Ducato semi air rear only
Recently replaced my Bumpstops for semi air.
it is the cheap variety that uses a top bracket that can be difficult to align and requires removal and replacement of the U bolt clamps.
There are different versions that maybe easier to fit because of the alignment issues. I think my method reduces the problems (well the 2nd was easier)
First things first it is a low mileage 2017 reg in 18 so not rusty as xxxx needing the clamps cutting off, the welder was also readied for use (just in case the bumpstops were rusted in place and the poor welding of stud to ring gave up), but not required. look at at least 3 vids you will get an idea what you need to do.
What I did (on 2nd side) not mentioned on vids I watched.
Van on high ramps
lubricate u bolt threads and time to penetrate.
filled water tank up. Not a good idea the rear of van needs jacking up, second side opposite water did not.
In comfort:
get bellows, fit air connection.
compress bellows and restrain with tie wraps.
fit air line.
fit lower bracket (feed air line through)
attach with 2 bolts loosely.
sup tea.
Back to van.
Remove Bumpstop.
I used hammer and chisel, then by hand mine was easy. Alternatively use a mega chain wrench. Welder was ready to threaten poorly welded items.
there is a bracket on one side that would interfere with the bellows, modify it by bending or cutting and rerouting the cable/pipe.
Remove U bolts and bracket.
This requires muscles like what I avent got or serious leverage a 2 foot bar min and at one stage I added a 4 foot pipe. If really rusty its time for the angle grinder and new U bolts.
Top Plate fitting
At this point one u tuber hammered the top mounting area flat.
Using a thread lubricant eg copaslip, Rocal thread lubricant or the like attach top plate with the centre bolt.
place 2 bolts in plate hole, align plate front to back and tighten centre bolt.
Bellows Fitting
Put compressed bellows assembly into position
fit pipe to gauge / inflation device. this is a temporary fix to control inflation of the bellows.
Align bellows and fit ubolts, tighten to allow movement to align the top fixing bolts.
cut tie wraps. the expansion can be controlled by the schrader valve.
Remove tie wraps.
Align and fix top bolts to the bellows.
Align entire assembly and tighten bolts expand the bellows until pressure is totally released and all bolts tightened.
Remove the air pipe from gauge and route to the favoured location through favourite protection. Following the curve of the brake cable should give sufficient travel with suspension movement. tie wrap losely to cable and other mounting points
Pipework
Remove the air pipe from gauge and route to the favoured location through favourite protection. Following the curve of the brake cable should give sufficient travel with suspension movement. tie wrap losely to cable and other mounting points.
Locate gauges/inflation device in an appropriate position.
I chose the Gas Cupboard.
Alternative Gauge positions
At rear in garage or near Barn doors.
In front:
Side panel of drivers seat.
Cubby hole on rhs under the air vent
Behind drivers seat on B pillar
Last Lap
Pump up each side if separate and check for leaks. If none your almost done. Pump to a set value clear up and remove from ramps.
Ive read that 2-3 bar is a good place to start, 2.5 if towing.
Recently replaced my Bumpstops for semi air.
it is the cheap variety that uses a top bracket that can be difficult to align and requires removal and replacement of the U bolt clamps.
There are different versions that maybe easier to fit because of the alignment issues. I think my method reduces the problems (well the 2nd was easier)
First things first it is a low mileage 2017 reg in 18 so not rusty as xxxx needing the clamps cutting off, the welder was also readied for use (just in case the bumpstops were rusted in place and the poor welding of stud to ring gave up), but not required. look at at least 3 vids you will get an idea what you need to do.
What I did (on 2nd side) not mentioned on vids I watched.
Van on high ramps
lubricate u bolt threads and time to penetrate.
filled water tank up. Not a good idea the rear of van needs jacking up, second side opposite water did not.
In comfort:
get bellows, fit air connection.
compress bellows and restrain with tie wraps.
fit air line.
fit lower bracket (feed air line through)
attach with 2 bolts loosely.
sup tea.
Back to van.
Remove Bumpstop.
I used hammer and chisel, then by hand mine was easy. Alternatively use a mega chain wrench. Welder was ready to threaten poorly welded items.
there is a bracket on one side that would interfere with the bellows, modify it by bending or cutting and rerouting the cable/pipe.
Remove U bolts and bracket.
This requires muscles like what I avent got or serious leverage a 2 foot bar min and at one stage I added a 4 foot pipe. If really rusty its time for the angle grinder and new U bolts.
Top Plate fitting
At this point one u tuber hammered the top mounting area flat.
Using a thread lubricant eg copaslip, Rocal thread lubricant or the like attach top plate with the centre bolt.
place 2 bolts in plate hole, align plate front to back and tighten centre bolt.
Bellows Fitting
Put compressed bellows assembly into position
fit pipe to gauge / inflation device. this is a temporary fix to control inflation of the bellows.
Align bellows and fit ubolts, tighten to allow movement to align the top fixing bolts.
cut tie wraps. the expansion can be controlled by the schrader valve.
Remove tie wraps.
Align and fix top bolts to the bellows.
Align entire assembly and tighten bolts expand the bellows until pressure is totally released and all bolts tightened.
Remove the air pipe from gauge and route to the favoured location through favourite protection. Following the curve of the brake cable should give sufficient travel with suspension movement. tie wrap losely to cable and other mounting points
Pipework
Remove the air pipe from gauge and route to the favoured location through favourite protection. Following the curve of the brake cable should give sufficient travel with suspension movement. tie wrap losely to cable and other mounting points.
Locate gauges/inflation device in an appropriate position.
I chose the Gas Cupboard.
Alternative Gauge positions
At rear in garage or near Barn doors.
In front:
Side panel of drivers seat.
Cubby hole on rhs under the air vent
Behind drivers seat on B pillar
Last Lap
Pump up each side if separate and check for leaks. If none your almost done. Pump to a set value clear up and remove from ramps.
Ive read that 2-3 bar is a good place to start, 2.5 if towing.
