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Reikiman

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Has anybody come across this problem a CI conversion on a ford chassis

purchased a new motorhome in 2007 a autoroller 500 made by CI its on a ford transit 350m chassis and is now due for an mot.Mileage 001847

So i took it to Ford Evans Halshaw at bury testing station and they failed it on

Rear (both sides) Suspension has inadequate clearance with bump stop.

So i took the vehicle back to Emm-Bee caravans at bury where i bought it from they said it wasnt a bump stop but a suspension aid and is part of the suspension.

So rang Ford at bury and they said it makes no difference its still a failure.

So i rang CI caravans in hull which is now autotrailers who said its a suspension aid i explained the position of the mot station and then they said we will contact Ford Technical but dont hold your breath it could take months

So im left with a motorhome i cant get an MOT on

Any ideas on solving this would be appreciated

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You mean one of these, don't you?  I think you should go to a Ford commercial dealership, preferably one of the "backbone" dealers, who you can find from Ford's website.  Best of all would be a Transit specialist - they are listed.

Your branch of Evans Halshaw are talking rubbish, and the tester doesn't know his job (or at least his Transits)!  It is a synthetic suspension aid and not a bump stop.  Get him to check with Ford - it's only a phone call - or to simply stick his head under the rear of any other 3.5 tonne FWD Mk 7 Transit, and look for himself.  If he won't, complain to the service manager and get him to contact Ford for you.  It is arrant nonsense.

1200394410_Transitsuspensionbuffer.jpg.c1b58d8fd9d09b9d5827becd15a432cc.jpg

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I suggest that then you insist on a free retest (preferably by another technician) & valid MOT certificate from Ford Evans Halshaw.

With a suggestion to the Service manager that the original technician receives some training. :$

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Appealing against a failed test result

 

If you want to appeal against a failed test result, then you’ll need to complete an appeal form ‘VT17’ available from any MOT test station, online or by ringing VOSA on 0300 123 9000.

 

Your appeal must be received within 14 working days of the test, and VOSA will need a full test fee from you. VOSA will then offer you an appointment within five days to recheck your vehicle.

 

If your appeal is successful, then some or all of the test fee will be refunded to you.

 

Exracted from...

http://www.direct.gov.uk/en/Motoring/OwningAVehicle/Mot/DG_4022113

 

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This is a potential problem for every owner of a FWD Transit-based motorhome that needs to be MOT-tested.

 

Since 2004 many Continental European manufacturers have constructed coachbuilt motorhomes based on a Transit Mk 6 or Mk 7 3500kg FWD platform-cab chassis. To the best of my knowledge all of these vehicles have been fitted as original equipment (OE) with 'spring assister' units as shown in Brian Kirby's photo.

 

There's a recent letter in MMM May 2010 (Interchange Pages 220 & 222) headed "Rattle & Roll, but No Rock and Roll" that suggests that all Continental European-built panel-van conversions using the 3500kg FWD Transit base also have these spring assisters as OE.

 

The trouble comes when an MOT tester considers the unit to be a 'bump stop' rather than a 'spring assister'. I would have thought it was glaringly obvious that it's the latter not the former, but it's worth noting that even Interchange's technically-expert editor confuses the two.

 

For non-MMM readers, the Interchange article includes 2 photos. The 1st photo is similar to that posted by Brian Kirby. It clearly relates to the rear suspension of a FWD Transit and Interchange's editor has added the footnote "Tall original bump stop only gave a few mm of clearance, which wouldn't do any favours to ride quality". The 2nd Interchange photo is actually of a RWD (NOT FWD) Transit's rear suspension and shows a genuine 'bump stop'. This picture has the footnote "Shorter Ford bump stop gives far more clearance to the rear beam axle but failed to stop the noises".

 

Apparently, in an attempt to cure a mysterious rattling noise on the Interchange letter writer's Transit-based FWD motorhome, a Ford agent replaced the original spring assisters with "revised" parts. It needs to be emphasised that, as the full-length assisters are an integrated element of the rear suspension system, replacing them with shorter alternatives of the type shown in the 2nd Interchange photo, merely to gain free air between unit and axle reveals a worrying unfamiliarity with the FWD chassis. Fitting a Transit FWD motorhome with suspension parts intended for a RWD chassis will produce unpredictable handling effects - the rear suspension will be a lot softer than before and, as there's no rear anti-roll bar on FWD Transits, there's every likelihood that cornering will be significantly less precise.

 

My own motorhome is serviced at a motorcaravan dealership, but is taken to a nearby commercial-vehicle specialist to be MOT-tested. The last time this was done the dealer mentioned that the tester had commented on the rear 'bump stops' being in contact with the axle. As there was no evidence that the motorhome's rear springs were damaged or weakened, or that the vehicle was sagging at the back, the tester chose to ignore this lack of clearance, but Reikiman's experience proves that other testers can take a different attitude.

 

I don't know if this type of OE spring assister is unique to 3500kg FWD Transit-based Continental European MOTORHOMES. UK mainstream motorcaravan converters have never built on FWD Transits and RWD Transits have 'bump stops' not 'spring assisters'. So it's possible (I guess) that Ford agents and MOT testers may be unaware that Ford factory-fits spring assisters to certain FWD Transit chassis. It may even be the case that most (or all?) ordinary 'white van' FWD Transits have a genuine bump stop that does leave a big air-gap above the rear axle. This is pure speculation - but otherwise one might reasonably expect a lot of FWD Transit panel vans to have failed their UK MOT-test by now.

 

The 'bump stop' thing has been mentioned before on this forum when 'air suspension' was being discussed. See

 

http://www.outandaboutlive.co.uk/forums/forums/thread-view.asp?tid=16985&posts=18

 

In that thread Brian Kirby advises that the spring assister units are easily detached from the chassis. If it's essential to gain a MOT certificate ASAP, then a potential solution might be to remove the units before the test and replace them immediately after. But it really needs Ford(UK) to issue an official statement about these units that will satisfy UK MOT-testers and prevent other Transit motorhome owners being put in the same difficult situation as Reikiman.

 

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Hello Derek.  It seems this does need clarification from Ford, so anyone who still has theirs present, who wishes to copy my photo and send it to Ford's technical department for their input, is most welcome.

Just one thing: I didn't say they were easily removed, just that they could be pulled out!  There is a fair bit of puffing and grunting under the van before they come away, and you need to be a little bit careful not to pull them directly toward you, 'cause they come with a rush, a bit like that hippopotamus in the song!  A suspension aid in your eye, you do not want.  (Mine missed, but it was a damn close run thing!  :-D) 

As to removing and replacing for the test, once the stop is out, the "shorthouse" stops put in and, assuming you can still see well enough to drive, the test completed and the "shorthouse" stops removed, if the vehicle chassis is jacked up a bit, a spacer placed on the "saucer", and the vehicle then lowered gently with the stop in place I guess the weight of the van will shove it back in place - but, overall, a letter to Ford would seem far easier!  :-)

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Thinking back, I vaguely recall a conversation 3 or 4 years ago with some guys who were selling rear suspension 'air assistance' systems at the Malvern outdoor show.

 

At the time FWD Transit-based motorhomes were rare in the UK, with Hobby and Eura Mobil being the main players. I inquired if an air-assistance kit was available for FWD Transits and was asked whether my vehicle was "on its bump stops". I replied that it didn't have bump stops, but had 'spring assisters' that were always in contact with the rear axle. I was then warned that, whether I wanted to call these units "bump stops" or "spring assisters", if they were touching the rear axle then the vehicle would probably fail an MOT test.

 

GOOGLE-searching retrieves some potentially useful information on this issue.

 

In his final posting on the following Transit Forum thread

 

http://fordtransit.org/forum/viewtopic.php?f=5&t=47854&p=517701&hilit=helper#p517701

 

COCONUT (a very reliable and expert Transit Forum guru) states

 

"On a FWD 300 or above they are not only bump stops but also 'helper springs' and it's perfectly normal for them to be near or touching the rear beam axle."

 

So, if you've got a Transit FWD-based motorhome (coachbuilt or panel-van conversion) based on a 3000kg-or-higher MAM chassis, then the vehicle will have these long 'bump stops/spring assisters' as standard and you may have to beware at MOT-test time.

 

Apparently it's not just some Transits that use this suspension arrangement and may have MOT-test problems. See:

 

http://www.ukcampsites.co.uk/chatter/display_topic_threads.asp?ReturnPage=Thread&ForumID=36&TopicID=202060&PagePosition=&ThreadPage=1

 

Posting 2 (from PETE1946) says

 

"I had the same problem 2 years ago. After hours of trawling through the net nothing came up, so I called at a local M/Home company near me. He said tell the examiner to go to the MOT updates on these types of vehicles - it's only accessible by the MOT station with their log-in security code. I did that and then they passed it after reading about this type of suspension. Had no problems since. Just goes to show they don't know it all and some think they are God being an examiner."

 

Although the ukcampsites thread relates primarily to a Fiat-based motorhome, it's possible there is something on the MOT updates database about the spring-assister units fitted to 3000kg-and-above FWD Transits.

 

See also

 

http://www.motorhomefacts.com/forum-printtopic-1-43281-0-0-asc-viewresult-1.html

 

(For what it's worth, it would appear that, if bump stops/spring assisters are completely removed before the MOT test, this action should not result in failure.)

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Hi Brian

Thanks for your advice i ve been back to ford garage still no joy and they wont phone there technical either awkward sods wont get any more servicing etc off me.Also been to a transit specialist ford OMC at oldham and they said the same its a bump stop

So i went to see a guy called john moss senior tester at vosa at chadderton and it goes worse he said even if i appealed against the mot and they retested it the out come would still be a fail because they class it has a bump stop too and it requires a clearence between this and the axle.

he did say however that there is no requirement for a bump stop so if its not there it cant be a fail.

he agreed the mot should be class4 as all motorhomes are and not a class 7 test although the outcome would be the same just the price thats different.

So against my better judgement im going to see if i can get them out.I still think its a manufacturing fault and they should pay for it but they have now moved to italy What a nightmare i wouldnt have a autoroller give me after this.

reikiman

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I have now e-mailed MoT UK, to see if they can shed light, plus VOSA and Ford technical, with the details of this issue.  I have "ratted" on OMC Motorgroup Oldham to Ford over their reported attitude, in the hope someone will get a poke with a sharp stick!  :-)

It might help if anyone else with a FWD Mk 7 Transit based motorhome does likewise, especially if the MoT is due soon, as several similar enquiries on the same topic may attract a bit of urgency.

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Whilst rummaging around under my van today to see if I can get the spare wheel under there rather than in the garage (found a spot - will be visiting local garage to get them see if they can do it for me ... sorry I digress ...) I noticed that we've got the same 'spring assisters' too! Hopefully by the time we need a MOT it will be well know about! :-D

 

When's YOUR MOT due Brian ... 8-)

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To try to clarify matters...

 

If Coconut's informed advice on the Ford Transit forum is correct (and I'm sure it is), then ALL front-wheel drive (FWD) Transit panel vans with a MAM of 3000kg or higher, marketed since the Mk 6 Transit was introduced in Year 2000, have probably been factory-fitted with the long flexible-plastic spring assisters shown in Brian Kirby's photo.

 

Logically, that means there must have been hundreds of UK-marketed FWD Transit panel vans with these spring assisters that have been presented for the MOT-test since around 2003 (when the first FWD Mk 6 models would have become 3 years old). As I observed earlier, if a large number of these vehicles were being failed due to 'bump stop' lack of clearance, then one might think the problem should surely have been well advertised by now.

 

In addition to those Transit panel-van models, EVERY coachbuilt motorhome built from 2004-onwards on a Transit FWD platform-cab chassis (a derivative of the panel-van chassis) will also have been factory-fitted with these spring assister units. My 2005 Transit Mk 6-based Hobby motorhome has them, Brian Kirby's 2007 Transit Mk 7-based Hobby had them, Riekiman's 2007 Transit Mk 7-based CI Auto-Roller 500 has them, Hobby Mel B's brand-new Transit Mk 7-based Chausson has them. These are NOT 'add-on' parts fitted by Hobby, CI Auto-Roller, Chausson, etc: they are suspension components installed as original equipment when the chassis on which these motorhomes are based were constructed in Ford's factory in Turkey. If Ford-based motorhomes are experiencing problems at MOT-time due to their suspension design, it's definitely NOT the fault of the motorhome manufacturer.

 

I'm not the only member of this forum with a motorhome based on a FWD Transit chassis that's more than 3 years old. My Hobby has been submitted for MOT-testing twice and (although the fact that the spring assisters touch the axle has been remarked on once by the tester) has not been failed for 'bump stop' lack of clearance. Presumably other forum members' FWD Transit motorhomes have also passed, otherwise I'm certain there would have been loud complaints about this before now.

 

Yesterday I spoke to the motorhome dealer who arranges the MOT-test for my Hobby and mentioned Reikiman's problem. He explained that a MOT-test pass or fail often depended on how the MOT rules were interpreted and/or whether or not the tester was familiar with the 'quirks' of the make/model of vehicle being tested.

 

I said that, although the parts fitted to my Hobby (and a lot of other FWD Transits) obviously did act as 'bump stops', their primary function plainly was to assist the rear springing and, to do this, they needed to be in contact with the vehicle's rear axle. I felt that anyone with an ounce of mechanical understanding should appreciate this. He agreed and suggested that Reikiman take his motorhome to a Ford main agent specialising in Transits and who MOT-ed (or arranged MOTs) for those vehicles. I said that I believed Reikiman had already done this and that's when his problems began. The dealer laughed and said "That's the motor trade for you!"

 

I find this situation surreal...

 

If a Mk 6 or Mk 7 FWD Transit with its original Ford factory-fitted long spring assisters is submitted for the UK MOT-test, there seems to be a good chance that it will be failed because the bottom ends of the spring assisters are near to (or touch) the rear axle. That the spring assisters are clearly intended to do this seems to be being ignored by some MOT-testers.

 

To be sure of passing the test, you could remove the spring assisters completely, or replace them with genuine 'bump stops' (perhaps from a RWD Transit) that come nowhere near the rear axle, but both of these ploys will conflict with Ford's original design rationale and must have some impact on how the vehicle's rear suspension will operate under load. (Ford don't fit these spring assisters just for fun!)

 

Alternatively, you could (as Brian Kirby has done) replace the spring assisters with 'air bellows' units. Despite air-bellows sitting on the rear axle in a similar manner to the spring assisters, they seem to be acceptable to MOT testers (otherwise an awful lot of motorhomes would fail the test), presumably because it's a lot harder to consider them as 'bump stops'. But it's daft fitting air-bellows to a vehicle unless (like Brian's Hobby Van) it's going to benefit from them.

 

It will be interesting to see how the various parties Brian has e-mailed respond to his inquiries (assuming they do, of course!)

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MEL B

 

My 2005 Hobby also has pre-cabling for a tow bar (though the wiring doesn't dangle!)

 

Dunno where the idea came that I'd fitted a 2nd leisure battery - I haven't. I think Transit minibus models have twin starter batteries as standard (both housed under the driver's seat) and it's an option on most other models. A current Transit brochure would reveal the present situation.

 

If I had to change my Hobby's 80Ah gel leisure battery, I'd stick a big 'conventional' battery in the lounge-seat base behind the passenger seat, rather than have two smaller batteries under the cab seats where it's hard to get at them. It might be worth you checking how easy it is to remove your Chausson's cab seats + swivel mechanisms, just in case you have to. The Hobby's swivels were held on by a mixture of Torx 30 and 40 fastenings and they were TIGHT.

 

If you envisage ever carrying out a DIY wheel change using the Ford-supplied equipment, check the Ford Transit manual for advice. You may well find that changing a rear wheel requires a special alloy 'block' to be placed beneath the jack to gain the necessary lifting height. On FWD Transit-based motorhomes this Ford-supplied block used to be stored within the standard spare wheel, but I don't know what happens when the vehicle comes without a spare wheel. I can't change the Hobby's rear wheels using the method recommended in the Transit manual as the Hobby's double rear springs prevent this. Your Chausson may be OK, but you'd be wise to confirm this.

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If I was wanting to get an MOT on a Ford Transit and there was a problem. My first thoughts are, which large organisation runs lots of Fords? answer BT.

 

Take it or speak to a local BT Fleet garage, if they can't get it MOT'd nobody can! They run thousands of them, and test all their own vehicles, as well as testing vehicles for members of the public.

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Take a look at page 220 and 222 of May 2010 MMM. Specifically the Interchange matter headed "Rattle and Roll, but no Rock and Roll".

 

This query relates to a La Strada Trento on a FWD Transit and on page 222 there is a photo of the long 'bump stop' and the caption "Tall original bump stop only gave a few mm of clearance which wouldn't do any favours to ride quality".

 

The next photo shows a cut-down 'bump stop' (a DIY operation?)

 

So confusion reigns, with even the mighty MMM Interchange seemingly unaware of the true function of these 'bump stops' 8-)

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spospe - 2010-05-05 11:38 AM Take a look at page 220 and 222 of May 2010 MMM. Specifically the Interchange matter headed "Rattle and Roll, but no Rock and Roll". This query relates to a La Strada Trento on a FWD Transit and on page 222 there is a photo of the long 'bump stop' and the caption "Tall original bump stop only gave a few mm of clearance which wouldn't do any favours to ride quality". The next photo shows a cut-down 'bump stop' (a DIY operation?) So confusion reigns, with even the mighty MMM Interchange seemingly unaware of the true function of these 'bump stops' 8-)

Not entirely correct, because the second pic, with the short (also standard) bump-stop, is actually a RWD Transit (Also has a round, and not square, section axle.  Peter Rosenthal is now aware of the difference!  :-)).  Look close and you can just see the "banjo" of the RWD axle bottom right.

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Derek Uzzell - 2010-05-05 9:25 AM To try to clarify matters... If Coconut's informed advice on the Ford Transit forum is correct (and I'm sure it is), then ALL front-wheel drive (FWD) Transit panel vans with a MAM of 3000kg or higher, marketed since the Mk 6 Transit was introduced in Year 2000, have probably been factory-fitted with the long flexible-plastic spring assisters shown in Brian Kirby's photo. .............

Correct!  It's even embossed "Ford"!  Beware of counterfeits.  :-)

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starvin marvin - 2010-05-05 11:21 AM

 

If I was wanting to get an MOT on a Ford Transit and there was a problem. My first thoughts are, which large organisation runs lots of Fords? answer BT.

 

Take it or speak to a local BT Fleet garage, if they can't get it MOT'd nobody can! They run thousands of them, and test all their own vehicles, as well as testing vehicles for members of the public.

 

Might be worth a try, but I was once told by one of the Transit Forum gurus that all BT Ford Transits were RWD. We were discussing the high gearing of the then 5-speed FWD Transit and he said BT wouldn't buy those vehicles because of this. Might be different now that the low-geared FWD 6-speeders are being marketed.

 

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I spoke to a local Ford main dealership yesterday, gave them my 2005 Hobby's VIN-number and asked if they would check how Ford's parts list refers to the 'spring assister' units fitted to my motorhome's rear suspension. I was told that two different part numbers were given, with one specific to the Transit 350 chassis (the basis for my motorhome). I had hoped that the Ford parts-list description would refer to the units' spring-assistance function, but (in both instances) the list just called the units "bump stops".

 

I then contacted the company that MOT-tests commercial vehicles for the Ford main dealership and inquired whether they were familiar with FWD Transits with long 'bump stops'. As the bottoms of the units were always close to or in contact with the rear axle, I asked how they viewed the units as far as the MOT-test bump-stop rules were concerned. The tester said that he had carried out MOT-tests on FWD Transits with these units, that he was aware that the units were original Ford factory-fitted parts and, as far as he was concerned, the fact that they touched (or almost touched) the axle did NOT warrant failure of the test.

 

Reikiman asked about his MOT-test failure problem on the Ford Transit forum. See

 

http://fordtransit.org/forum/viewtopic.php?f=2&t=65601

 

I also note that Mr Ian Pedley (the writer of the letter recently published in MMM's Interchange columns) posted to the Ford Transit forum back in January 2010. This produced the comment from "Coconut" that I mentioned earlier. See

 

http://fordtransit.org/forum/viewtopic.php?f=5&t=47854

 

My understanding of MOT-test regulations is that they come in two flavours. There is a general set of simplified rules that cover the basics, and then there is a separate mass of fine detail and updates. The latter used to be in hardcopy format, but (based on the comment I referred to in my 2nd posting to this thread) these 'small print' data are now held on-line, but unfortunately only accessible to MOT-testers.

 

The MOT-test was introduced some 50 years ago and the rules constantly need to be revised to cover vehicle technical advances and regulation changes. (For example, exhaust emission testing was never part of the original MOT-test and updated rules will have been introduced to cover this.)

 

There's nothing novel or revolutionary about flexible spring assisters being fitted by vehicle manufacturers, and I think there's a strong possibility that, if one trawled through the MOT-test database, you'd find references to this type of suspension aid, plus advice that would allow MOT-testers to ignore the basic 'bump-stop lack of clearance' rule.

 

Other than removing the spring assisters before submitting his motorhome for testing, I would have thought Reikiman's best bet would be to do as I did - contact Ford dealerships who sell Transits, ask who MOTs those vehicles for them and then check with those MOT testing stations what their attitude is to FWD Transits fitted with these long 'bump stop' parts. As Reikiman's problem doesn't seem to be widespread nationally, I'd expect it to be fairly straightforward to find a cooperative testing station within a reasonable driving distance of Reikiman's home address.

 

Once Reikiman has succeeded in obtaining a MOT-test pass for his motorhome, there's the matter of seeking a refund for the original test failure. How this is best done may depend on the responses Brian Kirby gets to his inquiries.

 

If there's something in the MOT-test files that the Bury, Oldham and Chadderton testers have overlooked, then getting a refund should be straightforward. If there's nothing relevant in the MOT-test files and right-thinking testers are passing these FWD Transits using their expertise and initiative (and common sense!), rather than slavishly following a kindergarten-level regulation, then getting a refund may prove difficult.

 

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Derek Uzzell - 2010-05-07 9:39 AM ............. If there's nothing relevant in the MOT-test files and right-thinking testers are passing these FWD Transits using their expertise and initiative (and common sense!), rather than slavishly following a kindergarten-level regulation, then getting a refund may prove difficult.

It is, as you commented earlier, Derek, all a bit surreal.  Without wishing to be the pessimist, I assume the vehicle has now been formally recorded as a fail, with the reason stated and recorded on the database.  I assume that recorded fail cannot now be expunged, so the next step has to be a re-test, after which, if the vehicle passes - it would do so with no change to its actual OEM configuration. 

Does anyone know if the grounds for a pass on re-test have also to be stated, so that the second tester has formally to record the fault as having been cleared?  Shall we see a duel at dawn between MoT testers to settle the issue?

I'm still waiting, without holding my breath, for replies to my queries.  Just an acknowledgement from VOSA so far!  I'll post soonest after.

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Oh me of little faith!  Just got the following from VOSA. 

I have removed the contact's name, but if anyone needs this and would like to PM me, I will pass it on.  The underlining mine.  I assume VTS = Vehicle Test Station.

"Dear Mr Kirby,

Thank you for your e-mail enquiry dated 5th May 2010, concerning Ford Transit Suspension.

Some vehicles such as Citroen Relay and Peugeot Boxer, have extended rear 'bump stops' which may have little or no clearance between itself and the spring leaf. These 'stops' are designed as spring assisters (the lower section is compressible) and should not be considered as a failure under 2.4A1 just because there is little or no clearance.

Must admit that we've never seen one on a Transit but many motorhome builders fit them as an after market conversion and use several types. This makes it extremely difficult to cite particular mfrs/models in VSI.  Some such as Fiat and Citroen may factory fit them as a 'standard' option on certain models at time of order but again it is not easy to identify them for VSI.

There are several designs but the most common is a concertina shape (straight or conical) which allows the rubber to collapse (which can be by as much as 50% or more) as  load is put on it. The concertina shape is a good indication of construction but there are others which are straight but are obviously much longer than a bump stop. They usually are in contact with the spring/axle,especially with motorhomes, which are usually close to DGW most of the time,  as they assist throughout the range of the main spring.

Though there is a note in the database we haven't had that many calls on this but we are looking at an article for Matters of Testing.

I would advise you to approach the VTS and ask them to ring the Contact centre for further advice. If the VTS is unwilling to do this then we can contact them if you supply the details. However we can only advise not instruct the VTS on this and ultimately an appeal may be the final option.

I hope this information has assisted you with your enquiry, but if you have any further questions please do not hesitate to contact us again.

Kind Regards, 

VOSA Contact Centre
Operations Directorate
Tel: 0300 123 9000"

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