Removal/Installation, Final Drive Only
USE OF COMPRESSION TOOL P/N 999-5577The compression tool is used when working with the suspension where it is vital that the screwed joints to the rubber bushings are tightened in the normal position, that is to say in the same position as when the car is on the ground.
The compression tool off-loads pressure on the component parts in the suspension when carrying out removal/installation operations. The tool is attached to the rear axle member, which means that it has no affect on the stability of the hoist during work.
Take care to keep the contact surfaces of the tool clean where it meets the rear axle member.
Attach the tool to the member and tighten the clamp.
During tightening rock the tool.
- Connect puller shaft 5577-1 to the puller cylinder 999 5575.
- Screw the shaft to its contact face.
- Hook the shalt in the actuator arm and the holder for the puller cylinder.
The link can now be pressed up to its normal position.
Insert the locking pin.
The puller cylinder can be removed and used for other operations, e.g. bushing replacement.
TOOLS REQUIRED
^ 999 5577 Compression Tool
^ 999 5580 Holder
^ 999 5972 Universal Fixture
^ 999 5579 Holder
^ 999 5088 Drift
^ Or Equivalent
REMOVAL
1. Raise the car.
- Locate the rear arms of the lift so as to avoid obstructing the support arms and the arm brackets of the vehicle.
2. Remove:
- The wheels.
- Nuts on the anti-roll bar links to the rear axle beam.
- Screws in the support arms.
- Anti-roll bar.
3. Install compression tool, refer to: USE OF COMPRESSION TOOL P/N 999-5577 (at top).
- Apply the compression tool lightly against the link.
- Remove damper lower screw, remove damper from support arm.
4. Press up link to normal position:
- Secure the compression tool with locking pin.
- Remove the screws in the front and rear edges of the support arm.
- Slacken nut in front edge.
Tap support arm off the wheel bearing housing.
- Remove the nut in front edge.
- Remove the support arm.
5. Remove the following:
- Track rod screw and tap off rod from wheel bearing housing.
- Nut to link screw in the wheel bearing housing.
Tap out the screw.
Use a brass drift.
- Release compression tool and remove.
- Repeat steps 3 and 4 on other side.
6. Loosen screws on lower rear axle beam.
- Slacken screws approx. one turn.
- Remove the two front screws and the spacers.
Tool No. 999 5579, Holder For Differential Housing, Rear Axle Beam Or Leaf Spring Bushing Replacement:
- Install retainer to front edge and rear edge of [1][2]differential.
7. Position lift unit lightly against the lower rear axle beam.
- Use universal fixture.
- Remove the screws loosened earlier.
- Lower and remove lower rear axle beam.
8. Remove screws to propeller shaft intermediate bearing.
9. Locate the lift unit with fixture the [1][2]differential.
a. Adjust the supporting arms and raise the lift until it in contact with the [1][2]differential.
b. Remove retainer from [1][2]differential.
10. Carefully lower the [1][2]differential housing.
a. Lower approximately 50 - 60 mm. So that no breaks occur in the propeller shaft.
b. Remove:
- The front bushing halves.
- The rear bushings. Use a screwdriver against the bushing inner sleeve.
- Tap off the bushing from the [1][2]differential.
11. Tap the new bushings into place. Use drift. Install the front upper bushing half.
12. Raise the [1][2]differential carefully with the lifting unit. Make sure the front bushing half is inside the guide flanges on the rear axle beam
13. Press up [1][2]differential against the beam. Fix the differential in place with tools. Press the new lower front bushing half into place.
14. Remove the lift unit. Install screws to the propeller shaft intermediate bearing.
NOTE: Washer between bearing and beam. Tightening torque 25 Nm (18 ft. lbs.).
15. Install rear axle beam.
16. Position rear axle beam on the lift unit:
- Use universal fixture.
- Check that the contact surfaces of the beams are clean and that the [1][2]differential lower, front bushing is in place.
17. Press up beam:
- Check that the bushing is outside the guide flanges on the rear axle beam.
- Install new screws.
Do not tighten screws yet.
- Remove lift unit.
- Remove retainer and Holder from [1][2]differential.
- Install the two spacers between the beams.
Use new screws.
Tighten all screws first diagonally with light pressure and then to 80 Nm (63 ft. lbs.).
18. Install the following:
- Compression tool.
Press link up to normal position and install locking pin.
- Screw to link.
- Wheel bearing housing.
Use a new nut.
Tighten to 80 Nm (63 ft. lbs.).
- Track rod.
Use a new screw.
Tighten to 80 Nm (63 ft. lbs.).
19. Install the following:
- The support arm with new screws and new nut in front and rear edge.
Do not tighten.
- Tighten in the following order:
The rear screw, tighten to 80 Nm (63 ft. lbs.).
The nut in front edge, tighten to 80 Nm (63 ft. lbs.).
Screws in front edge, tighten to 50 Nm (37 ft. lbs.).
20. Install dampers (shock absorbers):
- Standard type:
ompress damper by hand and install on support arm.
Use a new screw.
Tighten to 80 Nm (63 ft. lbs.).
- Self-levelling type:
Release compression tool slightly so the damper can be attached to the support arm.
Push up to normal position.
Use a new screw.
Tighten to 80 Nm (63 ft. lbs.).
21. Release compression tool and remove.
- Repeat operations on other side.
22. Install anti-roll bar.
- Check that the washers and rubber bushings are in position on the anti-roll bar links.
- Install anti-roll bar to rear axle beam.
Use new nuts.
Tighten to 30 Nm (24 ft. lbs.).
- Install anti-roll bar to support arm.
Use new screws.
Do not tighten screws yet.
23. Install the wheels.
24. Lower car, then tighten anti-roll bar screws in the support arms to 80 Nm (63 ft. lbs.).