Replacing Spring/Shock Absorber

Replacing spring/shock absorber

Special tools:
999 5498 SOCKET 999 5498 Socket
999 5499 KEY UPPER PIN REAR SHOCK ABSORBER 999 5499 Key Upper Pin Rear Shock Absorber
999 5500 SOCKET UPPER NUT REAR SHOCK ABSORBER 999 5500 Socket Upper Nut Rear Shock Absorber
999 5501 KEY UPPER PIN REAR SHOCK ABSORBER 999 5501 Key Upper Pin Rear Shock Absorber
951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor

Note! If replacing spring only continue to Replacing spring Replacing Spring.

4 door, early version

Fold the backrests forward. Release the front edge of the cargo compartment carpet






Remove support panel under front edge of carpet

Disconnect front edge of side panels, push to one side
Remove backrest catches and panel retaining clip.

4 door, new version

Remove support panel as described above




Cut side panel vents in the front and rear edges as illustrated. Turn up the panel cover which covers the shock absorber mounting

Raise the rear suspension so that the wheels are clear of the ground






Remove the two upper shock absorber mounting screws

Caution! The spring should not be under load when the screws are removed.

Raise the car






Press up trailing arm so that load is taken from the shock absorber
Use a mobile jack. Position it on the recess for the spring mounting screw.

Slacken off shock absorber from lower mounting. Pull off shock absorber from shaft journal and lower trailing arm

Lower car and lift out shock absorber with upper mounting






Remove shock absorber upper mounting
Check the mounting bushing for wear and damage. Replace if necessary.
Use socket 999 5498 SOCKET 999 5498 Socket and wrench 999 5499 KEY UPPER PIN REAR SHOCK ABSORBER 999 5499 Key Upper Pin Rear Shock Absorber for standard shock absorbers. For Nivomat shock absorbers use socket 999 5500 SOCKET UPPER NUT REAR SHOCK ABSORBER 999 5500 Socket Upper Nut Rear Shock Absorber and wrench 999 5501 KEY UPPER PIN REAR SHOCK ABSORBER 999 5501 Key Upper Pin Rear Shock Absorber.

Install mountings onto the new shock absorber




Use a new nut

Tighten nut:
- shock absorbers to 40 Nm (29.5 lb.ft)
- Nivomat shock absorber and M12 nut to 40 Nm (29.5 lb.ft)
- for Nivomat shock absorber and M10 nut to 20 Nm (14.75 lb.ft). Angle-tighten 90° .
Use the same tools as in the previous paragraph and a protractor 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor.

Reinstall shock absorbers in car




Tighten mounting screws a few turns.

Caution! If replacing shock absorber only continue to Replacing shock absorber Replacing Shock Absorber.

Remove:




- spring mounting nut
- spring from car.

Transfer spring rubber spacer, auxiliary spring and lower mounting to the new spring






Install the new spring
Locate the spring end in the trailing arm stamped section and locate the mounting washer guide pin in the hole on the trailing arm.
Install a new nut on the mounting washer. Tighten to 40 Nm (29.5 lb.ft).

Position a mobile jack under trailing arm and lift up






Install shock absorber on lower mounting

Caution! Check that the spring is correctly positioned on the upper spring seat.

Tighten the shock absorber nuts to 80 Nm (59.0 lb.ft).

Tighten upper shock absorber mounting screws to 25 Nm (18.44 lb.ft)






Reinstall:
- front edge of panels with clips
- backrest catches. Use thread sealant. Tighten to 20 Nm (14.75 lb.ft)
- cover plate and cargo compartment carpet.

4 door late version

Fold down the cover over shock absorber mounting. Reinstall support panel and carpet