Remove/install front spring

AR32.20-D-0200E

Remove/install front spring

4.3.10



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

 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

 Only if GFP transverse leaf spring fitted

In order to avoid damaging the transverse leaf spring, cushion jacking head of vehicle jack appropriately.

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-0200-02B

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

 Roll vehicle approx. 1m forwards and back, and rock firmly.



*BA32.20-N-1001-01A

18

Tighten nuts (3) on transverse control arm bearing retaining bolts


 The vehicle must be on its wheels.

*BA33.20-N-1002-01A

19

Actuate brake pedal until brake pressure is built up again

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

Number

Designation

Model
WD1/WD2/
WD3/WD6/
WD7/XD1/
XD2/XD3/
XD4/XD5/
XD6/XD7/
YD1/YD2/
YD3/YD4/
YD5/YD6/
YD7

BA32.20-N-1001-01A

Bolt, lower spring clamp plate to front axle beam

M121.5

Stage 1

Nm

130

Stage 2

°

-

M8

Nm

-

M10

Nm

65

Number

Designation

Front axles
730.408/409/410/
411/413/414/
415/606

Front axle
732.2 in model 690.6

BA33.20-N-1002-01A

Nut, transverse control arm to front axle housing

M141.5

Nm

150

150

Number

Designation

Model 904

Model 690.6

Model
XD4, XD5,
YD4, YD5

BA42.10-N-1001-10A

Bolt securing brake caliper

M141.5

Nm

170

170

170

Number

Designation

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

Model
WD1/WD2/
WD3/WD6/
WD7/XD1/
XD2/XD3/
XD4/XD5/
XD6/XD7/
YD1/YD2/
YD3/YD4/
YD5/YD6/
YD7

BA46.40-N-1001-06D

Nut on ball head

M141.5

Stage 1

Nm

-

-

Stage 2

°

-

-

M161.5

Nm

130

130

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