Remove/install air suspension bellows on front axle

AR32.22-W-2013H

Remove/install air suspension bellows on front axle

13.06.2019

Model

963

with code A1A (Front axle with air suspension)

Modification notes

22.05.2019

Work procedure completely revised.

1

Air suspension bellows

2

Compressed-air connector coupling

3

Clamp

4

Passage grommet

5

Guide pins (only on vehicles with air suspension bellows (1) from production period up to approx. 28.02.2014)

6

Upper air suspension bellows support

 Danger

Risk of death caused by vehicle slipping or toppling off during lifting

Only lift vehicle at the lift support points specified by the vehicle manufacturer.

AS00.00-Z-0032-01A

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

 Danger

Risk of death from lowering vehicle when working between wheels and body. Risk of injury from pinching or crushing when working on the air suspension.

Testing and repair work between the wheel and wheel arch or in the wheel well should only be performed if the vehicle is secured using suitable support fixtures to prevent it from lowering.
Adjustment operations should only be performed from underneath the vehicle.
Use only suitable support fixtures to secure the vehicle frame or vehicle axles in order to prevent them from lowering.
If necessary, additionally use suitable support fixtures in order to prevent other moving vehicle parts that are in the working area from lowering, or use suitable retaining devices to prevent these parts from moving suddenly and without warning.
Secure areas with moving vehicle parts against unauthorized access.

AS32.22-Z-0001-01A

Topical note

Special instructions for lifting and supporting vehicle

AH00.60-N-0100-01B

Notes on compressed air connection systems

AH00.18-N-0001-01A



Remove

1

Secure vehicle at rear axle using wheel chocks to prevent it from rolling away.

2

Lift and support front of vehicle at frame using pit hoist.

3

Switch on ignition.

4

Completely lower vehicle at front axle using level control operating unit.

 To depressurize the air suspension bellows on the front axle.

5

Switch off ignition.

6

Remove compressed-air connector coupling (2).

AR42.10-W-0900H

7

Remove clamp (3).

8

Remove air suspension bellows (1).



Air suspension bellows of front axle modified

Model 963 (except 963.004/005/021/404/405/406) as of 01.03.18

BT32.22-W-0001-01H


Do not apply mechanical force to the bellows and the roller piston of air suspension bellows (1).
Otherwise, the bellows and the roller piston of the air suspension bellows (1) may be damaged.

 Model 963 (except 963.004/005/021/404/405/406) as of 01.03.18
To remove the air suspension bellows (1) rotate through 90° so that the connection fitting for the compressed-air connector coupling (2) faces forwards or backwards.



Install

9

Clean contact surfaces of air suspension bellows (1), air suspension support and upper air suspension mounting (6).

10

Insert air suspension bellows (1) and fasten with clamp (3) at top.


Do not apply mechanical force to roller bellows and roller piston of air suspension bellows (1).
Otherwise, the roller bellows and the roller piston of the air suspension bellows (1) may be damaged.

 Check feed-through grommet (4) is correctly seated.

 Only on vehicles with air suspension bellows (1) from the production period up to approx. 28.02.2014
Make sure that the guide pins (5) of the air suspension bellows (1) are seated in the recesses (arrow) of the upper air suspension mounting (6).

11

Fill air suspension bellows (1) with compressed-air gun until the air suspension bellows (1) contacts at bottom at air suspension support.

12.1

Push air suspension bellows (1) downwards onto air suspension support until the fastener engages.

Model 963 (except 963.004/005/021/404/405/406) as of 3/1/18
with code A1A (Front axle with air suspension)



Air suspension bellows of front axle modified

BT32.22-W-0001-01H


Do not apply mechanical force to roller bellows and roller piston of air suspension bellows (1).
Otherwise, the roller bellows and the roller piston of the air suspension bellows (1) may be damaged.

 The air suspension bellows (1) is fixed in place by engaging the fastener and can therefore not lift off the air suspension support.

12.2

Push air suspension bellows (1) downwards onto air suspension support and fully insert fastener into bore.

Model 963 (except 963.004/005/021/404/405/406) up to 2/28/18
with code A1A (Front axle with air suspension)


Do not apply mechanical force to roller bellows and roller piston of air suspension bellows (1).
Otherwise, the roller bellows and the roller piston of the air suspension bellows (1) may be damaged.

 The air suspension bellows (1) is fixed in place in the bore by tilting the fastener and can therefore not lift off the air suspension support.

13

Attach compressed-air connector coupling (2).

AR42.10-W-0900H



Check

14

Switch on ignition.

15

Completely lower vehicle at front axle using level control operating unit.

16

Switch off ignition.

17

Check compressed-air connector coupling (2) for leak tightness.

 Use commercially available leak detector spray.

18

Raise vehicle at front, remove jack stands and lower vehicle.

19

Switch on ignition.

20

Move vehicle to driving level using level control system operating unit.

21

Switch off ignition.

22

Remove wheel chocks from rear axle.