Introduction
For truck owners who frequently haul or tow heavy loads, suspension upgrades are essential to maintain vehicle performance and safety. Hellwig Products offers a range of helper springs designed to complement factory spring packs, ensuring that trucks remain level and stable under load. These helper springs are adjustable, easy to install, and backed by a lifetime warranty. The installation process varies slightly depending on the truck’s make, model, and year, but all Hellwig helper springs are engineered to be installed with common hand tools in a home workshop setting.
This article provides a detailed, step-by-step installation guide based on information from Hellwig Products' technical documentation and product specifications. It also explores the types of helper springs available, their applications, and key considerations for installation and adjustment.
Understanding Hellwig Helper Springs
Hellwig helper springs are designed to work in conjunction with a truck’s original equipment manufacturer (OEM) spring pack to improve load-carrying capacity and stability. These springs are manufactured from heat-treated 5160 alloy spring steel and are produced in the United States at an ISO 9001-certified factory. The design of each helper spring is tailored to the specific suspension configuration of the vehicle, ensuring proper fit and function.
There are several types of Hellwig helper springs, including:
- Load Leveler Helper Springs (LP Series): These are full-time helper springs that provide continuous support and are ideal for vehicles that carry heavy loads consistently.
- Contact Helper Springs: These springs engage only when the vehicle is loaded, offering additional support without affecting the ride quality when the truck is empty.
- EZ Level Helper Springs: These are designed for lighter hauling and offer adjustable load rates for fine-tuning the suspension performance.
Each helper spring is accompanied by an installation manual that includes detailed instructions, torque specifications, and visual aids to guide the user through the installation process.
Preparing for Installation
Before beginning the installation of Hellwig helper springs, it is important to gather the necessary tools and materials. The following items are typically required:
- Basic hand tools: Wrenches, ratchets, sockets, pliers, and screwdrivers
- Vehicle jack and jack stands: For models that require lifting and wheel removal
- Wheel chocks: To secure the truck during the installation
- Torque wrench: To ensure proper tightening of bolts
- Safety gear: Gloves, safety glasses, and appropriate footwear
It is also crucial to consult the installation manual provided with the helper spring kit. The manual contains truck-specific instructions and diagrams that outline the exact steps for installation based on the vehicle’s make, model, and year.
Installation Process Overview
The installation process for Hellwig helper springs is generally straightforward, but the exact steps may vary depending on the vehicle's suspension design. Below is a general overview of the installation process based on information from Hellwig's technical documentation.
Step 1: Vehicle Preparation
- Park the vehicle on a level surface and apply the parking brake.
- Chock the wheels to prevent the truck from rolling.
- Allow the exhaust system to cool if the installation involves working near it.
- If the vehicle's design requires it, or if easier access to the OEM spring pack is desired, properly jack up the vehicle and remove the rear wheels.
Some vehicles, such as certain Ford Ranger models, do not require wheel removal for installation. In such cases, the helper spring can be installed with the wheels still in place.
Step 2: Locate the OEM Spring Pack
- Identify the OEM spring pack and ensure it is clean and free of debris.
- Determine the orientation of the helper spring based on the instructions. Some helper springs are symmetrical, while others are asymmetrical.
- Position the helper spring over the OEM spring pack, aligning it with the factory mounting points.
Proper orientation is critical to ensure that the helper spring functions correctly and provides the intended support.
Step 3: Mount the Helper Spring
- Secure the helper spring to the OEM spring pack using the provided hardware.
- Follow the torque specifications outlined in the installation manual to ensure that all bolts are tightened to the correct specifications.
- Double-check that the helper spring is properly seated and aligned with the OEM spring pack.
Some helper spring kits include U-bolts or cradles to hold the helper spring in place. It is important to ensure that all mounting hardware is properly installed and tightened.
Step 4: Lower the Vehicle and Test the Suspension
- Carefully lower the vehicle to the ground and remove the jack stands.
- Remove the wheel chocks.
- Load the truck with the expected weight (e.g., a camper or heavy cargo) and drive it for 10 to 15 miles to allow the suspension to settle.
- After the drive, inspect the helper spring for proper tension and adjust if necessary.
Adjustments may be required to fine-tune the suspension performance based on the specific load and driving conditions.
Installation Variations by Vehicle
The installation process for Hellwig helper springs may vary depending on the truck’s make, model, and suspension design. The following are some examples of how the installation process differs across various vehicle applications:
Ford F-Series Super Duty
- F-250 and F-350 Models: These vehicles often require the removal of the rear wheels to access the OEM spring pack. The helper spring is typically mounted using U-bolts and a cradle that holds it in place. The installation is designed to be completed with hand tools in a home workshop setting.
- E-450 Super Duty: This model may require the use of an installation kit, as the OEM spring pack is more complex. The LP-35 Heavy Duty Load Leveler Helper Springs are commonly used for these applications and provide up to 3,500 lbs of level load capacity.
Chevrolet and GMC Heavy-Duty Trucks
- Silverado and Sierra 3500 HD Models: These trucks are designed to accept Hellwig Contact Helper Springs, which engage with the factory contact pads to provide additional support when the vehicle is loaded. The installation is straightforward and does not require the removal of the wheels in most cases.
Ram Heavy-Duty Trucks
- Ram 4500 and 5500 Models: These vehicles are compatible with Hellwig Contact Helper Springs, which are mounted directly to the factory contact springs. The installation process is designed to be simple and does not affect the vehicle’s ride quality when it is empty.
Special Design Applications
- LP-35 Heavy Duty Load Leveler Helper Springs: These springs are ideal for fleet applications or vehicles that consistently carry heavy loads. The installation process is similar to other helper spring kits, but the LP-35 is specifically designed for 1-ton applications and provides full-time spring rate support.
Key Considerations for Installation
While Hellwig helper springs are designed to be easy to install, there are several key considerations that should be kept in mind to ensure a successful installation and optimal performance:
1. Follow the Installation Manual
Each Hellwig helper spring kit includes a detailed installation manual that provides step-by-step instructions, torque specifications, and visual aids. It is important to follow these instructions carefully to avoid damaging the vehicle or the helper spring.
2. Use Proper Tools and Techniques
Although the installation can be completed with hand tools, using a torque wrench is essential to ensure that all bolts are tightened to the correct specifications. Over-tightening or under-tightening can lead to premature wear or failure of the components.
3. Test the Suspension After Installation
After the helper spring is installed and the vehicle is lowered, it is important to test the suspension with the expected load. This allows the suspension to settle and ensures that the helper spring is providing the intended support. Adjustments may be necessary to fine-tune the suspension performance.
4. Monitor for Wear and Damage
Over time, helper springs may show signs of wear or damage, especially if the vehicle is frequently subjected to heavy loads. It is important to inspect the helper spring regularly and replace it if any signs of fatigue or damage are detected.
5. Consult a Professional if Needed
While Hellwig helper springs are designed for at-home installation, there may be cases where professional assistance is needed. If the installation process is unclear or if the vehicle has a complex suspension design, it may be beneficial to consult a qualified technician or contact Hellwig Products for additional guidance.
Troubleshooting Common Issues
Despite the ease of installation, some users may encounter issues when installing Hellwig helper springs. The following are some common problems and potential solutions:
1. Helper Spring Does Not Fit Properly
Solution: Double-check the vehicle's make, model, and year to ensure that the helper spring is the correct fit. If the helper spring is not the right fit, it should be returned or exchanged for the correct model.
2. Excessive Sag When Loaded
Solution: Adjust the helper spring tension according to the manufacturer's instructions. If the sag persists, it may indicate that the helper spring is not providing sufficient support for the load, and a different model may be needed.
3. Unusual Noises or Vibrations
Solution: Check that all mounting hardware is properly tightened and that the helper spring is aligned with the OEM spring pack. If the issue persists, it may be necessary to inspect the helper spring for damage or fatigue.
4. Difficulty in Adjusting the Helper Spring
Solution: Consult the installation manual for proper adjustment procedures. If the helper spring is not adjustable, it may be necessary to contact Hellwig Products for further assistance.
Maintenance and Longevity
Hellwig helper springs are backed by a limited lifetime warranty and are designed to provide long-term performance and reliability. However, proper maintenance is essential to ensure that the helper spring continues to function as intended.
1. Regular Inspections
It is recommended to inspect the helper spring regularly for signs of wear, corrosion, or damage. Look for cracks, bends, or any other signs of fatigue that could indicate a potential failure.
2. Lubrication of Moving Parts
If the helper spring has adjustable components, it may be beneficial to lubricate the moving parts with a high-quality grease to ensure smooth operation and prevent rust or corrosion.
3. Avoid Overloading the Vehicle
While Hellwig helper springs are designed to handle heavy loads, it is important to avoid exceeding the vehicle’s gross vehicle weight rating (GVWR). Overloading can put excessive stress on the helper spring and may lead to premature failure.
4. Replace Worn or Damaged Components
If any signs of wear or damage are detected, it is important to replace the helper spring as soon as possible. Continuing to use a damaged helper spring can compromise the vehicle’s stability and safety.
Conclusion
Hellwig helper springs offer a reliable and cost-effective solution for truck owners who need to enhance their vehicle's suspension performance. With a variety of models available, these helper springs can be tailored to the specific needs of different vehicles and applications. The installation process is designed to be simple and can be completed with common hand tools in a home workshop setting.
By following the manufacturer's instructions and using proper tools and techniques, users can ensure a successful installation and optimal performance. Regular maintenance and inspection are also essential to prolong the lifespan of the helper spring and maintain the vehicle’s stability and safety under load.
For those who need additional guidance or have questions about the installation process, Hellwig Products provides detailed installation manuals and customer support. With the right tools, knowledge, and attention to detail, users can confidently install Hellwig helper springs and enjoy improved load-carrying capacity and suspension performance.