INSTALLATION INSTRUCTIONS Air Spring Kit Ford F250 Single Wheel 4WD Ford F350 Dually 4WD (2011 F350 Single Wheel 4WD use p/n 6113)

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1 INSTALLATION INSTRUCTIONS 6108 Air Spring Kit Ford F250 Single Wheel 4WD Ford F350 Dually 4WD (2011 F350 Single Wheel 4WD use p/n 6113) 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 100 PSI 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.

2 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. Jack up frame of vehicle to allow clearance to install air spring assembly. Rest frame of vehicle on jack stands before working on or under vehicle. 2. Remove factory bump stops from vehicle by removing nuts from studs using a 15mm wrench or socket. 3. Install fitting in port of air spring. Torque fitting to approximately 20 ft-lb.

3 Brake hose bracket leave loose to be attached to a new bracket later. 3. 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. 3 Axle vent fitting 3/8 X1 Bolts torque to 20 ft-lb. Torque Air fitting to 20 ft-lb. 3/8 X 2 threaded stud to be inserted into hole on frame for bump stop stud Heat Shield pass side only 4 4. Install frame bracket to air spring with 3/8 X 1 bolts. Install heat shield as shown for passenger side only. Torque bolts to 20 ft-lb. Install 3/8 X 2 threaded stud into frame bracket as shown. 5. Attach axle bracket to bottom of air spring using 3/8 X 1 bolts and washers leave loose for adjustment later. 5

4 Remove 8mm bolt before installing air spring assembly. Replace with M8-1.25xX40 bolt and washer included in kit. 3/4 bolt 3/4 bolt without washer on inside of frame. Frame bracket will rest on cast bump stop. Driver Side Driver Side 6a 6b 6c Passenger Side 6. Driver Side: Before installing air spring assembly, remove 8mm bolt in location shown in figure 6a. This bolt will be replaced with a M8-1.25xX40 bolt and washer kit after installing air spring assembly. To install air spring assembly, insert between frame and axle as shown with the axle bracket resting on cast bump stop tongue note fit of brackets to frame and axle. Stud on frame bracket will install in hole where bump stops were attached. Fasten stud on frame bracket to frame rail with 3/8 lock nut and washer. Install 3/4 bolt, washer and nut through hole in frame rail. No washer will be used between the head of the 3/4 bolt and the inside of the frame rail on the driver side. After aligning assembly to rail, Tighten M bolt to 15 ft-lb. Then tighten nut on stud to 20 ft-lb. Finally tighten 3/4 bolt to ft-lb. If bolt is used by fifth wheel hitch mounting brackets, tighten bolt to hitch manufacturer s specifications. Special Note: If vehicle has factory installed fifth wheel hitch, do not install 3/4 bolts. See step 7 for instructions. Passenger Side : To install air spring assembly, insert between frame and axle as shown with the axle bracket resting on cast bump stop tongue -note fit of brackets to frame and axle. Stud on frame bracket will install in hole where bump stops were attached. Fasten stud on frame bracket to frame rail with 3/8 lock nut and washer. Install 3/4 bolt, washer and nut through hole in frame rail. Then tighten nut on stud to 20 ft-lb. Finally tighten 3/4 bolt to ft-lb. If bolt is used by fifth wheel hitch mounting brackets, tighten bolt to hitch manufacturer s specifications. Special Note: If vehicle has factory installed fifth wheel hitch, do not install 3/4 bolts. See step 7 for instructions.

5 Factory Installed 5th Wheel Only 7 3/8 Bolts 7. If vehicle has factory installed 5th wheel, it will cover the mounting holes for the 3/4 bolt. Do not install 3/4 bolt. Drill 2 holes in each frame rail using the frame bracket as a guide and fasten to rail using 3/8X1-1/4 Grade 8 bolts, washers and locknuts as shown. BEFORE DRILL- ING ANY HOLES IN THE RAIL RELOCATE AND/OR PROTECT ANY FUEL, ELECTRICAL OR BRAKE LINES THAT MAY INTERFERE WITH THE DRILL BIT OR INSTALLATION. 8. Insert legs of U-bolt through holes in axle bracket. Attach U-bolt using 3/8 lock nuts and washers as shown. Leave loose for adjustment later. U-bolt

6 Air Spring Bolts Flanged lock nut U-bolt Threaded Rod Locknut and washer 9 Clamp 9. Install threaded rods and flanged locknuts as shown in picture. Threaded rods should be installed so that the threads slightly protrude above top of axle bracket. Tighten flanged lock nuts to 20 ft-lb to lock threaded rods to bracket. Attach clamp to threaded rods as shown with 3/8 locknuts and washers. Reposition brake lines or cables so that they will not interfere with the bracket or the threaded rods. Tighten locknuts until ears on clamp bend slightly. Tighten locknuts on u-bolts to 20 ft-lb. Tighten bolts to air spring to 25 ft-lb.

7 3/8X1 Bolts 10a Brake Relocation Bracket 10b Brake hose bracket 10. Attach brake relocation bracket to axle bracket as shown using 3/8X1 bolts, washers and locknuts. Attach brake hose bracket to brake relocation bracket as shown using 3/8X1 bolts, washers and locknuts. Tighten bolts to 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 assembly 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, wiring harnesses, etc. Make sure that heat shields are positioned for maximum protection of air spring.

8 12. Complete passenger and driver s side installation of air spring assembly. 13.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. 14.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. 15. Inflate air springs to 40 psi and check for leaks. A soapy water solution can be used to find slow leaks. 16.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. 17.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. HELLWIG SUSPENSION SUSPENSION SYSTEMS

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