Hellwig 1250 EZ Level Helper Spring Kit Instruction Manual

1. Product Overview

The Hellwig 1250 EZ Level Helper Spring Kit is designed to enhance the load-carrying capacity and stability of your vehicle's suspension. These medium-duty helper springs are installed on top of the existing leaf springs at the rear of your truck. They work in conjunction with the stock spring pack to effectively increase the level load rating up to the vehicle’s gross vehicle weight rating (GVWR).

This system helps prevent rear-end sag when carrying heavy loads or towing, maintaining proper vehicle stance and improving handling characteristics.

2. Components Included

The Hellwig 1250 EZ Level Helper Spring Kit comes complete with all necessary components for installation. These include:

• Heavy-duty helper springs (alloy steel, heat-treated ASTM 5160)
• Powder-coated and plated mounting components
• Heavy-duty U-bolts
• All necessary hardware (nuts, washers)
• Installation instructions

Image 1: Hellwig 1250 EZ Level Helper Spring Kit. This image displays the main components of the helper spring kit, including the springs and U-bolts.

3. Installation Instructions

Installation of the Hellwig 1250 EZ Level Helper Spring Kit is designed to be straightforward, utilizing common hand tools. It is recommended to perform installation on a level surface with the vehicle securely supported.

1. Prepare Vehicle: Park the vehicle on a level surface and engage the parking brake. If lifting the vehicle, ensure it is properly supported with jack stands.
2. Position Helper Springs: Place the helper springs on top of the vehicle's existing leaf springs. Ensure proper alignment with the factory leaf spring pack.
3. Install U-Bolts: Secure the helper springs to the leaf spring pack using the provided heavy-duty U-bolts and hardware. Tighten nuts evenly to the manufacturer's specified torque settings.
4. Check for Obstructions: Verify that all components clear any existing vehicle parts, such as rebound clips or brake lines, throughout the suspension's full range of motion. Adjust positioning if necessary.
5. Final Tightening: Once positioned correctly, perform a final tightening of all U-bolt nuts. It is highly recommended to use a thread locker on all fasteners to prevent loosening due to vibrations.
6. Post-Installation Check: After driving a short distance (e.g., 50-100 miles), re-check the tightness of all U-bolt nuts and adjust as needed.

Image 2: Helper Springs Installation Diagram. This diagram illustrates how the helper springs are mounted onto the existing leaf spring assembly using U-bolts.

4. Adjustment

The Hellwig EZ Level Helper Springs are fully adjustable to accommodate varying load requirements. Adjustments are made using the heavy-duty U-bolts included in the kit, requiring only simple hand tools.

• Increasing Support: To increase the load support, tighten the U-bolts. This compresses the helper springs more, providing additional resistance to sag.
• Decreasing Support: To decrease the load support, loosen the U-bolts. This reduces the compression on the helper springs, allowing for a softer ride when unloaded.
• Independent Adjustment: For vehicles with uneven side-to-side loads, the helper springs can be adjusted independently on each side to achieve a level stance.

Always ensure adjustments are made evenly and that the vehicle remains stable. Re-check U-bolt tightness after any adjustments.

5. Maintenance

Regular maintenance ensures the longevity and optimal performance of your Hellwig Helper Springs.

• Periodic Inspection: Periodically inspect all components for signs of wear, damage, or corrosion. Check the helper springs, U-bolts, and mounting hardware.
• Fastener Tightness: Regularly check the tightness of all U-bolt nuts, especially after initial installation and after carrying heavy loads. Re-torque to specifications if necessary.
• Cleaning: Keep the helper springs and surrounding suspension components clean from dirt, salt, and debris, which can accelerate wear.

6. Troubleshooting

If you encounter issues with your Hellwig Helper Springs, consider the following common scenarios:

• Persistent Sag: If the vehicle still sags after installation, ensure the U-bolts are tightened sufficiently. Adjust the helper springs for increased support as described in Section 4. Verify that the helper springs are correctly positioned on the leaf pack.
• Uneven Ride Height: If one side of the vehicle is lower than the other, adjust the U-bolts on the lower side to increase support, or loosen them on the higher side to decrease support, until the vehicle is level.
• Hardware Issues: In some cases, U-bolts may appear too long for specific vehicle applications. Spacers (e.g., large bolts and washers) may be required to achieve proper fitment. Always ensure secure fastening.
• Interference: If components interfere with existing vehicle parts (e.g., rebound clips), minor modifications to the vehicle's existing components (such as cutting a leaf spring clamp or rebound clip) might be necessary for proper installation. Consult a professional if unsure.
• Loose Fasteners: If fasteners become loose, re-tighten them immediately. Using a thread locker during installation can help prevent this issue.

7. Specifications

8. Warranty and Support

Hellwig Helper Springs are proudly manufactured in the USA and come with a Limited Lifetime Warranty. For warranty claims, technical assistance, or any questions regarding installation or operation, please contact Hellwig customer support.

Refer to the official Hellwig website or the contact information provided with your product packaging for the most current support details.