RENAULT MASTER X62 (FRONT WHEEL DRIVE) W21-760-3118 ...

Unit 626 Kilshane Avenue, North West Business Park, Ballycoolin, Dublin 15, Ireland
Telephone: +353 1 8612 632, Fax: +353 1 8612 647, email: sales@driveriteltd.com
www.driveriteltd.com
RENAULT MASTER X62 (FRONT WHEEL DRIVE)
W21-760-3118
OUTBOARD KIT
PRELIMINARY INSTALLATION INSTRUCTIONS
All work should be carried out in a properly equipped workshop with due regard to Health and Safety
Regulations. No further reference to Health and Safety Regulations will be made, but they must be
considered at all times.
The kit should be opened and the contents checked against the parts list provided.
Identify the various components and familiarise yourself with them using pictures and information
provided.
WARNING
Do not inflate this assembly when it is unrestricted. When installed, a minimum of 0.5 bar should be
maintained in the air springs at all times to avoid damage. Do not inflate beyond 6.5 bar.
Note: The assembly of this kit should be carried out by trained technical personnel. This is
necessary, as auxiliary tools are required for assembly.

Brackets
Parts List
Leaf-spring saddle Bracket x 2 (Handed)
Airspring Bracket x2 (Handed)
Spacer x2
Upper Bracket x2 (Handed)
Cross Member x1
Left Right
Left Right
Left Right
2

Fasteners
Description Quantity
M8 x 25 Countersunk Bolts 8
M10 x 40 Countersunk Bolt 2
M10 Flat Washer 2
M10 Locknuts 2
M8 x 55 Hex Head Bolt 4
M8 Locknuts 8
M8 Flat Washers 16
Cable Ties 10
3/8 x 3/4 Flange Bolt 2
Thermal Sleeves 2
6781 Air Bellows 2
6mm Tubing 5
3/8 x 3/4 Flange Nuts 4
1/4"-6mm Elbow 2
6mm Inflation valve 2
6mm Tee piece 1
IMPORTANT
This kit is not designed to increase the GVW (Gross Vehicle Weight) of your vehicle. For your safety
and to prevent possible damage to your vehicle, do not exceed the maximum load recommended by
the vehicle manufacturer at any time.
3

INSTALLATION PROCEDURE
There 2 different types of bump stop arrangements.
Option 1
Full length bump stop
Option 2
Reduced length bump stock with 60mm spacer
Remove the rubber bump stop by pulling the rubber
bumper away from the metal plate.
This will reveal an M10 bolt. Remove this bolt and the
bump stop bracket.
Remove the 60mm spacer if present.
The remaining hole will be used to fix the upper
bracket to the chassis.
Option 1
Option 2
4

If your vehicle has Option 1 with the full length bump
stop then it is very important that the length of the
M10 threaded bar on the upper brackets is reduced
from 80mm to 20mm as shown.
If the threaded bar is not reduced it will make contact
with the bump stop receiver plate and potentially cause
damage.
If your vehicle has Option 2 do not reduce the length
of the threaded bar.
There is an M8 bolt securing the brake line brackets to
the leaf spring saddle (Circled).
Temporarily remove this bolt.
Option 1
20mm
Option 2
80mm
5

Place the leaf spring saddle bracket on a surface with a
90 degree angle so the face with the red line is resting
flat on the surface as shown.
Bolt the airspring to the airspring bracket using the
3/8” UNC flange head bolt. Do not tighten fully at this
stage.
Insert the head of the bolt through the 25mm hole in
the leafspring saddle bracket and align the countersunk
holes with the corresponding holes in the lower
leafspring bracket. Ensure the countersunk holes are
facing up.
These brackets are handed. Ensure you are installing
the correct bracket on each side (See parts list).
Measure the distance from a fixed 90 degree angle
(Indicated by the broken line) to each of the studs.
Measurement A must be the same as measurement B.
When both measurements match tighten the 3/8” UNC
flange head bolt fully and re-check the measurements.
6

Screw a ¼” elbow into the airspring with the tubing
inlet facing the direction shown.
There are 2 holes on the leaf-spring saddle saddle. The
foreword hole is used to fix the brake line bracket in
place while the rear one should be free. Place the
spacer over the rear hole as shown.
(A)
(B)
7

Place the leaf-spring saddle bracket over the 2 x M8
holes in the saddle bracket. The brake line bracket and
the spacer will be clamped under the saddle bracket.
Ensure the indicated flange is facing inboard.
Remember these brackets are handed so ensure you are
installing the correct bracket on each side.
Bolt in place using the M8 countersunk bolts.
Ensure the brake line bracket is correctly seated.
Repeat on the opposite side again ensuring the brake
line brackets are correctly seated. There is a small
amount of movement in the brake line bracket that will
allow it to be twisted from left to right in order to
ensure the saddle bracket does not interfere with it.
Place the airspring with the lower bracket assembly
over the leaf-spring saddle bracket and bolt in place
using the M8 countersunk bolts, flat washer and nyloc
nut.
Note that each bracket is held in place using 2
countersunk bolts, one of which is indicated in the
picture on the right. Ensure each bracket is secured
using 2 countersunk bolts
8

Place the upper bracket over the airspring as shown
Bolt the upper bracket to the airspring using the 3/8”
UNC flange nuts.
Now is a good time to face the air fitting in the
direction that the airline will be routed because once
the upper bracket is in place access will be restricted.
Bolt the upper bracket to the chassis using the M10
countersunk bolts.
Ensure the upper bracket is resting firmly against the
chassis as shown, there should be no gaps.
9

Replace the bump stop bracket over the M10 threaded
bar and secure in place. The picture on the right shows
the full length bump stop bracket. If your vehicle has
the reduced length bump stop with the 60mm spacer
then you must replace both the 60mm spacer and bump
stop bracket.
Reinsert the rubber bump stop.
Bolt the cross member in place using the M8 hex head
bolts, flat washers and nyloc nuts.
10

Uncoil the air tubing and cut it into two equal lengths.
DO NOT FOLD OR KINK THE TUBING. The air
line tubing should not be bent or curved sharply as it
may buckle with age.
Make the cut as square as possible. Insert one end of
the tubing into the elbow fitting installed in the top of
the air helper spring.
Select a location on the vehicle for the inflation valves.
The locations can be on the bumper or the body of the
vehicle but be sure that it is in a protected location so
the valve will not be damaged yet still be accessible
for the inflation wand. Drill an 8mm hole or use an
existing hole and install the air inflation valve using
two 8mm flat washers per valve as supports. Run the
tubing from the air spring to the inflation valve,
routing it to avoid direct heat from the exhaust, and
away from sharp edges.
Thermal sleeves may be provided for these conditions.
Push the end of the air line tubing into the inflation
valve. Secure the tubing in place with the nylon ties
provided.
Once the inflation valves are installed, inflate the air springs and check the fittings for air leaks with an
applied solution of soap and water. If a leak is detected at a tubing connection then check to make sure
that the tube is cut as square as possible and that it is pushed completely into the fitting. The tubing can
easily be removed from the fittings by pushing the collar towards the body of the fitting and then pulling
out the tube. If a leak is detected where the fitting screws into the spring, screw the elbow into the spring
until the leak stops.
Reinflate the air springs and check for leaks as noted above.
This now completes the installation. Before proceeding, check once again to be sure you have proper
clearance around the airsprings. With a load on the vehicle and the helper air springs inflated, there
must have at least 15mm clearance around the air springs.
For best comfort use only enough air pressure in the air springs to level the vehicle when viewed from
the side (front to rear). This amount will vary depending on the load, location of load, condition of
existing suspension and personal preference.
NOTE: Too much air pressure in the air springs will result in a stiffer suspension, while too little air
pressure will allow the air spring to bottom out over rough conditions. Too little air pressure will also
not provide the improvement in handling that is possible.
TO PREVENT POSSIBLE DAMAGE MAINTAIN A MINIMUM OF 0.5 BAR IN THE AIR
SPRINGS AT ALL TIMES.
11