4.1.7. Dismantling and assembly of knots of a suspension bracket

Dismantling and assembly of a telescopic rack

Dismantling

Fig. 4.1. Forward suspension bracket assembled: 1 – top support of a telescopic rack; 2 – top basic cup; 3 – the compression course buffer with the protection cover; 4 – compression buffer support; 5 – suspension bracket spring; 6 – lower basic cup of a spring; 7 – spherical hinge of steering draft; 8 – rotary fist; 9 – telescopic rack; 10 – eccentric washer; 11 – adjusting bolt; 12 – rack arm; 13 – rotary fist; 14 – protection cover of a forward brake; 15 – disk of the brake mechanism; 16 – lock ring; 17 – wheel nave nut; 18 – shlitsevy wheel drive hinge case shaft; 19 – the directing pin; 20 – wheel bearing; 21 – spherical hinge; 22 – suspension bracket lever; 23 – adjusting washers; 24 – stabilizer rack; 25 – stabilizer bar; 26 – stabilizer bar pillow; 27 – arm of fastening of a bar of the stabilizer; 28 – a body arm for fastening of the lever of a suspension bracket; 29 – suspension bracket lever extension; 30 – arm of fastening of an extension; 31 – protective cover of a spherical finger; 32 – bearing of a spherical finger; 33 – spherical finger; 34 – case of a spherical finger; 35 – suspension bracket rack rod; 36 – external case of the top support; 37 – internal case of the top support; 38 – bearing of the top support; 39 – rubber element of the top support; 40 – limiter of the course of the top support; 41 – protective cap of the top support; In — a zone for control of the hinge of a suspension bracket

Put tags of a relative positioning on a head of an adjusting bolt 11 (see fig. 4.1) and on a rack arm that at assembly to combine tags for approximate preservation of disorder of forward wheels. Then turn off bolts of fastening of a rotary fist 13 to an arm of a rack and remove a rotary fist assembled with a nave. Needlessly do not press off a wheel nave from bearings as at its vypressovka damage of the bearing is possible. At damage of a nave of a wheel or the bearing to a vypressuyta a nave and the bearing, using a press and mandrels 67.7853.9583 and 67.7853.9587.

Fig. 4.5. Rotary fist and details of a nave of a forward wheel: 1 – rotary fist; 2 – external mud-reflective ring; 3 – hug bearing; 4 – wheel nave; 5 – persistent washer; 6 – nut; 7 – lock ring; 8 – internal mud-reflective ring

At a vypressovka of a nave dismantling of the bearing is possible and an external half of an internal ring can remain on a nave. In this case it needs to be removed a universal stripper. For this purpose in a nave there are two special dredging. Then remove lock rings of 7 (fig. 4.5) and a mandrel to 67.7853.9587 vypressuyta the bearing from a rotary fist. At damage of landing diameter of a nave replace it.
Order of installation of the new bearing following:


Fig. 4.6. A bearing press fitting in a rotary fist: 1 – rotary fist; 2 – bearing; 3 – mandrel

– establish an external lock ring 7 (see fig. 4.5) in a rotary fist 1 and press the bearing 3. At the same time you watch that the mandrel of 3 (fig. 4.6) pressed only on an external ring of the bearing, differently its damage is possible;

Fig. 4.7. Wheel nave press fitting: 1 – mandrel; 2 – rotary fist; 3 – nave

– establish an internal lock ring and start a nave press fitting a mandrel 67.7853.9530. At its press fitting the mandrel of 1 (fig. 4.7) surely has to lean on an internal ring of the bearing. After installation of a rotary fist assembled with a nave install on the car new or former in the use, but on other car, a nut and tighten its moment 225,6–247 N · m (23–25 kgfs · l) also stop.
Turn off bolts of fastening of the protection cover 14 (see fig. 4.1) a brake disk and remove it.

Fig. 4.8. Dismantling of a rack of a forward suspension bracket: 1 – adaptation 67.7823.9545; 2 – telescopic rack; 3 – spring

Fig. 4.9. Elements of a forward suspension bracket: 1 – protective cap; 2 – limiter of the course of compression of a support; 3-top support of a rack; 4 – bearing of the top support; 5 – top cup of a spring; 6 – spring of a forward suspension bracket; 7 – adjusting bolt; 8 – eccentric washer; 9 – protection cover; 10 – compression course buffer

Install a suspension bracket rack in adaptation 67.7823.9545 (fig. 4.8), squeeze a suspension bracket rack spring. Holding a rod a key 67.7812.9535, turn off a nut on a rod, using a key 67.7812.9533. Remove the limiter 2 (fig. 4.9), the top support 3 assembled with the bearing. Having unloaded a spring 6, remove it and the top basic cup 5, and then the compression course buffer 10 with a casing 9.
Before further dismantling of a rack check its state. At vertical position of a rack (a rod up) execute several full courses stretching compression then the rod has to move without failures and jammings and there should not be knocks and extraneous noises. Also liquid dribble, deformation and destruction of the case of a rack, a basic cup, arms and the rotary lever of a rack is not allowed. The insignificant otpotevaniye in the top part of the case of a rack is not a sign of malfunction and does not serve as the reason of replacement or repair of a rack of a suspension bracket.
You carry out more exact assessment of operability of a rack at the dynamometer stand according to the removed chart as it is stated above.

Fig. 4.10. Removal of a support of the limiter of the course of compression: 1 – mandrel; 2 – compression course limiter support; 3 – rack arm

In need of repair of a rack clamp its arm in a vice so that his cheeks were perpendicular to sponges of a vice (fig. 4.10). At such fastening the possibility of deformation of a rack is excluded.
Sort a rack, using a tool 67.7824.9518 set, in the following order:
– remove a support 2 (see fig. 4.10) compression course buffers for what easy blows of the hammer to a flat drift tap a support from below up and around;
Fig. 4.11. Otvertyvany nuts of the case are resistant: 1 – key 67.7811.9510; 2 – nut

– turn off a key of 67.7811.9510 (fig. 4.11) a case nut, take out from the rack case the working cylinder assembled with a rod and its details;

Fig. 4.2. Telescopic rack: 1 – compression valve case; 2 – compression valve disks; 3 – throttle disk of the valve of compression; 4 – plate of the compression valve; 5 – compression valve spring; 6 – compression valve holder; 7 – return valve nut; 8 – return valve spring; 9 – plate of the return valve; 10 – return valve disk; 11 – throttle disk of the valve of return; 12 – piston; 13 – plate of the perepuskny valve; 14 – spring of the perepuskny valve; 15 – plunger; 16 – plunger spring; 17 – the directing rod plug with a ftoroplastovy layer; 18 – a holder of the directing plug; 19 – sealing ring of the case of a rack; 20 – rod epiploon; 21 – epiploon holder; 22 – laying of a protective ring of a rod; 23 – protective ring of a rod; 24 – rack case nut; 25 – compression buffer support; 26 – rod; 27 – spring cup; 28 – rotary lever; 29 – restrictive plug of a rod; 30 – rack case; 31 – cylinder; 32 – drain tube

– remove from a rod a protective ring 23 (see fig. 4.2), laying 22, I will embrace 21 assembled with an epiploon 20;
– having pressed a plate of the compression valve, merge liquid from the cylinder for what repeatedly move a rod at a size of its full speed, without blow in the compression valve not to deform its holder;
– having installed the compression valve in a mandrel from a set 67.7824.9518, clamp it in a vice and slightly shake a hand the cylinder before separation of the valve of compression with the cylinder;
– having given a rod down, take out through the lower opening of the cylinder the piston assembled with a rod; at the same time you watch that the ftoroplastovy covering of the directing plug was not damaged;
– clamp a rod in a vice for lysk on its shaft and turn off a nut 7 (see fig. 4.2) the return valve then remove from a return valve detail rod, the piston 12 and details of the perepuskny valve;
– having exempted the rack case from a vice, merge from it liquid;

Fig. 4.12. Removal of the directing rod plug: 1 – the directing plug; 2 – cylinder

– carefully copper hammer or a special drift beat out the directing plug (fig. 4.12) from the working cylinder; at the same time you watch that on the cylinder there were no zaboina;

Fig. 4.2. Telescopic rack: 1 – compression valve case; 2 – compression valve disks; 3 – throttle disk of the valve of compression; 4 – plate of the compression valve; 5 – compression valve spring; 6 – compression valve holder; 7 – return valve nut; 8 – return valve spring; 9 – plate of the return valve; 10 – return valve disk; 11 – throttle disk of the valve of return; 12 – piston; 13 – plate of the perepuskny valve; 14 – spring of the perepuskny valve; 15 – plunger; 16 – plunger spring; 17 – the directing rod plug with a ftoroplastovy layer; 18 – a holder of the directing plug; 19 – sealing ring of the case of a rack; 20 – rod epiploon; 21 – epiploon holder; 22 – laying of a protective ring of a rod; 23 – protective ring of a rod; 24 – rack case nut; 25 – compression buffer support; 26 – rod; 27 – spring cup; 28 – rotary lever; 29 – restrictive plug of a rod; 30 – rack case; 31 – cylinder; 32 – drain tube

– take out from the cylinder a spring 16 (see fig. 4.2) and a plunger of the 15th hydraulic buffer;
– disassemble the compression valve for what remove a holder 6, and then consistently take out from the case a spring 5, a plate 4 and disks 2 and 3 valves.
Assembly
You carry out assembly of a rack of a forward suspension bracket to the sequences, the return dismantling taking into account the following:
– provide purity of a workplace and all details of a rack;
– be convinced that in liquid there are no foreign impurity, if necessary filter it;
– be convinced that the carving of a nut of the valve of return is not damaged at its otvertyvaniye by a raskernenny rod;
– examine a rod in the place of a kerneniye; if deformation of a carving is big and does not allow to screw a return valve nut without damage of its carving, besiege a rod carving in the place of a kerneniye;
– the throttle disk of the valve of return of a forward rack has three grooves on outer diameter, and a throttle disk of the back shock-absorber — four;
– the throttle disk of the valve of compression of a rack of a forward suspension bracket has three grooves on internal diameter, and a throttle disk of the back shock-absorber — two;
– a nut of the valve of return tighten the moment of 12,7-17,5 N · m (1,3–1,8 kgfs · l) then to its zakontrita, раскернив the carving end of a rod in the places which are not deformed earlier; the nut otvorachivaniye moment after a raskernivaniye has to be not less than 19,6 N · m (2 kgfs · l);
– the epiploon and a sealing ring of the case of a rack at repair is recommended to be replaced new;
– fill a working surface of an epiploon (between sealing edges) with SHRUS-4 lubricant in number of 0,3–0,4 g;
– in the case of a rack and in the cylinder fill in (320±5) cm3 of liquid for shock-absorbers, in the back shock-absorber – (250±5) cm3;
– a nut of the case of a rack tighten at completely put forward rod a key 67.7811.9510/11, the moment of an inhaling of 117-147 N · m (12–15 kgfs · l) (at the back shock-absorber the moment of an inhaling of 69-88 N · m (7–9 kgfs · l);
– after an inhaling of a nut fuller the rack case. The nut otvorachivaniye moment after a zachekanka has to be not less than 294 N · m (30 kgfs · l);
– after assembly of the valve of compression be convinced available a free wheeling of a plate and disks of the valve;
– press the valve of compression in the cylinder a special mandrel from a set 67.7824.9518 then be once again convinced available a free wheeling of a plate and disks;
– for installation and a press fitting of the directing rod plug in the cylinder use a special mandrel from a set 67.7824.9518;
– on a suspension bracket establish springs of one class.

       NOTE
Springs on length under control loading are divided into two classes: And yes Century. Springs of a class A are marked yellow (white) * by paint on outer side of average rounds, and a class B — green (blue) *

In exceptional cases, if on a forward suspension bracket class A springs are established, and for a back suspension bracket of springs this class is absent, installation on a back suspension bracket of springs of a class B is allowed. But if on a forward suspension bracket class B springs are established, then on a back suspension bracket establish springs only of a class B.

Dismantling and assembly of the lever of a suspension bracket, extension and arm

Dismantling
Having noted quantity of the adjusting washers established on the ends of an extension 23 (see fig. 4.1), turn off nuts and disconnect extensions from levers 22 suspension brackets and from arms 30.

Fig. 4.13. Vypressovka of rubber-metal hinges from the lever of a suspension bracket and an arm of fastening of an extension: 1 – plug; 2 – suspension bracket lever; 3 – rubber-metal hinge; 4 – mandrel; 5 – adaptation 67.7823.9540; 6 – arm of fastening of an extension; 7 – rubber-metal hinge; 8 – mandrel

At wear, damage or destruction of rubber-metal hinges of the lever and an extension — their vypressuyta. For a vypressovka and a press fitting of the hinge of an extension use special adaptation. Press off the hinge of the lever and the forward hinge of an extension and press devices 67.7823.9535 and 67.7823.9540 (fig. 4.13 and 4.14).

Fig. 4.14. Press fitting of rubber-metal hinges: lever of a suspension bracket and arm of fastening of an extension: 1 – mandrel; 2 – rubber-metal hinge; 3 – the directing plug; 4 – suspension bracket lever; 5 – basic plug; 6 – mandrel; 7 – rubber-metal hinge; 8 – arm of fastening of an extension; 9 – basic plug; And — a surface with marking of the hinge

Before a press fitting of rubber-metal hinges and rubber plugs plentifully grease with soap solution 30–35% or IGP-30 oil of a nest of hinges and their external surface. Observe the precautionary measures excluding damage of hinges at a press fitting (emergence of zadir, cracks or ruptures of rubber).
After a press fitting hinges have to be symmetric are located in the nests and not to have the places involved in nests or made buldge out from it.
After a press fitting of hinges and prior to operation of the car, it is necessary to give endurance on time not less than 24 h.
At a press fitting of the forward hinge of an extension in an arm establish it by the marked part outside. Marking is applied on surfaces "And" (see fig. 4.14) a persistent burt of the hinge of smaller diameter.
Assembly

Fig. 4.15. Assembly of the lever of a suspension bracket with an extension: 1 – extension; 2 – suspension bracket lever; And — distance between an axis of the lever and the center of an extension

At assembly of the lever with an extension establish into place the removed adjusting washers so that facets on them were turned towards a persistent end face of an extension. Before tightening an extension nut, install the lever and an extension on the special adaptation providing distance And (fig. 4.15) between an axis of the lever and the center of an extension, equal 10 mm and record an extension. In this situation tighten a nut of fastening of an extension the moment of 160-176,4 N · m (16,3–18 kgfs · м). Then remove from adaptation the lever assembled and establish adjusting washers on other end of an extension, following rules of their installation. Then fix by a nut an arm, tightening it only before the choice of a gap in a joint. You carry out a final inhaling of a nut on the car as it is specified in the head "Installation of knots and details of a forward suspension bracket".
At installation of protective covers of spherical support put 6 g of ShRB-4 lubricant in each cover.

Dismantling and assembly of the top support of a rack of a suspension bracket

At wear, damage, emergence of corrosion on the bearing of the top support of a telescopic rack it should be replaced. For this purpose a special mandrel to a razvaltsuyta the support case, and then a mandrel to 67.7853.9588 vypressuyta the bearing from the support case under a press, using a support 67.7822.9530.

Fig. 4.16. Compression of the case of a support: 1 – mandrel; 2 – top support; 3 – emphasis

Before pressing the new bearing be convinced that in a nest of the bearing there are no agnails and zadir. Eliminate the found roughnesses with a fine-grained grinding skin. Using a mandrel 67.7853.9588, press the bearing in the support case then press out on the press the support case in four ravnoraspolozhenny places which are earlier not deformed, using for this purpose a special mandrel (fig. 4.16). After sinking of the case of a support the bearing should not move in the axial direction. The effort of a vyryv of an external holder has to be not less than 5880 N (600 kgfs).
At emergence of need of replacement of a bolt of fastening of the top support to a body to its vypressuyta. After a press fitting of a new bolt make subcooking of its head in one point for ensuring reliable fixing by arc welding. At the same time avoid a support overheat, and also hit of metal splashes on it and slag.
Of the worn-out, damaged or destroyed rubber-metal hinges of racks of the stabilizer you see off Vypressovka on the press special mandrels as it is specified in half-section. "Dismantling and assembly of the lever of a suspension bracket, extension and arm".
At assembly of the stabilizer of cross stability establish arms of its pillows at distance of 350 mm from the average line of a bar.

Check of technical condition

Telescopic rack
Wash out kerosene all details and dry. Attentively check compliance of details to the following requirements:
– disks of valves of compression and return, and also a plate of the perepuskny valve should not be deformed; not planeness of a plate of the perepuskny valve is allowed no more than 0,05;
– the working surfaces of the piston, a piston ring, the directing plug, a rod, the cylinder, a plunger of the buffer of return and details of valves have to be without zadir, dents and wear tracks able to influence normal work of a rack;
– working edges of an epiploon have to be without damages or wear;
– risks, teases and peelings of a ftoroplastovy layer at the directing rod plug are not allowed;
– springs of valves of return and compression, and also a plunger of the buffer of return have to be whole and rather elastic;
– the internal surface of the case of a rack has to be pure, without рисок and damages, the carving has to be in good shape; check tightness of the case of a rack air under pressure of 0,3 MPas (3 kgfs/cm2); leak of air is inadmissible;
– the rack case, an arm, a cup of a spring and the rotary lever should not have deformations and destructions;
– the buffer of the course of compression and the protection cover should not have damages and destructions.
Welding works on a rack are not allowed as it can influence change of angles of installation of wheels and on operability of a rack.
Suspension bracket levers
Deformation of levers of a suspension bracket is defined by adaptation 67.7851.9508. The suspension bracket lever assembled with the spherical hinge is installed so that the mandrel for centering was jointed with a cone of a finger of the spherical hinge of the lever, and adjusting fingers of adaptation came into average and extreme openings of the lever.
Sign of deformation is the impossibility of introduction without effort of adjusting fingers of the lever or a bad joint of a mandrel on a hinge finger cone.
Spherical hinges
Be convinced of safety of protective covers of hinges. Gaps, peelings of rubber from metal fittings, traces of leak of lubricant through a cover are inadmissible. Insignificant expression of lubricant through the litnikovy opening in the case of the spherical hinge located in the top part of the case is allowed.
Check whether there is no wear of working surfaces of spherical hinges, turning manually a spherical finger. Considerable (over 0,7 mm) the free wheeling of a finger or its jamming are inadmissible.

Fig. 4.17. Check of the spherical hinge on adaptation 02.8701.9502: 1 – spherical hinge; 2 – indicator; 3 – dynamometer key; 4 – adaptation 02.8701.9502; And — the scheme of check of a radial gap; In — the scheme of check of an axial gap

Exact check of a condition of the spherical hinge in size of a radial and axial gap is carried out on adaptation 02.8701.9502. For this purpose install the spherical hinge 1 (fig. 4.17) in a nest of adaptation and clamp it the screw. Install the indicator 2 in adaptation arm so that his leg rested against the side surface of the case of the hinge, and the arrow of the indicator stood on zero.
Establish a dynamometer key 3 in the top nest of adaptation and, having put to it the moment of 196 N · m (20 kgfs · l) alternately in both parties, determine by the indicator a total radial gap in the spherical hinge. If it exceeds 0,7 mm the hinge replace new.
Similarly check an axial gap in the spherical hinge, previously having changed its fastening in adaptation as it is specified fig. 4.17. The axial gap in the hinge is allowed no more than 0,7 mm.
Stabilizer of cross stability
Check whether the bar is deformed and whether there are its ends in one plane; if deformation is insignificant, then correct a bar, at considerable deformation replace a bar.
Check a state and safety of pillows in bar arms. At wear or damage of pillows replace them.
Check in caliber deformation of racks of the stabilizer; if fingers of caliber do not come into rack openings, replace it.
Suspension bracket springs
Carefully examine springs. If cracks or deformation of rounds are found, replace a spring new.

Fig. 4.18. Parameters for check of a spring of a forward suspension bracket: N — spring length under loading

For check of a spring it is triple to its prozhmita before contact of rounds. Then apply load of 3188 N (325 kgfs) to a spring. Length of a spring of "N" (fig. 4.18) under the specified loading has to be not less than 201 (182) * mm. You carry out compression of a spring on a spring axis; basic surfaces have to correspond to surfaces of basic cups on a telescopic rack.
If the spring with yellow marking (class A) has length less than 207 (188) * mm, replace its marking on green (class B).
Extensions
Deformation of extensions is defined by adaptation 67.7851.9509. At insignificant deformation correct an extension on the press, at impossibility of editing, replace an extension new.
Rubber-metal hinges
Signs by which need of replacement of hinges is determined are described above (see. "Definition of a condition of details of a suspension bracket on the car").
Top support of a telescopic rack

Fig. 4.19. Check of elastic deformation (draft) of the top support: And — the control size

Check the elastic characteristic (draft) of the top support, having put load in 6860 N (700 kgfs) of the bearing (fig. 4.19) of a support and having measured distance "And" from a bearing end face to an end face of the external case of a support. This distance should not exceed 29 mm. Otherwise replace a support new.
Make sure that the bearing has no axial movement in the support case. Corrosion, damage or jamming of the bearing owing to wear is not allowed. In these cases replace the bearing new.
Check a condition of the case of a support. It is not allowed rubber peelings, rushes, support cracks.