Suspension Strut

FRONT SPRING AND / OR SHOCK ABSORBER REPLACEMENT





Jack up Front End and Remove Wheel
^ Place jack stands beneath jack attachments.
^ Remove wheel.





Remove link from steering rod
^ Remove nut and press out link using puller 5259.
^ Place a jack beneath control arm.





^ Remove:
- Anti-roll bar link from link.
- Bolt from brake pipe bracket.
^ Detach pipes from clips.





Loosen Shock Absorber Nut
^ Counterhold strut with 5037 and loosen nut a few turns with socket 5036.

NOTE: Use the wrench handle carefully. On certain models the ignition coil can be damaged if accidently hit.





^ Mark position of upper mount Remove mount nuts and washers.





^ Lower jack.
^ Pull down spring strut to free it from wing.

NOTE: Take care not to damage wing.

^ Hook spring strut onto anti-roll bar.
^ Use support hook 5045.





Attach Spring Compressor Tool 5407 and Compress Spring
^ Place compressor tools opposite each other and with three free spring coils between the tool jaws.
^ Compress each side alternately.





Remove Shock Absorber Nut
^ Use socket 5036 and holding tool 5037.

NOTE: For replacement of axial bearing only, remove washer, bearing, and axial bearing, then proceed to: Locate New Axial Ball Bearing in Spring Plate section below.

^ Remove:
- Washer.
- Mount.
- Axial bearing.
- Shaped washer.
- Spring seat.
- Rubber spacer.
- Bump stop.
- Bellows.
- Guide sleeve.
- Spring.

NOTE: The spring seat and rubber spacer are one unit on 760 and 780 models 1988 and on.

NOTE: When replacing the spring only proceed to: Remove Spring Compressor Tool 5407 section below.





Remove Shock Absorber Nut and Compress Absorber
^ Use hook spanner 5406, key 5303 and a wrench handle as a brace.
^ Install the new shock absorber and mounting nut.
^ Tighten nut using hook spanner 5406, key 5303 and a wrench handle as a brace.

NOTE: For replacement of shock absorber only, proceed to: Component Inspection section below.





Remove Spring Compressor Tool 5407
^ Remove spring compressor tool by loosening alternately from the old spring.





Compress the New Spring With Tool 5407
^ Place compressor tool 5607 opposite each other and with three free spring coils between the tool jaws.
^ Compress each side alternately.
^ Compress the spring until the length is approximately 275 mm (10.8 in) between ends.





Component Inspection
^ Check:
- mount.
- axial bearing.
- rubber spacer.
- bellows, etc. for wear and damage.
^ Replace as needed.

NOTE: The picture shows only parts for the 740 model, not the 760 or 780 models from 1988.





Install Spring
^ Pull the shock absorber piston rod out as far as possible.
^ Install spring on spring strut, bellows with guide sleeve, bump stop, rubber spacer, spring plate and the shaped washer with taper downward.





Locate New Axial Ball Bearing in Spring Plate
^ Ensure that the bearing seat is clean.
^ Locate axial bearing with the yellow half upwards.
^ Install mount, washer and nut.
^ Tighten nut but do not tighten completely.
^ Use socket 5036 and holder 5037.





Remove Compression Tools
^ Loosen the jaws alternately.
^ Ensure that the spring ends are properly located in upper and lower plates.





Guide spring strut into wheel housing
^ Remove suspension hook 5045 and raise jack.
^ Make sure anti-roll bar link is correctly seated.





^ Install spring strut in wheel house tower according to previous markings.

Torque to 48 Nm (36 ft lb).





Tighten Upper Shock Absorber Nut
^ Use socket 5036 and holding tool 5037.

Torque to 70 Nm (52 ft lb).





^ Install:
- Anti-roll bar to link.

Tighten nut so that distance between washers is 42 mm (1.65 in).

- Brake pipe bracket.
- Brake pipe to clips.

NOTE: Ensure that pipes sit correctly in rubber grommets.





Install link on steering rod

Torque to 60 Nm (44 ft lb).





Install wheels

Torque to 85 Nm (63 ft lb).

^ Lower vehicle.