Removal and Replacement

Tensioner 999 5659, User instructions

Special tools:
999 5659 Tension caliper 999 5659 Tension Caliper
999 7061 Mounting 999 7061 Mounting
998 9761 Modifying kit 998 9761 Modifying Kit

Note! The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Preparation
Raise the vehicle.
Remove the Handbrake cable mountings from the sub-frame.
Install the tensioner.

Note! The tensioner must be positioned as far out as possible on the tensioner plates to provide the correct lifting force.

Use the tensioner




Tensioner 999 5659 Tension caliper 999 5659 Tension Caliper is used when working on the suspension. It is vital that the screwed joints for the rubber bushings are tightened in the normal position (in the same position as when the car is on the ground and has three people in the car and a full fuel tank).
The tensioner relieves the pressure on the components in the suspension when removing and installing.
The tool is secured to the sub-frame with mounting 999 7061 Mounting 999 7061 Mounting. This means that the lift stability is not affected during work.

Note! Thoroughly check that the power cable to the AOC connection does not get trapped between tool 9997061 and the sub frame.




Install the threaded bar on the tensioner caliper 999 5659 Tension caliper 999 5659 Tension Caliper.




Lift up the tensioner caliper with the threaded bar 999 5659 Tension caliper 999 5659 Tension Caliper.
Insert the threaded bar in the mounting 999 7061 Mounting 999 7061 Mounting from underneath.
Insert the locking washer with the handle in from the side in mounting 999 7061 Mounting 999 7061 Mounting under the threaded screw.
Lock the screw in the locking washer. Align the locking washer in the mounting.

Note! The locking washer has a locating pin which must be aligned with the screw.




Install the 2 screws (5740-3c) from kit 998 9761 Modifying kit 998 9761 Modifying Kit in the control arm holes.




Install the rails 5740-1 modified according to (VM-277) on the control arms.
Make sure that the outer support lugs of the rail come in contact with the edge of the cast holes in the control arms and that the inner of the two center holes is used for the screw.
Make sure that the rollers on the tensioner comes in contact with the rails on both sides.

Note! The tensioner must be positioned as far out as possible on the rails with the lifting arms extended equally on both sides to provide the correct lifting force.




Raise the control arms to their normal position using the tensioner.

Normal position




The normal position of the rear suspension is 453 mm from the wing edge to the center of the wheel.

Removing the tensioner
Detach the tensioner, pull out the fork and lower the tensioner using the threaded bar.

Remove:
- mounting 999 5659 Tension caliper 999 5659 Tension Caliper from the sub frame.
- the rails 5740-1 from the control arms.
Install the Handbrake cable mountings in the sub-frame.