Page 5 of 10. Ball joints

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1 Page 5 of 10 Ball joints BALL JOINTS ON SUSPENSION LEVERS The ball joints are fastened to the arms by means of stop rings and they are equipped with special boots that protect the joint from the outside agents and preserve the original lubrication of the surfaces subject to friction. Upper arm Lower arm Test the rotation of the internal component manually: If there is excessive clearance or the rotation is jammed, it must be replaced. Check the state of the protective boots. If they are torn or damaged, replace them. Replacing the ball joint and protection boots Remove the boots (1), on the upper lever (2) and the lower one, working on both sides of the joint with Seeger pliers. Place the lever under the press, resting it on tool AV 3281 or AS (for the upper lever) and AV or AV 3189 (for the lower lever). Position tool AV 3189 (for the upper lever) or AV 1651 (for the lower lever), on the joint, then heat the joint area with a hairdryer (40-60 C) to facilitate removal.

2 Page 6 of 10 The lower lever must be positioned under the press as shown in Fig. 1, as the lever and ball joint have a ledge on the side opposite the shock absorber coupling. Make sure it is centred and operate the press until the joint is completely extracted. Immergere la sede dello snodo sferico sulla leva in un recipiente contenente diluente alla nitro, per eliminare dall alloggiamento l adesivo residuo. Lasciare la leva a riposo nel solvente per circa 3 ore e successivamente rimuovere completamente ogni traccia di adesivo residuo, utilizzando un raschietto e una paglietta abrasiva. Dopo aver accuratamente pulito la sede dello snodo, controllare il diametro dell alloggiamento dello snodo con calibro da interni oppure alesametro, confrontando le misure rilevate con quelle riportate in Fig. 2. Se le misure rilevate sono fuori tolleranza, sostituire la leva. Lower arm Upper arm Clean the contact area on the seat and the new joint with isopropilic alcohol. After retrieving the stop rings from the original protection boots (3) on the upper lever and (4) on the lower onefit them in the housing on the lever to prevent the adhesive from running into the seats.

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4 Page 8 of 10 Using an extrusion gun (5, Fig. 3), apply LOCTITE Hysol EA ML SEMPAK (6 adhesive, code ) to the bristles of a small brush (Fig. 4) then, spread it evenly over the external surface of the joint and the seat on the lever.

5 Page 9 of 10 Make sure the adhesive does not corrode the inside of the joint. Fit the new joint in the upper lever, after removing the stop rings (3) fitted earlier. Fit the new joint in the upper lever, after removing the stop rings (4) fitted earlier on the side opposite the shock absorber coupling. Push the new joint until it is touching the other stop ring, then remove the latter from the lever. Make sure there are no traces of adhesive left inside the stop ring seats. Apply FIAT TUTELA Z2 grease inside the new boots equipped with stop rings and fit them in their seats Fig. 5). Rotate the stop ring to ensure the ball joint moves and engages correctly.

6 Page 10 of 10 Carefully clean the outside of the protection boots to remove any residual grease. To prevent infiltrations of water and dirt, we recommend you stop the two holes in the boots for the stop ring engagement with silicon. Remove any excess silicon. Before refitting the lever in the vehicle, place it in a stove at 90 C, for 45 minutes. BALL JOINT ON REAR TOE-IN TIE-ROD The rear wheel toe-in adjustment tie-rod has a ball joint with the same characteristics. It is found on the fastening point on the hub-holder. On the side where it is fastened to the chassis, the tie-rod is equipped with a spherical head that operates inside a seat, anchored to the flexible support frame. Said parts cannot be disassembled. If there is excessive clearance, replace the entire tie-rod. Prior to any re-assembly procedures, clean all joints and the respective boots and then lubricate with FIAT MR3 grease.