Special tool
Pneumatic spring tester 204-538 | Front air shock absorber rod nut remover 204-700 |
Removing
NOTE: This procedure must also be used when removing the front air spring.
1. Remove the front shock absorber assembly with air spring. For more information, please refer to
2.
NOTE: If no leak is found, inspect other areas of the air suspension for faults.
Check the tightness of the assembly.
- Pressurize the module to 4 bar and use a leak detection spray to test for pressure drop.
- If leaks are suspected, immerse the air spring/damper assembly in a container of water to locate the air leak. Mark the location of the leak.
3. Remove the nylon retaining pin.
4. Loosen the nut using the special tool.
5. Remove the kick washer.
6.
CAUTION: Install protective spacers on the vise jaws. Failure to follow this instruction may result in damage to the element.
CAUTION: Do not pinch the shock absorber tube. Failure to follow this instruction may result in damage to the element.
Clamp the front shock absorber assembly with air spring in a vise.
7. Remove and discard the three spacers and two o-rings.
8. Remove the air spring. With a soft-faced mallet, carefully tap the bushing caliper up to remove it from the two o-rings.
9.
NOTE: Mark the installation position.
Remove the striker plate and auxiliary spring.
10. Remove and discard the two large black o-rings from the bottom seal housing.
11. Remove the front shock absorber and air spring assembly from the vise.
Installation
1.
CAUTION: Install protective spacers on the vise jaws. Failure to follow this instruction may result in damage to the element.
CAUTION: Do not pinch the shock absorber tube. Failure to follow this instruction may result in damage to the element.
Clamp the front shock absorber assembly with air spring in a vise.
2.
CAUTION: Use compressed air and a lint-free cloth.
Clear the details.
3. Lift the seal housing to expose the o-ring kit. Make sure that the shock absorber body O-rings and spacers are fully seated on the spring plate.
4.
CAUTION: Be careful not to damage the O-rings during installation.
Install new o-rings in the seal housing. Apply loctite 8021 (silicone based oil) on sealing rings.
5.
NOTE: The elements must be installed in the original position marked when removed.
Install the striker plate and auxiliary spring.
6. Install the pneumatic spring. Align the support sleeve with the first o-ring, making sure that the locating lug fits correctly into the cutout on the spring plate.
7.
CAUTION: Wrap the threads of the front air spring with protective tape.
CAUTION: Be careful not to damage the O-rings during installation.
Install the items in the following order:
- 1) Sealing ring
- 2) remote element
- 3) Sealing ring
- 4) remote element
- 5) remote element
8.
NOTE: After assembly, the top surface of the impact washer should be marked "T5".
Install the impact washer.
9. Using the special tool, screw on the new nut and tighten it to 98 Nm.
10.
WARNING: The supply air must not contain moisture.
WARNING: If the air tube is unfolded during disassembly, it may not fill properly with air (on one side only). In such a case, release the pressure and insert a suitable tool that cannot damage the air sleeve or stem (e.g. screwdriver handle), from the side opposite to the swelling. Pressurize and release pressure until the air sleeve is correctly filled with air (the air hose must be located symmetrically in the casing).
NOTE: To prevent damage when installing the support sleeve over the large black o-rings, use compressed air to inflate the air spring.
Using a special tool connected to the tire inflator with a pressure gauge, apply a pressure of about 2 bar to the air spring so that the support sleeve is fully seated on the o-rings.
11. Check the tightness of the assembly.
- Pressurize the module to 4 bar and use a leak detection spray to test for pressure drop.
- If leaks are suspected, immerse the air spring/damper assembly in a container of water to locate the air leak.
12. Relieve pressure and remove the special tool from the shock absorber and air spring assembly.
13. Install the nylon retaining pin.
14.
NOTE: Install a new air spring tubing fitting.
Install the front shock absorber with air spring assembly.
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