Front Air Shock Absorber

Front Air Shock Absorber

Special Service Tools






Air spring tester

204-538

Removal

NOTE:
This procedure should also be used to remove the front air spring.
1 Remove the shock absorber and spring assembly. For additional information, refer to Front Shock Absorber and Air Spring Assembly




2 Remove the nut, rebound washer and rubber bushing.
- Discard the nut.




3 Remove and discard the O-ring seals and spacer.




4 Remove the nylon retaining pin.




5 Remove the air spring.
- Using a soft faced mallet, gently tap the sleeve support upwards to release it from the O-ring seals.
- Remove and discard the 2 O-ring seals.
6 Remove the rebound plate and spring aid.
7 Remove the shock absorber from the vise.

Installation
1 Install the shock absorber in the vise.
2 Clean the components.
3 Lubricate and install new O-rings to the seal carrier.
4 Install the spring aid and rebound plate.




5 Install the air spring.
- Align the piston with the first O-ring seal, making sure the location tag is correctly aligned.
- Install the new O-ring seals and spacer, taking care not to damage the seals.




6 Install the rubber bushing and rebound washer.
- Make sure the formed insert on the bushing is located against the O-ring seal.
- Install and lightly tighten the nut.




7
CAUTION: The air supply must be free of any moisture.
CAUTION: If during disassembly the air sleeve is unrolled, the air sleeve may inflate incorrectly (to one side). If this occurs, release the air pressure, and insert a suitable tool that will not damage the air sleeve or piston (a screw driver handle), into the side opposite the bulge. Inflate and deflate until the air sleeve inflates correctly (the air sleeve will be uniform inside the shroud).
Using the special tool coupled to a tire inflator with a gauge, apply approximately 2 bar of air pressure to the air spring to fully seat the piston over the O-ring seals.
8 Install the nylon retaining pin.
9 Install a new nut and tighten to 98 Nm (72 lb.ft).

10 Check the assembly for leaks.
- Inflate the module to 4 bar and check for pressure loss.
- If a leak is suspected, immerse the spring and shock absorber assembly in a tank of water to locate the source of the leak.

11 Remove the special tool.

12 Install the shock absorber and spring assembly. For additional information, refer to Front Shock Absorber and Air Spring Assembly