection. Inspect your Hellwig installation looking for secure hardware and tight fitting brackets. If you do
not perform this inspection, have your professional mechanic inspect as described.
DO NOT INFLATE AIR SPRINGS OVER 50 PSI

If Equipped with Hellwig Sway Bar p/n 7705
Relocate saddle brackets to inside bends
as shown for additional clearance.
SUSPENSION SYSTEMS
HELLWIG SUSPENSION