Suspension Spring ( Coil / Leaf ): Service and Repair

1. Raise and support side of vehicle to be serviced.
2. Remove wheel.
3. Remove bottom shock absorber mounting nuts and bolts, then the two top mounting bolts.
4. Remove assembly by pressing lower control arm down so that it will not contact driveshaft boot.
5. Clamp bottom of shock absorber in suitable vise.

Fig. 3 Front spring removal.:

6. Install adapter SUS. 863.99 in base of spring compressor, just below spring mount, install compressor on spring, then tighten nuts (A) gradually and evenly, Fig 3.
7. Remove nut on top of shock absorber piston rod.

Fig. 4 Strut components.:

8. Remove components (1) to (5), Fig. 4, then lift spring and compressor assembly from shock absorber. Washer (4) is crimped to mounting plate (2).
9. Using tool Sus. 594 or equivalent, secure rod of tool in vise and install spring together with its bottom cup and tool Sus. 863 over tool Sus. 594.
10. Compress spring with tools Sus. 594 and Sus. 594-02 or equivalents to remove tool Sus. 863.
11. Slowly release spring until it reaches its free length and remove spring.
12. Install spring bottom cup and spring over rod of tool Sus. 594 or equivalent.
13. Using tools Sus. 594 and Sus. 594-02 or equivalents, compress spring until sixth coil can be held by tool Sus. 863 or equivalent, then remove tools Sus. 594 and Sus. 594-02.




14. Secure body of new shock absorber in vise, then install components (7), (6) and (5), Fig. 4, shock absorber.
15. Install spring, with tool Sus. 863, ensuring that end of bottom coil rests against stop in bottom cup.

Fig. 5 Aligning locating peg of strut cushion with lower cup.:

16. Install washer (4) and component (2) with its plastic spring thrust cup, noting locating peg (B), Fig. 5.
17. Install washer and nut, then remove tool Sus. 863 and torque piston rod nut to 44 ft.lbs.
18. Install spring and shock absorber assembly on vehicle by pressing lower suspension arm down so that shock absorber does not contact driveshaft boot.
19. Install two shock absorber top mounting bolts and torque to 17 ft.lbs.
20. Install two bottom mounting bolts and nuts with nuts toward front of vehicle and torque nuts to 55 ft.lbs.
21. Install wheel and lower vehicle.