Disassembly and Assembly Instructions

Disassembly

Caution:
Danger of injury due to spring tensioning!
^ Never use an impact bolter to loosen or tighten the fastening nut!
^ Use commercially available changeover ratchet!

Note:
^ Observe the correct allocation (running gear version) when installing new springs and/or dampers!
^ It is recommended to replace the coil springs only in pairs!
^ If the coil springs are exchanged, it might be necessary to use a different spring plate than before!





1. Tension the coil spring with the spring clamp until the piston rod is relieved.
2. To undo the connection (piston rod to spring strut mount) counter at the piston rod with a 7mm open-ended wrench.
3. Remove all parts from the piston rod.
4. Replace nut for fastening the piston rod on the spring strut mount.

Preliminary work and notes on assembly:

The following spring plates (compensation parts) are available:

Allocation of the spring plate according to the coil spring tolerance group.

1 green line = 4.0 mm thick compensation part (colored black)





1 white line = 0.5 mm thick compensation part (natural color)





5. Press intermediate part (compensation part -4-) into the spring plate -5- in the correct position (not twisted) and complete with the mount -3-. Observe following note!

Note:
^ In the correct position means: None of the 7 cutouts -A- must be free on the spring plate -5-!

6. Fit protective bellows on additional spring.

Distinguishing feature of coil springs and dampers





A Identification of the running gear version (spring constant/spring length) by two different colored lines (for example, 1 x gold and 1 x red).

B Identification of the coil spring tolerance group (load group) for determination of the compensation part (spring plate) thickness. Coil spring with:

1 green line 4.0 mm thick compensation part (black)

1 white line 0.5 mm thick compensation part (natural color)

C Color dot (color label) to differentiate the vibration damper. For the Turbo, there is a variant for the USA and a variant for the RoW. Vibration damper with:

Golden color dot = RoW running gear

Red color dot = USA running gear

1. Tension coil spring with spring clamp.
2. Clamp eye of vibration damper in the vice (use jaw liners).

Assembly

Caution: Danger of injury due to spring tensioning!
^ Never use an impact bolter to loosen or tighten the fastening nut!
^ Use commercially available changeover ratchet!

1. Place pre-tensioned coil spring on the vibration damper.
2. Slide the protective tube/additional spring assembly onto the piston rod.





3. Slide the washer -7- and stop plate -6- (No. 6 in correct position) as far as they will go onto the piston rod.





4. Place the spring strut mount (assembly of spring strut mount / intermediate part / spring plate) onto the piston rod so that the end of the coil spring lies against the stop of the spring plate.
5. Place stop plate in the correct position on the spring strut mount.





6. Screw new fastening nut onto the piston rod until approximately 1 to 2 threads are visible above the fastening nut.





Note:
^ The mounts for the right and left sides are identical parts!
^ The mount is positioned correctly if one of the 3 fastening pins is aligned with the holder on the damper tube!

7. Position the spring strut mount for installation (correctly position spring strut mount with respect to the damper).
8. Tighten the fastening nut once the mount has been correctly positioned and the coil spring lies properly against the stop. Tightening torque 58 Nm (43 ft. lbs.).
^ Never use an impact bolter to tighten the fastening nut!
9. When tightening the fastening nut, hold at the piston rod using a special tool 9630 countering tool or a 7 mm open-ended wrench.