Remove/install supporting strut

AR31.35-B-4350A

Remove/install supporting strut

12.02.16



Remove



Important information and preliminary measures

1

General: The removal and installation of the spring supports, shock absorbers, stabilizers and other items fastened to the longitudinal members, as a general rule, can only be removed in the case of serious accidents in which they have been affected and deformed. All the supports fastened to the longitudinal members can be replaced relatively easy due to their standardized fastening.

2

 We recommend to carry out the repairs per axle, always at both sides of the vehicle.

3

Bolts and nuts to be used: All the supports are standardized, in such a way that they are fastened to the longitudinal members with bolts and nuts of the Torx type (both with flanges). The nuts are self-locking and can be removed and reused for 5 times. If their re-utilization exceeds 5 times, the nuts must be replaced. In the case of substitutions, the bolts and nuts with flange quality requirement is of 10.9.

The bolts original assemblage positions must be considered for each support.

4

Supports contact surfaces: The contact surfaces must be in perfect conditions for the placement of the components. In the case new supports are to be installed, if necessary, before the assemblage, put a protective layer of the appropriate base pain on the surfaces that contact the longitudinal members.

5

Put the vehicle on a flat and leveled floor that permits to work with safety. Choke the rear wheels to avoid that it accidentally moves.

6

Turn the general switch off.

 As this refers to electronic vehicles, always observe the recommendations for this type of vehicles.

7

With the vehicle on the ground, unscrew a little bit the front axle wheels. The removal of the front wheels will be carried out later, when the vehicle has been already lifted.

AR40.10-B-1100E

Danger!

Take the due care when lifting the vehicle.

Risk of severe accidents.

AS60.80-B-0002-01A

 Do not lift the vehicle by the axles center point.

 During this type of work it is necessary to support the vehicle on the longitudinal members in order to be able to move the axle. If this axle is hung, the shock absorbers can exceed their normal travel distance and get severely damaged without this being noticed by the workshop staff. In this case, in order to avoid any type of damage, the shock absorbers must be unfastened at their bottom part before the longitudinal members are choked and before the springs are unfastened or removed.

AR32.25-B-0105F

8

Support the vehicle on racks placed safety under its longitudinal members, at both sides, in order to be able to work safely. In this position, it will be possible to move the front axle according to the work needs.

 Lifting the vehicle only at one side while keeping the wheel of the opposite side supported on the ground is not recommended. It must be equally lifted at both sides.

9

Unfasten the front stabilizer side rods (17).

 This enables the movements of the front axle.

AR32.35-B-2050K

10

Remove the wheels corresponding to the place where the support will be removed from, if this is the case.

 The removal of the wheels facilitates the access to the place where the supports are located, however, if a modern and appropriate lifter where the wheels remain supported is used, it is also possible to remove some supports without removing the wheels.

AR40.10-B-1100E

Danger!

Take due care during the cabin tilting operation.

Risk of severe accidents.

AS60.80-B-0001-01A

AS60.80-B-0002-01A

11

Tilt the cabin up to its final opening position.

 Fasten the cabin with the appropriate safety equipment.

 With the vehicle in this position, it will be possible to remove almost all the front supports fastened to the longitudinal members, except for those that serve to support and lift the cabin.

AR60.80-B-0010D



Remove

Front axle spring support and limiting stoppers

 The front spring support at the right side requires special care, due to the fact that a part of the assisted steering hydraulic set (17.1) is fastened to the support and the fastening differs very much from the support located at the left side.

1

At the springs (5) remove the bolts and nuts with flange (6) from the front articulations.

 At the right side, if necessary, unfasten the steering bar at the terminal linked to the Pitman arm (17) of the assisted steering hydraulic set (7.1).

AR32.20-B-0200G

2

In the back of the springs (11) remove the bolts with flange from the shackles upper articulations. At this point the springs get released enabling to move the front axle. Put away the spring ends (5) and (11) lowering the front axle.

 The shackle's bolts use nuts with flange, differently from the rear spring shackle bolts in which the bolts are screwed in the inner plate.

AR32.20-B-0200G

3

In the rear part of the front springs, remove the nuts and bolts with flange (9) and remove from the longitudinal members (2) the supports (8) of the spring stoppers.

 Together with the rear supports, the shackles upper articulation upper bushings will go out still assembled.

 If it is necessary to carry out a complete repair, it is preferable to remove the front springs.

AR32.20-B-0200G

4

In the spring front right part (5), remove the bolts and nuts with flange (3) and remove the right support (1) from the longitudinal member (2).

 The rivets(4) fasten the lower part of the supports and do not interfere. New supports are supplied already riveted.

5

At the front left part of the spring (5), remove the two bolts and nuts with flange (3.1) which fasten the assisted steering hydraulic set with the support (1).

 From inside, unfasten a little bit the other bolts that fasten the assisted steering hydraulic set. Remove the other support fastening bolts, whereas the upper one is screed in the hydraulic set and the other, the lower one with the nut fastens the support to the longitudinal member. Remove the support (1) from the longitudinal member (2).

6

Remove bolts and nuts with flange (13) and remove the supports (12) of the shock absorbers from the longitudinal members (2).

Remove the springs cylindrical stoppers from the supports.



Install

Front axle spring supports and limiting stoppers

7

Assemble new spring limiting stoppers in the supports (12). Then, assemble the supports on the longitudinal members (2) and fasten them with the bolts and nuts with flange (13).



*BA31.30-B-1013-01G

8

Assemble new elastic bushings in the springs front and rear adapters (eye bolts). Assemble the elastic bushings in the adapters of the new rear supports (8) to the shackles upper articulation.

 Pay attention to the correct position of the bushings in the springs and shackles articulations.

AR32.20-B-6721E

9

Assemble the front support (1) on the right longitudinal member and fasten it with the bolts and nuts with flange (3).

 Tighten the nuts (3) in a gradual and crosswise manner to avoid tension points in the longitudinal members.



*BA31.30-B-1001-01G

10

At the left side it is necessary to pay attention in order to have the assisted steering hydraulic set (7.1) enables the assemblage of the new support (1).

Fit the new support (1) in the longitudinal member (2) and from outside, put without tightening, the two bolts (3.1) with the nuts (both with flanges)

From inside the longitudinal member put he upper bolt with flange which is screwed in the assisted steering hydraulic set.

In the lower part, put the bolt and the nut with flange that fasten the support to the longitudinal member .

Tighten all the bolts and nuts that fasten the hydraulic assisted steering set (7.1) and the support (1) on the longitudinal member (2).

 Tighten the nuts and bolts in a gradual and crosswise manner to avoid tension points in the longitudinal member and in the assisted hydraulic steering set.

*BA31.30-B-1014-01G

11

Assemble the front springs and put the bolts and nuts with flange in the front articulations.

In the rear part (11) assemble the shackles (10) with bolts with flange screwed in the inner plates.

AR32.20-B-0200G

If it has been removed, assemble the steering bar terminal in the Pitman arm outlet (7).



Remove

Supports of the front stabilizer and shock absorbers

 We consider that the vehicle is in a favorable position after the items from 1 to 10 have been complied with: Important preliminary information and measures.

1

With the front stabilizer bar side rods (17) loosened at their upper part, remove the bolts and nuts with flange (19) that fasten the supports (18) to the longitudinal members (2) and remove them.

 Together with the supports, the stabilizer side rods upper articulation bushings will go out assembled.

AR32.35-B-2050K

2

In order to remove he supports (14) from the front shock absorbers (16), firstly disassemble them from the supports upper fastenings (4).

 Take care with the harness formed by the power cables and by the front brakes polyamide tubes.

AR32.25-B-0105F

3

Remove the bolts and nuts with flange (15) and remove the supports (14) of the shock absorbers from the longitudinal members (2).



Install

Supports of the front stabilizer and shock absorbers

4

Assemble the new elastic bushings in the front stabilizer side rods (17) new support (18) adapters (eye bolts).

 Pay attention to the correct position of the elastic bushings in the support adapters (18).

AR32.35-B-2050K

5

Install the new supports (18) of the front shock absorbers in the longitudinal members (2) and tighten a little bit the nuts and the bolts with flange (19).

 Carry out the final tightening of the nuts and bolts in a gradual and crosswise manner to avoid tension points in the longitudinal members.



*BA31.30-B-1008-01G

6

Assemble the side rods (17) on the supports (18) and tighten the bolts and nuts with flange of the upper articulations.



*BA32.35-B-1001-02D

7

Install the new supports (14) of the front shock absorbers on the longitudinal members (2) and tighten a little bit the nuts and bolts with flange (15).

 Carry out the final tightening of the nuts and bolts in a gradual and crosswise manner to avoid tension points in the longitudinal members.



*BA31.30-B-1006-01G

8

Fasten the upper part of the shock absorbers (16) to the supports (14).

 The shock absorbers lower part must be fastened to the front axle, only when it is not necessary to move the axle anymore.

AR32.25-B-0105F



*BA32.25-B-1001-01B

9

Considering that the front springs and the stabilizer have been totally assembled, fasten the shock absorbers at the lower part to the front axle.

AR32.25-B-0105F

10

Install the wheels and tighten them a little bit, if applicable. The final tightening will be carried out after the vehicle have been put on the ground.

AR40.10-B-1100E

Danger!

Take due care during the cabin closing operation.

Risk of severe accidents.

AS60.80-B-0001-01A

AS60.80-B-0002-01A

11

Remove the safety equipment and lower the cabin up to its normal driving position.

Danger!

Take due care to remove the chokes from the longitudinal members and lower the vehicle.

Risk of severe accidents.

AS60.80-B-0002-01A

AS60.80-B-0002-01A

12

Lower the vehicle up to the ground and carry out the final tightening of the wheels.

 Carry our rigorously the later re-tightenings after having driven the loaded vehicle 500 to 1000 Km.

AR40.10-B-1100E

13

Turn the general switch on.

 As this refers to electronic vehicles, always observe the recommendations for this type of vehicles.

14

Check whether everything is in order in the vehicle.

 Carry out a test drive and check the vehicle behavior.

Número

Denominação

Vehicles 979.0

BA31.30-B-1001-01G

Front support of the chassis rail spring

M14x1.5

Nm

150

BA31.30-B-1006-01G

Front damper support on the frame rail

M12x1.5

Nm

140

BA31.30-B-1008-01G

Torsion bar console/front and rear thrust shackle on the frame rail

M12x1.5

Nm

100

BA31.30-B-1013-01G

Central stops support to the frame rail springs

M12x1.5

Nm

92

BA31.30-B-1014-01G

Steering box on the frame rail

M14x1.5

Nm

150

Número

Denominação

Vehicles 979.0, 979.272/276/277

BA32.25-B-1001-01B

Front shock absorbers in the rail supports

M14 x 1.5

Nm

150

Número

Denominação

Vehicles 979.01/02/04, 979.07, 979.276/277

BA32.35-B-1001-02D

Upper and lower joints of the rods/shacklers

M12X 1.5

Nm

92