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 Appraisal of accident vehicles
  4
• 2 Servicing front suspension
  5
• 2.1 Overview - front axle
  5
• 2.2 Raising wheel suspension to unladen position
  6
• 3.1 Repairing threads in longitudinal member
  11
• 3.2 Fixing position of subframe
  12
• 3.3 Checking swivel joint
  14
• 3.4 Removing and installing swivel joint
  14
• 3.5 Installation position of swivel joints
  17
• 3.6 Removing and installing suspension link
  17
• 3.7 Removing and installing suspension bracket
  19
• 3.8 Renewing bonded rubber bush for suspension bracket
  21
• 3.9 Removing and installing subframe
  24
• 3.10 Removing and installing anti-roll bar, vehicles with power steering
  27
• 3.11 Removing and installing rubber bush for anti-roll bar
  29
• 4 Assembly overview: subframe made of steel, anti-roll bar, suspension links
  33
• 4.1 Repairing threads in longitudinal member
  35
• 4.2 Fixing position of subframe
  35
• 4.3 Checking swivel joint
  37
• 4.4 Removing and installing swivel joint
  38
• 4.5 Installation position of swivel joints
  40
• 4.6 Removing and installing suspension link
  41
• 4.7 Renewing front bonded rubber bush for suspension link
  46
• 4.8 Renewing rear bonded rubber bush for suspension link
  49
• 4.9 Removing and installing subframe
  51
• 4.10 Removing and installing anti-roll bar
  53
• 4.11 Removing and installing rubber bush for anti-roll bar
  55
• 5 Assembly overview: wheel bearing
  58
• 6 Assembly overview: suspension strut
  71
• 6.1 Vehicle data sticker
  72
• 6.2 Removing and installing suspension strut
  72
• 6.3 Repairing front coil spring suspension strut
  78
• 7 Removing and installing drive shafts
  81
• 7.1 Removing and installing drive shaft with constant velocity joint
  81
• 7.2 Removing and installing drive shaft with triple roller joint AAR 2000 (bolted on)
  84
• 7.3 Removing and installing drive shafts with triple roller joint AAR 2000i (inserted)
  86
• 8 Repairing drive shaft - overview of drive shafts
  91
• 8.1 Heat shields for drive shafts
  93
• 9 Assembly overview: drive shaft with VL90 or VL100 constant velocity joint
  94
• 9.1 Dismantling and assembling drive shaft with VL90 or VL100 constant velocity joint
  96
• 9.2 Checking outer constant velocity joint
  100
• 9.3 Checking inner constant velocity joint
  101
• 10 Assembly overview: drive shaft with VL107 constant velocity joint
  104
• 10.1 Dismantling and assembling drive shaft with VL107 constant velocity joint
  106
• 11 Assembly overview: drive shaft with triple roller joint AAR 2000/100 (bolted-on)
  111
• 11.1 Dismantling and assembling drive shaft with triple roller joint
  113
• 12 Assembly overview: drive shaft with triple roller joint AAR 2000/108 (bolted-on)
  119
• 12.1 Dismantling and assembling drive shaft with triple roller joint
  120
• 13 Assembly overview: drive shaft with triple roller joint AAR 2000i (inserted)
  121
• 13.1 Dismantling and assembling drive shaft with triple roller joint AAR2000i
  123
• Rear suspension
  128
• 1 Appraisal of accident vehicles
  128
• 2 Repairing rear axle
  129
• 2.1 Rear axle in unladen position
  129
• 2.2 Removing and installing rear axle
  131
• 2.3 Assembly overview - rear axle beam, drum brake
  135
• 2.4 Assembly overview - axle beam (disc brakes)
  138
• 2.5 Removing and installing bonded rubber bush
  140
• 2.6 Removing and installing spring
  143
• 2.7 Removing and installing shock absorber
  144
• 2.8 Assembly overview - shock absorber on vehicle with front-wheel drive
  145
• 3 Repairing wheel bearing, drum brake
  148
• 3.1 Assembly overview - wheel bearing
  148
• 3.2 Removing and installing wheel bearing/hub unit on vehicles with drum brakes
  149
• 4 Repairing wheel bearing (disc brake)
  152
• 4.1 Assembly overview - wheel bearing
  152
• 4.2 Removing and installing wheel bearing/wheel hub on vehicles with disc brakes
  153
• Wheels, tyres, vehicle geometry
  156
• 1 Appraisal of accident vehicles
  156
• 2 Specified torque for wheel bolts
  157
• 3 Fitting wheel and tyre
  158
• 3.1 General information
  158
• 3.2 Fittings instructions
  158
• 4 Removing and fitting tyres with run-flat properties to wheel rims
  160
• 4.1 Notes on safety and prerequisites
  160
• 4.2 Fittings instructions
  160
• 4.3 Pressing tyre off wheel rim
  161
• 4.4 Removing tyre from wheel
  162
• 4.5 Fitting tyre to wheel rim
  163
• 5 Tyre Pressure Loss Indicator (TPLI)
  166
• 6 Vehicle alignment check
  168
• 6.1 General information
  168
• 6.2 Conditions for testing
  169
• 6.3 Test preparations
  170
• 6.4 Vehicle data sticker
  170
• 6.5 Wheel alignment specifications
  170
• 6.6 Transverse vehicle inclination “zero position”
  172
• 6.7 Overview - wheel alignment procedure
  172
• 6.8 Adjusting camber at front wheels, subframe made of aluminium
  173
• 6.9 Correcting front axle camber, subframe made of steel
  174
• 6.10 Check rear axle camber
  176
• 6.11 Check rear axle toe
  176
• 6.12 Adjusting front axle toe
  176
• 6.13 Checking left and right-hand wheel lock
  176
• 7 Wheels, tyres
  178
• 7.1 Models with breakdown set
  178
• 7.2 Tyre sealant
  178
• 7.3 Removing a tyre
  178
• 7.4 Fitting a new tyre
  179
• 7.5 Tyre sealant disposal
  179
• 8 Instructions for changing or fitting wheels
  180
• 8.1 Fitting wheels
  181
• 9 Protecting wheel centring seat against corrosion
  182
• 10 Vibration due to wheels/tyres - causes and rectification
  183
• 10.1 Causes of rough running
  183
• 10.2 Balancing wheels
  183
• 10.3 Conducting a road test before balancing wheels
  183
• 10.4 Balancing wheels on stationary wheel balancing machine
  184
• 10.5 Vibration control system VAS 6230
  186
• 10.6 Finish balancer
  186
• 10.7 Radial and lateral runout of wheels and tyres
  187
• 10.9 Checking radial and lateral run-out on wheel rim
  188
• 10.10 Matching
  189
• 10.11 Flat spots caused by storage or handling
  190
• Steering
  192
• 1 Appraisal of accident vehicles
  192
• 2 Electrical/electronic components and locations
  193
• 3 Steering column
  194
• 3.1 Removing and installing steering column
  194
• 3.2 Checking steering column for damage
  198
• 3.3 Removing and installing steering lock housing
  199
• 3.4 Assembly overview - cross member for steering column
  200
• 3.5 Removing and installing locking cable for ignition with key removal lock
  201
• 3.6 Checking ignition key removal lock
  202
• 3.7 Removing and installing mounting bracket
  202
• 3.8 Removing and installing strut
  203
• 4 Repairing mechanical (manual) steering rack
  205
• 4.1 Assembly overview - mechanical (manual) steering rack
  205
• 4.2 Removing and installing mechanical (manual) steering rack
  206
• 4.3 Dismantling and assembling mechanical steering rack
  210
• 4.4 Removing and installing track rod
  212
• 4.5 Checking play, security and boots of track rod ends
  213
• 4.6 Checking and adjusting left track rod length
  213
• 4.7 Allocation of track rod ball joints
  214
• 4.8 Determining centre position of steering rack
  214
• 4.9 Adjusting steering rack
  214
• 5 Repairing electrohydraulic power steering (TRW)
  216
• 5.1 Assembly overview - power steering rack (TRW)
  216
• 5.2 Removing and installing power steering rack (TRW)
  217
• 5.3 Removing and installing power steering sensor G250 (TRW)
  224
• 5.4 Dismantling and assembling power steering rack (TRW)
  227
• 5.5 Removing and installing track rod (TRW)
  229
• 5.6 Checking play, tightness and bellows of track rod ball joints (TRW)
  230
• 5.7 Checking and adjusting length of left track rod (TRW)
  230
• 5.8 Allocation of track rod ball joints (TRW)
  231
• 5.9 Determining centre position of rack (TRW)
  231
• 5.10 Adjusting steering rack (TRW)
  232
• 5.11 Checking delivery pressure of motor/pump unit (TRW)
  232
• 5.12 Removing and installing motor/pump unit (TRW)
  235
• 5.13 Assembly overview - motor/pump unit (TRW)
  239
• 5.14 Renewing reservoir of motor/pump unit (TRW)
  240
• 6 Repairing electrohydraulic power steering (Koyo)
  244
• 6.1 Assembly overview - power steering rack (Koyo)
  244
• 6.2 Removing and installing power steering rack (Koyo)
  245
• 6.3 Removing and installing power steering sensor G250 ( Koyo)
  251
• 6.4 Dismantling and assembling power steering rack (Koyo)
  254
• 6.5 Removing and installing track rod (Koyo)
  256
• 6.6 Checking play, tightness and bellows of track rod ball joints (Koyo)
  257
• 6.7 Checking and adjusting length of left track rod (Koyo)
  257
• 6.8 Allocation of track rod ball joints (Koyo)
  258
• 6.9 Determining centre position of rack (Koyo)
  258
• 6.10 Adjusting steering rack (Koyo)
  259
• 6.11 Checking delivery pressure of motor/pump unit (Koyo)
  259
• 6.12 Removing and installing motor/pump unit (Koyo)
  261
• 6.13 Assembly overview - motor/pump unit (Koyo)
  265
• 6.14 Renewing reservoir of motor/pump unit (Koyo)
  266
• 7 Bleeding steering system, checking for leaks and checking fluid level
  270
• 7.1 Bleeding steering system
  270
• 7.2 Checking steering system for leaks
  270
• 7.3 Checking hydraulic fluid level of power steering
  271