Ford - Transit - Parts Catalogue - 2006 - 2020

Auxiliary Air Suspension Installation Manual L.TRA.EA.C.M Ford Transit Mark 6; V184 (2000—2006) Ford Transit Mark 7; V348 (2006 onwards) RWD Single Tires July 2011 www.dunlopsystems.com Ford Transit V184 and V384 Rear Wheel Drive single tire L.TRA.EA.C.M CONTENTS 1. 2. 3. 4. 5. FOREWORD .......................................................... INTRODUCTION .................................................... VERY IMPORTANT NOTES ........................................ OVERVIEW ........................................................... INSTRUCTIONS FOR INSTALLATION ......................... 3 4 5 7 8 5.1. Removal of Bump Stop from Chassis ............................................. 8 5.2. Attachment of Upper Bracket to Chassis ......................................... 8 5.3. Installation of the Air Spring ......................................................... 9 5.4. Load Sensing Valve (LSV) Adjustment.......................................... 10 5.5. Fitting of Inflator Console ........................................................... 11 5.6. Tube Connection and Disconnection, Cutting and Routing ............... 11 5.7. Spring Inflation......................................................................... 13 5.8. Spring Alignment ...................................................................... 14 5.9. Maintenance............................................................................. 14 5.10. Installation Drawings ............................................................... 15 6. EPILOGUE ............................................................ 19 Dunlop Systems and Components Het Wegdam 22 7496 CA Hengevelde Nederland Tel. +31 (0)547 33 30 65 Fax. +31 (0)547 33 30 68 Dunlop Systems and Components Holbrook Lane Coventry CV6 4QX United Kingdom Tel. +44 (0)24 7629 3300 Fax. +44 (0)24 7629 3390 www.dunlopsystems.com © 2008, Dunlop Systems and Components 2 www.dunlopsystems.com Ford Transit V184 and V384 Rear Wheel Drive single tire L.TRA.EA.C.M 1. FOREWORD This manual provides instructions for the installation of an auxiliary air suspension kit, developed specifically for the Ford Transit Mark 6; V184 (2000—2006) and the Ford Transit Mark 7; V348 (2006 onwards) Single tire Rear Wheel Drive. To ensure correct installation of the kit, it is strongly recommend that these instructions are read thoroughly before commencing any installation work. Installation should only be carried out by a suitably qualified mechanic or specialist installation facility. Dunlop Systems and Components will not accept any responsibility for faults or defects arising from incorrect installation, which automatically renders the guarantee invalid. IMPORTANT : Manufacturer’s Declaration Form A manufacturer’s declaration form is provided with your kit. Following installation of the kit please ensure that this form is completed, signed by a qualified fitter and returned to Dunlop Systems and Components. 3 www.dunlopsystems.com Ford Transit V184 and V384 Rear Wheel Drive single tire L.TRA.EA.C.M 2. INTRODUCTION Thank you for choosing an auxiliary air suspension kit from the range offered by Dunlop Systems and Components. Auxiliary air suspension is fitted in tandem with the standard steel springs of the vehicle suspension, and provides enhancements in terms of both the stability of the vehicle and the comfort of the passengers… Vehicle Levelling Simply by varying the air pressure in the springs, the vehicle can be levelled both front-to-rear and side-to-side. Keeping the vehicle level optimises stability, ensures correct headlamp beam distribution and reduces tyre wear arising from uneven distribution of weight. Straight Line Stability Straight line stability is greatly increased at higher speeds, and when subjected to buffeting from cross-winds or large overtaking vehicles. Reduced Body Roll Body roll when cornering or negotiating roundabouts is significantly reduced. Fatigue Reduction and Wear Compensation Suspension fatigue is reduced, so helping to prevent leaf springs from sagging under repeated or constant loading. Any sagging already present can be compensated-for. This is a particular benefit for motorhomes, which are always fully laden. Ride Comfort Air springs help to absorb shock loads from uneven road surfaces, therefore general ride quality is much improved. 4 www.dunlopsystems.com Ford Transit V184 and V384 Rear Wheel Drive single tire L.TRA.EA.C.M 3. VERY IMPORTANT NOTES Gross Vehicle Weight (GVW) Air assist kits are not in themselves designed to increase the gross vehicle weight (GVW) rating of a vehicle. They do not legally allow for carriage of a load greater than the carrying capacity stated on the data plate of the vehicle. Do not exceed the maximum load specified by the vehicle manufacturer… ♦ to avoid compromising passenger safety ♦ to prevent possible damage to the vehicle ♦ for legal reasons Load Sensing Valve (LSV) Adjustment If your vehicle is not fitted with an antilock braking system (ABS) then it will have a load sensing valve (LSV) to automatically adjust braking force under varying load conditions. This valve must be adjusted immediately after the fitting of an air assist kit and before the vehicle is driven again on public roads. If the LSV is not adjusted following the fitting of an air assist kit, it may misjudge rear load conditions to the extent that the braking pressure applied to the rear brakes is not correct (e.g. the rear wheels may lock with no load on the rear axle). The consequences of this in terms of vehicle stability and safety are potentially serious. Vehicle Uprating Despite the above words of caution, it is possible to upgrade the weight rating of your vehicle. This must be carried-out by a specialist supplier that will… ♦ carry out any necessary modifications in addition to fitting the air assist kit ♦ complete documentation as necessary to inform the Vehicle and Operator Services Agency (VOSA) – a mandatory requirement ♦ supply and fit a new weight plate to replace the original plate supplied with the vehicle This process applies to United Kingdom registered vehicles. The process in other countries may be different. 5 www.dunlopsystems.com Ford Transit V184 and V384 Rear Wheel Drive single tire L.TRA.EA.C.M Safety Guidance Note The following very useful guidance note is available for free download from the Health and Safety Executive (HSE)… PM85, July 2007 Safe recovery (and repair) of buses and coaches fitted with air suspension The uniform resource locator (URL) for this document is… http://www.hse.gov.uk/PUBNS/pm85.pdf 6 www.dunlopsystems.com Ford Transit V184 and V384 Rear Wheel Drive single tire L.TRA.EA.C.M 4. OVERVIEW The diagram below is an overview of the complete assembly... * front rear Number * Part Number Description Quantity 21.04.00.1.01.01 Top Bracket, Left and Right 2 21.04.00.1.01.02 Bushing Top Bracket 2 21.04.00.1.04 Lower Bracket, Left 1 21.04.00.1.05 Lower Bracket, Right 1 OP.LB.170-2.CPL Air Spring, 170/2 2 * only 2000 - 2006 7 www.dunlopsystems.com Ford Transit V184 and V384 Rear Wheel Drive single tire L.TRA.EA.C.M 5. INSTRUCTIONS FOR INSTALLATION Preparation and Precaution Before beginning installation, ensure that you have sufficient clearance between the axle and the chassis. Use a jack if necessary. Install at one side of the vehicle at a time. Pay attention to your safety at all times during installation always use axle stands to support the vehicle! The following instructions make reference to the diagrams on pages 17 to 18 inclusive. 5.1 Removal of Bump Stop from Chassis i. Your vehicle will have one of two shapes of rubber bump stop fitted to the chassis, either broadly oblong or round. See page 15 Oblong Bump Stop ii. Unscrew and Remove the bolt from the ‘tab’ bracket at one end of the bump stop—Figures 1 iii. Rotate the bump stop downwards from the end now freed and remove it from the chassis by unhooking the clip at the other end—Figures 2 Round Bump Stop ii. Unscrew and Remove the single, centrally-located bolt from the bump stop and lower it away from the chassis—Figures 6 and 7 8 www.dunlopsystems.com Ford Transit V184 and V384 Rear Wheel Drive single tire L.TRA.EA.C.M 5.2 Attachment of Upper Bracket to Chassis i. The upper bracket is attached to the chassis in the area left vacant by removal of the bump stop. The method of attachment is a little different depending upon which type of bump stop was removed… Oblong Bump Stop ii. Feed the top bracket up to the chassis, taking care to orientate correctly (longest protruding part of bracket nearest to the wheel) Figure 3 iii. Attach the bracket to the chassis using the long bolt, tube, washers and nut as shown in Figures 4 and 5. Note that (a) the bolt is inserted from the wheel-side of the chassis and (b) the larger of the two washers is on the inside of the chassis. Round Bump Stop ii. Feed the top bracket up to the chassis, taking care to orientate correctly (longest protruding part of bracket nearest to the wheel) Figure 7 iii. Attach the bracket to the chassis using a single bolt and spring washer, making use of the threaded hole left vacant by removal of the bump stop—Figure 8 (always check the pitch of the threat) 5.3 Installation of the Air Springs i. Position the lower bracket against the flange beneath the axle — Figure 9 ii. Attach the lower bracket to the flange via two bolts, two nuts and four flat washers — Figure 10 iii. Place the air spring onto the lower bracket with the air tube uppermost and then pass the tube through the large hole in the upper bracket iv. Attach the air spring to the lower bracket using two M8 x 16mm bolts and two M8 washers. Do not fully tighten the bolts at this stage because the bellow may require alignment once inflated (Figure 11, Section 5.8). v. Remove the bung from the tube. The spring now inflates until its top plate comes into contact with the upper bracket of the air assist kit. vi. Attach the upper bracket to the top plate of the air spring using two M8 x 16mm bolts and two M8 washers. Do not fully tighten the bolts at this stage because the bellow may require alignment once inflated (Figure 11, Section 5.8). 9 www.dunlopsystems.com Ford Transit V184 and V384 Rear Wheel Drive single tire L.TRA.EA.C.M The following instructions are only for vehicles without ABS. This may concern some vehicles from 2000 up to 2006. 5.4 Load Sensing Valve (LSV) Adjustment Vehicles without an antilock braking system have a load sensing valve fitted. This has a spring linkage as shown by Figures 12 and 13. The LSV must be adjusted. This is a relatively simple matter of adjusting the length of the spring linkage via the adjustment ring until the length of the rod is the same as it was before beginning installation. i. Deflate the air bellows completely, measure and record the length A of the spring from the top mounting bracket to the tip of the linkage rod Figure 15. ii. Inflated such that the desired vehicle ride height is achieved,( Mostly is the rear side of the vehicle app. 4 cm higher then front side, which is approximately 13,5 cm air bellow height). iii. measure and record the length b of the spring from the top mounting bracket to the tip of the linkage rod Figure 16. iv. Disconnect the bracket of the LSV from the rear axle Figure 17. v. The adjustment ring has a screw that locks it to the rod when tightened and enables the ring to slide along the rod when loosened. Move the adjustment ring upwards over a length of A-B Figure 18. vi. Connect the LSV bracket again to the axle and the adjustment is done. 10 www.dunlopsystems.com Ford Transit V184 and V384 Rear Wheel Drive single tire L.TRA.EA.C.M 5.5 Fitting of Inflator Console Standard Option 1 Option 2 Option 3 Your kit is supplied with one of the inflator console options shown above… • ‘Standard’, having two valves only (above, top-left) ‘Option 1’, ‘Option 2’ or ‘Option 3’, having both valves and pressure • gauges Mount the console in a position of your choice whereby it is firmly fixed, has some protection from the environment (particularly important for the console with gauges) and is easily accessible. Suggested possible locations include... ‘Standard’ Console… • on the rear bumper • at the rear beside the license plate • on the chassis next to a rear wheel • in a service shutter • beside the fuel cap ‘Option 1’, ‘Option 2’ or ‘Option 3’ Console… • in the vehicle cabin, within reach and sight of the driver • in the wall of a cupboard (motorhomes) • in a service shutter ‘Comfort’ Packages The ‘Option 2’ and ‘Option 3’ panels, as shown above, are each part of a Comfort Package that is supplied with a compressor (and also an air reservoir in the case of the ‘Option 3’ panel) for ease of spring inflation and ride height setting. For further information please ask your dealer. 11 www.dunlopsystems.com Ford Transit V184 and V384 Rear Wheel Drive single tire L.TRA.EA.C.M 5.6 Tube Connection and Disconnection, Cutting and Routing Connection and Disconnection Tubes are connected as shown by the diagrams below... A A. B. C. B C Slide a nut over the end of the tube Push the tube onto the connector as far as possible Feed the nut up to the connector, fully tighten by hand and finally tighten one additional turn using spanners Cutting To achieve good sealing and air-tight fitting of tube ends to their connecting parts, it is very important to cut tubing cleanly and squarely. A dedicated guillotine action tubing cutter is recommended, or a craft knife if such a tool is not available. Do not use electrician’s side cutters. A dedicated tubing cutter Recommended Electrician’s Side Cutters NOT Recommended 12 www.dunlopsystems.com Ford Transit V184 and V384 Rear Wheel Drive single tire L.TRA.EA.C.M Routing Study the underside of the vehicle and decide how to route each branch of the air circuit… • To minimise the risk of chafing, avoid running tubing over metal edges as much as possible • Avoid close proximity to heat sources such as the exhaust assembly • Choose a route that provides as much protection as possible from dirt, debris and any solid objects that may impact the underside of the vehicle It is recommended that tubes are guided alongside brake lines as much as possible. Use cable ties (‘tie wraps’) to secure tubing to the chassis, taking care not to over-tighten them. 5.7 Spring Inflation Once installation of the air assist kit is complete, inflate the springs via the inflator console taking careful note of the following... Maximum and Minimum Pressure Maximum Pressure 7.0bar Minimum Pressure 0.5bar Do not exceed 7.0bar (101psi), which is the recommended maximum charge pressure for the air springs. The springs may be deflated if the vehicle is to be stored for a lengthy period without use, but a pressure of at least 0.5bar (7.25psi) should be maintained at all times in order to avoid possible compression damage to the springs. 13 www.dunlopsystems.com Ford Transit V184 and V384 Rear Wheel Drive single tire L.TRA.EA.C.M 5.8 Spring Alignment Spring out of alignment mounting plate axes offset Spring in alignment mounting plates parallel and coaxial CAUTION! Before fully tightening the bolts that secure the air spring to the upper and lower brackets, set the vehicle at ride height (spring height approximately 13.5cm) and ensure that the springs are correctly aligned. 5.9 Maintenance Following installation, it is recommended that all metal parts are coated with a protective substance such as body wax. The system does not require very much maintenance other than… ♦ to maintain air pressure in the springs. Much like a tyre, the system may lose a little air over time. ♦ to keep the air bellows clean. It is suggested that, when washing the vehicle, the bellows are inspected and cleaned as necessary (preferable by spraying). Look in particular for stones or grit trapped between convolutes, as this may damage the bellow. ♦ Check before and after the winter period the wax coating. Re-wax when necessarily 14 www.dunlopsystems.com Ford Transit V184 and V384 Rear Wheel Drive single tire L.TRA.EA.C.M 5.10 Installation Drawings Ford Transit V184 (2000—2006) Ford Transit V384 (2006-present) 15 www.dunlopsystems.com Ford Transit V184 and V384 Rear Wheel Drive single tire L.TRA.EA.C.M 1 2 3 4 5 16 www.dunlopsystems.com Ford Transit V184 and V384 Rear Wheel Drive single tire L.TRA.EA.C.M 6 7 8 9 10 11 Spring out of alignment—mounting plate axes offset Spring in alignment— mounting plates parallel and coaxial CAUTION! Before fully tightening the bolts that secure the air spring to the upper and lower brackets, set the vehicle at ride height (spring height approximately 13.5cm) and ensure that the springs are correctly aligned. 17 www.dunlopsystems.com Ford Transit V184 and V384 Rear Wheel Drive single tire L.TRA.EA.C.M Vehicles with a Load Sensing Valve only (no ABS) 12 13 14 15 16 17 18 18 www.dunlopsystems.com Ford Transit V184 and V384 Rear Wheel Drive single tire L.TRA.EA.C.M 6. EPILOGUE Dunlop Systems and Components hopes that you enjoy the benefits that your air suspension system will provide for you. To ensure optimal performance, we advise that you have your system checked frequently by qualified personnel. As recommended in the fitting instructions, it is important to coat all the steel parts with a protective substance such as body wax. IMPORTANT : Manufacturer’s Declaration Form A manufacturer’s declaration form is provided with your kit. Following installation of the kit please ensure that this form is completed, signed by a qualified fitter and returned to Dunlop Systems and Components. As a condition of your warranty, modifications to the system may only be carried out by personnel of Dunlop Systems and Components. Enquiries For general enquiries please either telephone… Dunlop Systems and Components Nederland : +31 (0)547 33 30 65 Dunlop Systems and Components UK : +44 (0)24 7629 3300 ...or e-mail [email protected]. 19 www.dunlopsystems.com Auxiliary Air Suspension Dunlop Systems and Components Het Wegdam 22 7496 CA Hengevelde Nederland Tel. +31 (0)547 33 30 65 Fax. +31 (0)547 33 30 68 Dunlop Systems and Components Holbrook Lane Coventry CV6 4QX United Kingdom Tel. +44 (0)24 7629 3300 Fax. +44 (0)24 7629 3390 www.dunlopsystems.com