Overhaul

Front Damper/Spring Disassembly, Inspection, and Reassembly

Exploded View-Without active damper system





Exploded View-With active damper system





NOTE:

- When compressing the damper spring, use a commercially available strut spring compressor (Branick MST-580A or Model 7200, or equivalent) according to the manufacturer's instructions.
- Except where called out, the illustrations are shown without active damper system.
- Refer to the Exploded View as needed during the following procedure.

Disassembly

1. Compress the damper spring, then remove the self-locking nut (A) while holding the damper shaft with a hex wrench (B). Do not compress the damper spring more than necessary to remove the nut.





2. Release the pressure from the strut spring compressor, then disassemble the damper as shown in the Exploded View.

Inspection

1. Reassemble the damper mounting base, the damper mounting washer, and the self-locking nut.

2. Compress the damper assembly by hand, and check for smooth operation through a full stroke, both compression and extension. The damper should extend smoothly and constantly when compression is released. If it does not, the gas is leaking and the damper should be replaced.





3. Check for oil leaks, abnormal noises, and binding during these tests.

Reassembly

1. Install the damper spring (A) on the upper spring mounting cushion (B), then align the upper end (C) of the damper spring with the cushion stop (D) or the cushion end (E).

Without active damper system





With active damper system





2. With active damper system: Install the dust cover sleeve to the damper unit.

3. Install the tab (A) on the lower spring seat (B) in the locating hole (C) on the damper unit (D).

Without active damper system





With active damper system





4. Align the lower end (E) of the damper spring with the stepped part (F) of the lower spring seat.

5. Install all the parts except the damper mounting washer and the self-locking nut onto the damper unit (A) by referring to the Exploded View.





6. Compress the damper spring using a strut spring compressor. Do not compress the spring excessively.

7. Align the angle of the stud (A) on the damper mounting base (B) and the damper bracket (C) as shown.

Without active damper system





With active damper system





8. Install the damper mounting washer (A) and a new self-locking nut (B).





9. Hold the damper shaft (C) using a hex wrench (D), and tighten the self-locking nut to the specified torque.