Rear air shock absorber (Discovery 3)

Special tool

Pneumatic elastic element tester 204-538

Band-it Thrift Tool 100-050 (LRT-99-019)

Removal

NOTE: This procedure should also be used when removing the rear air spring.

1.

CAUTION: Never work on a vehicle supported only by a jack. Always support the vehicle with special stands.

Raise and support the vehicle.

2. Remove the wheel.

3. Remove the shock absorber assembly with the elastic element. For more information, refer to Rear Shock Absorber Assembly with Air Spring (64.21.01.99)

4. Remove the cover. Remove and discard the 2 tapes.



5. Unscrew the nut, remove the spring washer and rubber bushing. Discard the nut.





6. Remove and discard the O-rings and spacer sleeve.



7. Remove the nylon retaining pin.



8. Remove the shaped spring and auxiliary spring.

9. Remove the pneumatic spring.

• Using a soft-faced mallet, carefully tap the bushing support upward to remove it from the two sealing rings.
• Remove and discard the two O-rings.

10. Remove the shock absorber from the vice.

Installation

1. Clamp the shock absorber in a vice.

2. Clean the parts.

3. Lubricate the seal support surface and install two O-rings on it.

4. Install the auxiliary spring and the shaped spring.

5. Install the pneumatic elastic element. Align the rod with the first ring seal, checking the mark.



6. Install new O-rings and spacer sleeve, being careful not to damage the seals.

7. Install the rubber bushing and spring washer. Make sure the molded insert on the bushing faces the O-ring.



8. Screw on and tighten the nut slightly.

9.

CAUTION: The supplied air must not contain moisture.

CAUTION: If the air hose is turned during disassembly, it may not fill with air correctly. (only on one side)In this case, release the pressure and insert a suitable tool that will not damage the air hose or stem. (for example, a screwdriver handle), from the side opposite the bulge. Pump and release pressure until the air hose is filled with air correctly. (the air hose must be positioned symmetrically in the casing).

Install the pneumatic spring rod onto the O-rings. Using a special tool connected to a tire inflation compressor with a pressure gauge, apply a pressure of about 2 bar to the pneumatic spring so that the rod is fully seated on the O-rings.

10. Tighten the top nut (tightening torque 98 Nm).

11. Check the tightness of the unit.

• Bring the pressure in the unit to 4 bar and check the unit for leaks.
• If you suspect a leak, immerse the air spring assembly with the shock absorber in a container of water to locate the air leak.

12. Put on the cover. Using a special tool, install new tapes.



13. Install the air spring assembly with the shock absorber. For more information, refer to Rear Shock Absorber Assembly with Air Spring (64.21.01.99)