Suspension - Revised Front Bushings/Replacement
204-11DATE: 02/00
Amended 02/01
V8 XJ Series/XK8
MODEL:
1997 MY-ON XK8 Range
1998 MY-ON V8 XJ Series
VIN:
001001-ON
812256-ON
Revised Front Bushings - Revised Special Tools - Replacement Procedure
Remove and destroy Bulletin 204-11, dated 02/00. Replace with this Bulletin.
Updated information is shown by black bars and asterisks.
Issue:
The design of the bushings in the front suspension lower *wishbones* on the above vehicles *was* changed, requiring a change in the procedure for replacing the bushings. The change also requires the use of different Special Tools. Since replacement bushing for earlier vehicles have been superseded to the latest condition, *the revised procedure also applies to earlier vehicles*.
Up to *VINs* 034425 and 862294, the original bushings had a nylon casing. From *VINs* 034426 and 862295, the bushings have a steel casing. The latest type bushings, which are now used for service replacement have been used in production starting with *VINs A06104 (XK) and F11235 (XJ)*.
Action:
When replacing lower wishbone bushings on the above vehicles, observe the following procedures.
^ In all cases, disassemble the front suspension as necessary, as detailed in JTIS, Section 204, SRO 60.35.32.
REMOVAL OF NYLON-CASED BUSHINGS (EARLY DESIGN)
^ Using a hydraulic press and with Special Tool 204-214 Bush Remover positioned at the flanged end of the bush, press the bush through the wishbone arm. The casing will fracture, and the outer shell of the bush will pass through the bore in the wishbone arm.
REMOVAL OF STEEL-CASED BUSHINGS (LATER DESIGN)
1. Make 2 saw cuts through the rubber and *partly* into the flange of the steel casing, at the locations shown in Illustration 1, in line with the casing of the bush.
Caution:
Do *not* cut *fully* through the steel flange. The saw cuts should penetrate through only 75 - 80 % of the thickness of the steel flange, so that the wishbone arm is *not* touched by the saw blade.
2. Use a hammer and chisel, or similar hand-tool, to bend the 'half-moons' of the flange away from the wishbone arm.
*Caution:
Ensure that the wishbone arm is not nicked by hand tools used in this operation. If using a vise to hold the arm, use soft jaws*.
Use pliers or grips to repeatedly bend the 'half-moons' back and forth until the 'half-moons' break off along the line of the saw cuts.
3. position the wishbone arm on the support plates of the hydraulic press, so that the bushed end is supported by the plates where the "half-moons" have been removed, allowing the casing of the displaced bush to pass between the support plates. See Illustration 2. (Front arm illustrated - rear arm similar).
4. Using Special Tool 204-214, press the bush from the bore in the wishbone arm.
INSTALLATION OF STEEL-CASED BUSHINGS
1. Follow the existing procedures shown in JTIS, with the following changes:
^ Use Special Tool 204-279 when pressing in the bush for the rear lower wishbone.
^ Use Special Tool 204-280 when pressing the bush for the front lower wishbone.
2. Refer to JTIS for reassembly.
REPAIR AND INSPECTION GUIDELINES - LOWER WISHBONE BUSHINGS
Parts Information
Warranty Information
Note:
All R. 0. Number Labor Times include the necessary alignment adjustment.