Special tool
Pneumatic spring tester 204-538 | Bandit Thrift Tool 100-050 (LRT-99-019) |
Removing
NOTE: This procedure must also be used when removing the rear air spring.
1.
WARNING: It is forbidden to carry out work on a vehicle standing on only one jack. Always support the vehicle with vehicle stands.
Raise and support the vehicle.
2. Remove the wheel.
3. Remove shock-absorber in gathering with an elastic element. For more information, refer to Rear Shock Assembly with Air Spring (64.21.01.99)
4. Remove the cover. Remove and discard 2 tapes.
5. Loosen the nut, remove the spring washer and rubber bushing. Discard the nut.
6. Remove and discard o-rings and spacer.
7. Remove the nylon retaining pin.
8. Remove the shaped spring and the auxiliary spring.
9. Remove the pneumatic elastic element.
- Using a soft-faced mallet, carefully tap the bushing caliper up to remove it from the two o-rings.
- Remove and discard two o-rings.
10. Remove the shock absorber from the vise.
Installation
1. Clamp the shock absorber in a vise.
2. Clear the details.
3. Lubricate the seal seat and install two O-rings on it.
4. Install the auxiliary spring and shaped spring.
5. Install the pneumatic spring. Align the stem with the first O-ring, referring to the mark.
6. Install new o-rings and spacer being careful not to damage the seals.
7. Install the rubber bushing and spring washer. Make sure the molded insert on the sleeve faces the o-ring.
8. Screw on and lightly tighten the nut.
9.
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).
Install the air spring stem on the o-rings. Using a special tool connected to the tire inflation compressor with a pressure gauge, apply a pressure of about 2 bar to the pneumatic elastic element so that the stem is fully seated on the O-rings.
10. Tighten the top nut (tightening torque 98 Nm).
11. Check the tightness of the assembly.
- Pressurize the assembly to 4 bar and check the assembly for leaks.
- If a leak is suspected, immerse the air spring assembly with shock absorber in a container of water to locate the air leak.
12. Put on a cover. Use the special tool to install new tapes.
13. Establish a pneumatic elastic element in gathering with the shock-absorber. For more information, refer to Rear Shock Assembly with Air Spring (64.21.01.99)
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