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 Dunlop air suspension fitting guide x244 chassis

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Techno100

Dunlop air suspension fitting guide x244 chassis 100010
Techno100

Posts : 1719
Join date : 2012-11-15
Location : Leeds

Dunlop air suspension fitting guide x244 chassis Empty
PostSubject: Dunlop air suspension fitting guide x244 chassis   Dunlop air suspension fitting guide x244 chassis EmptyMon 3 Dec 2012 - 23:16

For this job you will need some additional ground clearance (Milenco Quattros ideal)
A long handled torque wrench
Hammerite Waxoyl to coat all metal parts during assembly
A tape measure for LSV load sensing valve
1/2" drive sockets 13,17,22mm
Hammer, cold chisel, sidecutters, stanley knife, battery drill, 8mm HSS bit

Begin with the rod measurement at the LSV as this may alter with the suspension upgrade and need to be adjusted later BEFORE driving
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Next having created more room for your comfort underneath the van if your bump stops are sat on the leaf springs? use your scissor jack to create a small amount of lift (about 25mm 1") make sure the head of the scissor is on a reinforced section of chassis
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The bump stop will need a slight persuasion with a hammer and drift or cold chisel on the castellations to just start it off anticlockwise
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BS removed
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The basic components are superb quality and very robust
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Upper bracket fitted and secured with bolt 17mm head
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Next comes the removal of the leaf spring U bolts and bump stop bottom plate, 22mm socket and long handled wrench with some brute force to get these babies off
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The bump stop plate is NOT replaced but saved for if you remove your kit to transfer to another vehicle.
Now attach a bellow unit to a bottom bracket loosely with the 13mm headed bolts and attach the appropriate air line (left or right) Marcle recommend red for left blue for right.
Compress the bellows until all the air is expelled and bend over the other end of the airline to prevent it re inflating, secure with tape or a small cable tie.
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Bellows located
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U bolted back in place 110nm tightening torque!
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Allow the air back into the bellows and fit the top bolts loosly
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tighten the bellows bottom bolts 13mm spanner, check alignment before tightening top bolts 13mm
Decide on a route for your airlines
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View below rear of driver footwell where handbrake cable goes through to lever 2 x 8mm holes drilled
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Airlines appear here and enter fill point and gauge
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Units inflated
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Now adjust the pressure until the units stand 13.5cm tall about 35psi and re measure the LSV ! remember mine was about 35mm in the first picture?
Now it is a tad under 30mm
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Adjust here until it is the original measurement 8mm spanner to lossen the collar
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This cost me £411 as illustrated inc VAT n delivery
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