Front

Damper/Spring Replacement





Exploded View

Special Tools Required
^ Ball joint remover, 28 mm 07MAC-SL00200
^ Strut spring compressor, Branick MST-580A or Model 7200 or equivalent, commercially available

NOTICE: To avoid damage, do not strike aluminum parts with a metal hammer. If necessary, tap gently with a plastic-tipped hammer.

NOTE: Bolts and nuts with the (star) mark are special corrosion-resistant Dacro fasteners. Use the same type if replacement is necessary.

Removal
1. Raise the front of the vehicle, and support it with safety stands in the proper locations.
2. Remove the front wheels.





3. Remove the cotter pin (A) from the tie-rod end ball joint, and remove the nut (B).
4. Disconnect the tie-rod end ball joint from the damper using the special tools.





5. Remove the flange nut (A) while holding the joint pin (B) with a hex wrench (C), and disconnect the stabilizer link (D) from the damper.





6. Remove the bolts (A), and remove the wheel sensor harness bracket (B) and brake hose bracket (C) from the damper. Do not disconnect the wheel sensor connector.
7. Remove the damper pinch bolts (D) while holding the nuts (E).





8. Remove the self-locking nuts (A) from the top of the damper.
9. Lower the lower arm, and remove the damper assembly (B).

Disassembly/Inspection





1. Compress the damper spring with a commercially available strut spring compressor (A) according to the manufacturer's instructions, then remove the self-locking nut (B) while holding the damper shaft (C) with a hex wrench (D). Do not compress the spring more than necessary to remove the nut.
2. Release the pressure from the strut spring compressor, then disassemble the damper as shown in the Exploded View.
3. Reassemble all the parts, except for the spring.





4. Compress the damper assembly by hand, and check for smooth operation through a full stroke, both compression and extension. The damper should extend smoothly and constantly when compression is released. If it does not, the gas is leaking and the damper should be replaced.
5. Check for oil leaks, abnormal noises, and binding during these tests.

Reassembly
1. Install the dust cover end inside the top of the dust cover sleeve, and install the dust cover lower mount on the bottom of the dust cover sleeve.
2. Install the bump stop on the damper shaft, then install the set of the dust cover (assembled in step 1) over it.





3. Install the rest of the parts except for the washer and self-locking nut onto the damper unit referring to the Exploded View. Align the spring bottom end (A), the stepped part of the dust cover lower mount (B), and the step on the lower spring seat (C).
4. Install the damper assembly on a commercially available strut spring compressor (D).
5. Compress the damper spring with the strut spring compressor.





6. Install a new washer (A) and a new self-locking nut (B) on the damper shaft.
7. Hold the damper shaft with a hex wrench (C), and tighten the self-locking nut to the specified torque.

Installation





1. Lower the lower arm, and position the damper assembly (A) in the body.
2. Loosely install new self-locking nuts (B) onto the top of the damper.





3. Position the damper bottom on the knuckle, install the new damper pinch bolts (A) and nuts (B), and lightly tighten the bolts.
4. Connect the stabilizer link to the damper, and lightly tighten the nut.
5. Place a jack with a wood block under the lower arm ball joint, and raise the suspension to load the suspension.
6. Tighten the flange nuts on the top of the damper to the specified torque value.
7. Tighten the damper pinch bolts to the specified torque value.





8. Connect the stabilizer link (A) to the damper, and tighten the flange nut (B) while holding the joint pin (C) with a hex wrench (D).





9. Connect the tie-rod to the steering arm, and tighten the nut (A) to the specified torque. Install the new cotter pin (B) after tightening, and bend its end as shown.
10. Install the brake hose bracket and the flange bolt to the damper, and tighten the bolt to the specified torque value.
11. Clean the mating surface of the brake disc and the inside of the wheel, then install the front wheels.
12. Check the wheel alignment, and adjust it if necessary.