Running gear, axles, steering

Chapter overview

• Technical data
  1
• 1 Checklist for evaluating running gear of accident vehicles
  1
• 2 General information
  3
• Front suspension
  4
• 1 Evaluating accident vehicles
  4
• 2 Repairing front wheel suspension
  5
• 2.1 Overview - front axle
  5
• 2.2 Raising wheel suspension to unladen position
  6
• 3 Subframe, anti-roll bar, suspension links
  9
• 3.1 Assembly overview: subframe, anti-roll bar, suspension links
  9
• 3.2 Repairing thread in longitudinal member
  11
• 3.3 Fixing position of subframe
  11
• 3.4 Removing and installing subframe
  15
• 3.5 Checking swivel joint
  17
• 3.6 Removing and installing swivel joint
  18
• 3.7 Installation position of swivel joints
  22
• 3.8 Removing and installing suspension link
  22
• 3.9 Renewing front bonded rubber bush for suspension link
  25
• 3.10 Renewing rear bonded rubber bush for suspension link
  28
• 3.11 Removing and installing anti-roll bar
  30
• 3.12 Removing and installing rubber bush for anti-roll bar
  33
• 4 Assembly overview: wheel bearing
  35
• 4.1 Pulling out and pulling in wheel hub with wheel bearing
  37
• 4.2 Removing and installing wheel bearing housing
  43
• 5 Assembly overview: suspension strut
  47
• 5.1 Removing and installing suspension strut
  48
• 5.2 Repairing front suspension strut
  55
• 6 Removing and installing drive shafts
  59
• 6.1 Removing and installing drive shaft with constant velocity joint
  59
• 6.2 Removing and installing drive shaft with triple roller joint AAR 2000 (bolted-on)
  61
• 7 Repairing drive shafts - overview of drive shaft's
  65
• 7.1 Heat shields for drive shafts
  65
• 8 Assembly overview: drive shaft with VL90 or VL100 constant velocity joint
  67
• 8.1 Dismantling and assembling drive shaft with VL90 or VL100 constant velocity joint
  69
• 8.2 Checking outer constant velocity joint
  76
• 8.3 Checking inner constant velocity joint
  77
• 9 Assembly overview: drive shaft with VL107 constant velocity joint
  81
• 9.1 Dismantling and assembling drive shaft with VL107 constant velocity joint
  83
• 10 Assembly overview: drive shaft with triple roller joint AAR 2000/108
  90
• 10.1 Dismantling and assembling drive shaft with triple roller joint AAR 2000/108
  92
• Rear suspension
  103
• 1 Evaluating accident vehicles
  103
• 2 Repairing rear axle
  104
• 2.1 Overview - rear axle
  104
• 2.2 Rear axle in unladen position
  105
• 3 Assembly overview: axle body, drum brake
  109
• 3.1 Removing and installing rear axle
  111
• 3.2 Removing and installing bonded rubber bush
  117
• 3.3 Removing and installing coil spring
  125
• 4 Assembly overview: axle body, disc brake
  127
• 5 Assembly overview: rear left vehicle level sender G76, front-wheel drive
  130
• 5.1 Removing and installing rear left vehicle level sender G76
  130
• 6 Assembly overview: shock absorber
  132
• 6.1 Removing and installing shock absorbers
  133
• 7 Assembly overview: wheel bearings, drum brake
  136
• 7.1 Removing and installing wheel hub with wheel bearing, vehicles with drum brakes
  137
• 8 Assembly overview: wheel bearings, disc brake
  140
• 8.1 Removing and installing wheel hub with wheel bearing, vehicles with disc brakes
  140
• Wheels, tyres, vehicle geometry
  144
• 1 Evaluating accident vehicles
  144
• 2 Specified torque for wheel bolts
  145
• 3 Removing and fitting tyres with run-flat properties to wheel rims
  146
• 3.1 Notes on safety and prerequisites
  146
• 3.2 Fittings instructions
  146
• 3.3 Pressing tyre off wheel rim
  147
• 3.4 Removing tyre from wheel
  148
• 3.5 Fitting tyre to wheel rim
  151
• 4 Tyre pressure monitor display
  154
• 5 Wheel alignment
  156
• 5.1 General
  156
• 5.2 Test prerequisites
  158
• 5.3 Test preparations
  158
• 5.4 Wheel alignment specifications
  159
• 5.5 Transverse vehicle inclination “zero position”
  160
• 5.6 Overview - wheel alignment procedure
  160
• 5.7 Correcting front axle camber
  162
• 5.8 Check rear axle camber
  163
• 5.9 Check rear axle toe
  163
• 5.10 Adjusting toe at front axle
  163
• 5.11 Checking left and right-hand wheel lock
  164
• 5.12 Vehicle data sticker
  165
• 6 Wheels, tyres
  167
• 6.1 Models with breakdown set
  167
• 6.2 Tyre sealant
  167
• 6.3 Removing a tyre
  167
• 6.4 Fitting a new tyre
  168
• 6.5 Tyre sealant disposal
  169
• 7 Instructions for changing or fitting wheels
  170
• 7.1 Fitting wheels
  171
• 8 Protecting wheel centring seat against corrosion
  173
• 9 Vibration due to wheels/tyres - causes and rectification
  174
• 9.1 Causes of vibration
  174
• 9.2 Balancing wheels
  174
• 9.3 Conducting a road test before balancing wheels
  175
• 9.4 Balancing wheels on stationary wheel balancing machine
  175
• 9.5 Vibration control system VAS 6230
  177
• 9.6 Finish balancer
  178
• 9.7 Radial and lateral run-out of wheels and tyres
  179
• 9.9 Checking radial and lateral run-out on wheel rim
  180
• 9.10 Matching
  181
• 9.11 Flat spots caused by storage or handling
  182
• Steering
  184
• 1 Steering wheel
  184
• 1.1 Assembly overview - steering wheel
  184
• 1.2 Removing and installing steering wheel
  184
• 2 Steering column
  187
• 2.1 Assembly overview - steering column
  187
• 2.2 Removing and installing steering column
  189
• 2.3 Handling and transporting steering column
  201
• 2.4 Removing and installing intermediate steering shaft
  203
• 2.5 Repairing steering column
  204
• 2.6 Removing and installing power steering control unit J500
  205
• 3 Steering rack
  217
• 3.1 Assembly overview - steering rack
  217
• 3.2 Removing and installing steering rack
  217
• 3.3 Repairing steering rack
  222
• 3.4 Removing and installing track rod
  223
• 3.5 Removing and installing track rod ball joint
  228
• 3.6 Adjusting steering rack
  230
• 4 Sensors
  231
• 4.1 Removing and installing steering angle sender G85
  231