General notes:
An Individual suspension unit can be removed by simply raising the required side of the vehicle with the jack supplied in the tool kit, using the correct jack location for the front.
- Figure 2 -
Should it be necessary to remove both suspension units, it is suggested that normal workshop jacking equipment be utilised, interposing a block of wood between the front suspension cross member and the crutch of the Jack.
It will be found that extensive use is made of nylon insert locking nuts on the suspension parts. It is suggested that replacement nuts be obtained, together with any other parts required, thus obviating the possibility of old nuts being inadvertently used in assembly.
THE LOCKING EFFECTIVENESS OF NYLON INSERT NUTS DETERIORATES WITH RE-USE.
- Figure 3 -
Removing a front suspension unit:
Before raising the front of the vehicle, check that the handbrake is firmly applied, or chock the rear wheels front and back.
Remove the front hub cap and loosen the front road wheel securing nuts. Place the Jack under the centre of the chassis front cross member, taking care to avoid damaging the fibreglass areas to the front and rear of the member. Support the vehicle by placing trestles or stands under the front cross member immediately behind the steering unit access panel, in the position indicated in Fig. 4.
- Figure 4 -
Remove the road wheel securing nuts, and lift off the road wheel. Replace the securing nuts on their studs to avoid their loss and consequential damage to the stud threads. Disconnect the front brake hose from the caliper by undoing the nut to the rear of the bracket holding the brake pipe to the vertical link, or remove the two bolts holding the caliper and the brake pipe to the caliper mounting bracket. Tie the unit conveniently out of the way taking care not to damage or kink the pipes. Undo the locknut and pull the brake hose forward through the bracket, clear of the suspension unit, and drain the brake fluid into a clean jar.
Remove the Nyloc nut on the end of the steering arm, and separate the track rod end from the steering arm using a suitable taper puller.
- Figure 5 -
Undo the locknuts (I Fig.5) securing both ends of the anti-roll bar to their respective studs situated on the lower mounting of each spring/damper unit. Swing the roll-bar slightly downwards off the mounting and remove the cup washers and rubber bushes.
Loosen the Nyloc nuts to the front and rear of the lower wishbone at its mounting pivot pins on the chassis.
Loosen the Nyloc nut of the spring/damper bolt ('A' Fig 5) at the lower wishbone mounting, three or four turns.
Undo the Nyloc nut and remove the bolt ('B' Fig 5) attaching the lower wishbone to the trunnion allowing the wishbone to splay slightly and swing down wards under the action of the spring/damper unit to take up its fully extended condition.
- Figure 6 -
Remove the nuts and washers from the front and rear lower wishbone chassis mounting pivot pins (Fig 6) and pull off each individual arm (making up the wishbone) from the chassis pivots.
Remove the grommet 'D' from the bodywork to the rear of the upper wishbone mounting pivot pin.
Pull the carpet away from the box in the foot well, exposing the hole.
Undo the Nyloc nuts and remove the washer on either end of the upper wishbone pivot pin ('E' Fig 6).
With a suitable drift, drive the pin rearwards, towards the exposed hole releasing the suspension components in the process. Care must be exercised not to damage the threads during this operation.
Remove the suspension unit to the bench for dismantling.
Refitting a front suspension unit:
- Figure 7 -
Before refitting check for correct assembly of the components, that all worn or damaged components are replaced, and that new seals and nuts are used in assembly (Fig 7).
The trunnion should be fitted to the vertical link in the manner prescribed in the ensuing chapter and should be in its first working position. This will allow the trunnion to turn at least 60° to either side of the straight ahead position without binding.
To refit the suspension unit, reverse the procedure outlined previously. [1]
Assembly is simplified if the top wishbone of the unit is secured to the chassis initially. During this operation the unit should be supported, and care taken to ensure that it does not swing about its pivots with consequential damage.
Do not tighten the bolt at the lower spring/damper mounting. This bolt also serves to clamp the lower wishbone halves together.
The lower wishbone assembly must therefore be carefully raised into position on either side of the trunnion with the seals and washers interposed and the holes aligned before the trunnion bolt is inserted.
Leave the nuts on the wishbone pivot pins, damper bolt and trunnion bolt slack until the vehicle is in the static laden condition, then tighten to the recommended torque loadings outlined in the technical specifications section of this manual.
When connecting up the roll bar, do not forget the attachment on the opposite suspension unit.
Assemble cup washers and bushes in the correct order when attaching the anti-roll bar to its mounting points on the lower spring/damper eyes.
If the brake caliper has been removed inspect the flexible pipe and its attachment points for wear and damage, replacing if necessary.
Connect up the pipe taking care not to kink the pipe.
Replenish the system with brake fluid and bleed the system.
Refit the road wheel, remove the stands or lower the vehicle to the ground.
Tighten the wheel nuts and refit the wheel trim and nave plate.
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