Air Suspension Issue

[ledzilla]

Ok, so after my MM sat mostly motionless for a month, it seemed to have developed an issue with the air ride suspension. The rear is a bit low, not really getting lower, but firing up the compressor it doesn't raise up. I suspect maybe the solenoids aren't opening, but I'm afraid to flip the switch to lower the rear end in case I can't reinflate the air bags. (the air ride controller failed some years back, so I performed a bypass mentioned in another thread here to install a switch) Since the compressor is firing up, am I most likely correct in my assessment of the solenoids? I suppose I should probably take a few moments to inspect the fuses just to be safe.

Has anyone had good experience with replacing the the air bags with springs? I'm seriously considering the conversion.

[RubberCtyRauder]

Have you checked the ride height sensor? It can pop off when worn or corroded..it's onthe driver's side attached to the watts link

[RF Overlord]

^^^what RubberCity said^^^

You said "the air ride controller failed some years back, so I performed a bypass mentioned in another thread here to install a switch"...can you elaborate? Are you talking about the module behind the glove box failed? You installed a manual switch of some kind?

[ledzilla]

Yes, that module failed. It would only work during warm weather which left me freezing my fingers off trying to manually pump air into the springs in the middle of winter. I found a guide in a post on the site somewhere that gave instructions on how to bypass the module and install a manual switch. That "fix" has been working well for several years now.

[1Marauder]

Where is the modulator? Can I raise the rear height a little? Is there a setting somewhere I can adjust?

[fastblackmerc]

Where is the modulator? Can I raise the rear height a little? Is there a setting somewhere I can adjust?

The module is behind the glovebox.

To raise the ride height, adjust the sensor on the Watts link.

[RF Overlord]

^^^what FBM said^^^

I *believe* sliding it toward the centre of the car raises the height. Also be gentle with the bolts on the sensor...they're small and have been known to shear off.

[ledzilla]

Ok, so I did a quick test and I can confirm hearing the solenoids open and close. I think maybe the air line is pinched or damaged. Can anyone fill me in on where that line runs so I can inspect it?

[Curless]

Ok, so I did a quick test and I can confirm hearing the solenoids open and close. I think maybe the air line is pinched or damaged. Can anyone fill me in on where that line runs so I can inspect it?


The compressor is located under your air filter box, the line runs along the driver's side frame rail inside next to the brake lines. I have GIGAN's car in the air right now and just looked at it.

[ledzilla]

I'm good on the compressor location, but I wasn't sure about the line. Thank you. Knowing that, I now suspect that when we had to cut the crossmember bolts out with a torch we may have damaged the air line. I'll have to inspect it first chance I get.

[RF Overlord]

I now suspect that when we had to cut the crossmember bolts out with a torch we may have damaged the air line.Since it's plastic, that sounds logical.

[Curless]

Yep, the line runs right above the X-member

[ledzilla]

When I have a few moments to spare I'm going to fire up the compressor using my handy-dandy switch I installed in the glove box, and listen for any leaking air along the chassis. With any luck I can find it in a spot easy to repair. Does anyone have recommendations for repair materials? I know there is the chance that the damage may be in an inaccessible spot and I might have to rig up some flexible hose or something.

[MyBlackBeasts]

When I have a few moments to spare I'm going to fire up the compressor using my handy-dandy switch I installed in the glove box, and listen for any leaking air along the chassis. With any luck I can find it in a spot easy to repair. Does anyone have recommendations for repair materials? I know there is the chance that the damage may be in an inaccessible spot and I might have to rig up some flexible hose or something.

Cut out damaged area & splice in repair section.

If lucky, only small spot damaged & enough slack to splice with air-line quick-union.

If larger section damaged, 2 quick-unions & a new section of line.

Back on the road.

[ledzilla]

I have a sneaky suspicion that the damaged section will be somewhere hard to reach in reference to the cross member, and I'll probably need a pair of connectors and some line. Who sells it?

[MyBlackBeasts]

I have a sneaky suspicion that the damaged section will be somewhere hard to reach in reference to the cross member, and I'll probably need a pair of connectors and some line. Who sells it?

NAPA sells line & the airline quick unions.

Take the bad piece you cut out to them & they will match the diameter to get you the correct pieces.

The quick unions are cool. They are semi truck technology. They are spring loaded with o-rings. You just push on the plastic line till they bottom out and they stay locked on the line and seal.

[ledzilla]

Ok, so it took forever for me to get the parts and do something about it. But I ran into a problem. The replacement air line I purchased connected up with the quick connects quite nicely. However, the original line in the car does nothing but leak. And now the rear is sagging even further, and trying to seal up one side caused me to beak the line a little.

[UncleLar]

Does anyone know where the thread is about putting in a bypass switch for the module?
Is anyone rebuilding the compressors?

[ledzilla]

Here's a thread for the manual bypass:

http://www.mercurymarauder.net/forums/showthread.php?t=49067

Suncore Industries makes a good replacement compressor. I bought one from them several years ago and it's been working great.

http://www.suncoreindustries.com/MERCURY-MARAUDER-suspension.php

[lifespeed]

Ok, so it took forever for me to get the parts and do something about it. But I ran into a problem. The replacement air line I purchased connected up with the quick connects quite nicely. However, the original line in the car does nothing but leak. And now the rear is sagging even further, and trying to seal up one side caused me to beak the line a little.

Replace . . . The . . . Entire . . . Line . . . :rolleyes:

[fastblackmerc]

Replace . . . The . . . Entire . . . Line . . . :rolleyes:

That would be the easiest and cheapest thing to do!

The less connections they are the less chances of any leaks.

[UncleLar]

My modules -12 volt goes intermittent sometimes,can I just cut the that wire coming out of the module and hook it up to a good ground and retain automatic control of the system,or would I have to hook a wire from a good ground to a SPST switch and then to the old -12 wire after cutting it so it's no longer hooked to the module,or what?
I want to stay fully automatic.

[fastblackmerc]

My modules -12 volt goes intermittent sometimes,can I just cut the that wire coming out of the module and hook it up to a good ground and retain automatic control of the system,or would I have to hook a wire from a good ground to a SPST switch and then to the old -12 wire after cutting it so it's no longer hooked to the module,or what?
I want to stay fully automatic.

Which wire are you going to cut?

To keep it automatic you need to trace the existing wires and fix the problem(s).

[UncleLar]

The problem is in the module itself,not in the wiring.

[lifespeed]

The problem is in the module itself,not in the wiring.

Not to state the obvious, but: repair or replace the module. If it contains relays that is an obvious place to start.

You may find it is not the module. Fun troubleshooting electrical.

[UncleLar]

It IS the module,-12 works intermittently.
My favorite wrench where all my MM work has been done tested it thoroughly,put a ground to it and it kicks right in.
Thanks though,but the reason I asked about if I should install a switch or not to the ground wire is I don't want to spend a couple hundred bucks to replace a module that's otherwise good.

[lifespeed]

It IS the module,-12 works intermittently.
My favorite wrench where all my MM work has been done tested it thoroughly,put a ground to it and it kicks right in.
Thanks though,but the reason I asked about if I should install a switch or not to the ground wire is I don't want to spend a couple hundred bucks to replace a module that's otherwise good.

I see. How do I fix my car without spending money? That is a tough one. I guess we have all been there. :(

[UncleLar]

I see. How do I fix my car without spending money? That is a tough one. I guess we have all been there. :(

Yeah,kinda like the blend door fix,the LCM fix and this http://www.mercurymarauder.net/forums/showthread.php?t=49067
You don't throw money at something to fix it if you don't have to.
So are justbob and others suckers for doing all the work themselves on their cars instead just paying somebody else to do it?

[lifespeed]

Yeah,kinda like the blend door fix,the LCM fix and this http://www.mercurymarauder.net/forums/showthread.php?t=49067
You don't throw money at something to fix it if you don't have to.
So are justbob and others suckers for doing all the work themselves on their cars instead just paying somebody else to do it?

These old cars are a headache sometimes. I have paid people to work on my car (exhaust, suspension rebuild, rear end rebuild), and I have done work myself (EATC, LCM, BCM, big brake upgrade, shock valving and adjustments, air springs, transmission pan, rear sway bar fitment issues).

I just try and remind myself how well the car works in general and how durable (most) of the car is. Certain electronic modules excepted, of course. ;)

But when I get out of the Ford Focus and step into the Marauder for a weekend drive I get a big smile on my face and forget about the hours I've spent squirming around underneath it!