Remove/install front spring

AR32.20-D-0200A

4.3.10

MODEL 901, 902, 903 with FRONT AXLE 730.4

MODEL 690.6 with FRONT AXLE 732.210 /211

D32.20-0005-06

1 Shock-absorber strut

2 Bolt M14x1.5

3 Nut M14x1.5

4 Nut M12x1.5

5 Nut M10

6 Bolt M14x1.5

7 Stop plate

8 Bolt M10

9 Bolt M14x1.5

10 Brake caliper

11 Rubber spring bearing

12 Upper rubber spring bearing, right

13 Nut M16x1.5

14 Spring clamp plate, right

15 Rubber spring bearing, right

16 Transverse leaf spring

17 Upper rubber spring bearing, left

18 Lower rubber spring bearing, left

19 Tie rod

20 Shear bush

21 Bolt M12x1.5

22 Spring clamp plate, left

23 ABS sensor

24 ABS sensor clamping bush

25 Bolt M10

Modification notes

19.9.00

Value changed from 75 Nm to 65 Nm

Value in BA32.20-N-1001-01A changed for models 901, 902, 903, 904 with front axle 730.4

*BA32.20-N-1001-01A

	Removing
1	Unscrew front and rear bolts (21) on left and right spring clamp plates	 The vehicle must be standing on its wheels.
2	Remove front wheels	 Attach stands to frame side member in front of front axle.	AR40.10-D-1100A
3	Detach brake caliper (10) and fasten in wheel housing with wire
4	Pull ABS sensor (23) with clamping bush (24) out of mounting bore in steering knuckle	On versions with ABS, code BB0.  Expose cables and fasten in wheel housing with sensor.
5	Detach track rod (19)		*601589043300
6	Detach transverse control arm from front axle housing	 Detach the stop plates (7) left and right on transverse control arm.	AR33.20-D-1452-04B
7	Support transverse leaf spring (16) in the center with a jack
8	Remove left and right spring clamp plates (14, 22)
9	Lower jack and remove transverse leaf spring (16) towards the side
	Install
10	Install transverse leaf spring (16)		AR32.20-D-0200-02A
		Grease	*BR00.45-Z-1015-06A
	Wooden block for compressing the transverse leaf spring		WF58.50-N-3220-01A
11	Attach transverse control arm to front axle beam	 Do not tighten nuts (3) of transverse control arm bearing fixing bolts yet.	AR33.20-D-1452-05B
12	Attach track rod to transverse control arm	 Replace nut (13)
			*BA46.40-N-1001-06D
13	Install ABS sensor (23) with clamping bush (24)		AR42.30-D-0620-01A
		Acid-free grease	*BR00.45-Z-1019-06A
14	Fix sensor cable in bracket	 Ensure that it cannot chafe.
15	Attach brake caliper (10)		*BA42.10-N-1001-10A
16	Mount wheels		AR40.10-D-1100A
17	Install spring clamp plates (14, 22)	 Replace nuts (4, 5) on retaining bolts.	AR32.20-D-0200-03A
			*BA32.20-N-1001-01A
18	Roll vehicle approx. 1m forwards and back, and rock firmly
19	Tighten nuts (3) on transverse control arm bearing retaining bolts	  The vehicle must be on its wheels.	*BA33.20-N-1002-01A
20	Actuate brake pedal until brake pressure is built up again

 Front axle steel suspension

Number	Designation				Model 901, 902, 903, 904 with front axle 730.4	Model 690.6 with front axle 732.2


BA32.20-N-1001-01A	Bolt, lower spring clamp plate to front axle beam	M121.5	Stage 1	Nm	130	130
			Stage 2	°	-	-
		M8		Nm	-	-
		M10		Nm	65	65

 Wheel location, hub

Number	Designation			Front axle 732.2 in model 690.6	Front axles 730.408/409/410/ 411/413/414/ 415/606


BA33.20-N-1002-01A	Nut, transverse control arm to front axle housing	M141.5	Nm	150	150

 Front axle brake caliper

Number	Designation			Models 901, 902, 903	Model 690.6


BA42.10-N-1001-10A	Bolt securing brake caliper	M141.5	Nm	170	170

 Steering linkage

Number	Designation				Model 690.6, 901, 902, 903, 904, 905


BA46.40-N-1001-06D	Nut on ball head	M141.5	Stage 1	Nm	-
			Stage 2	°	-
		M161.5		Nm	130

Puller

601 589 04 33 00

Repair materials

Number	Designation	Order number
BR00.45-Z-1015-06A	Vaseline	Karl Käppler GmbH & Co. KG Liebknechtstr. 48 70565 Stuttgart Germany Tel. +49 711 7868-481 Fax +49 711 7868-489 www.karl-kaeppler.de
BR00.45-Z-1019-06A	ABS sensor grease	A 000 989 62 51 10

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