5 x 1.8mm ASSEMBLY GUIDE

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1 5 x.8 7 ASSEMBLY GUIDE B E T A E D I T I O N. 0

3 DISCLAIMER B E T A E D I T I O N. 0 ASSEMBLY GUIDE FOR EVALUATION PURPOSES ONLY Whilst every effort has been made to ensure the information in the following pages is accurate; this beta version of Assembly Guide is published to gain feedback on the layout and principle only. Please address any coents to: assemblyguide@caterham.com July 06 i

4 HINTS & TIPS When using a torque wrench, listen/ feel the click and then stop. It does not need to be any tighter and you might actually weaken the fixing by over-torquing it. Always wind your torque wrench setting back to free when you ve finished with it. John K Nm of torque equals 0.736lbft. Mick F A nyloc nut is one with a nylon insert that gets cut by the bolt thread, making it resistant to unwinding itself. This means that they should not be repeatedly re-used. Chris B When using a spanner, always use the ring end wherever possible. The open end is really only for those times that access is too limited for a ring spanner or socket. Mick A A spring washer has a split in it and squashes up closed when a fixing is tightened. It is usually used under a bolt head to help resist it coming undone. John S A caphead bolt has a circular head with a hexagonal drive inside it. It is tightened with an allen key or hex drive socket. Capheads are useful where there is limited space around the head for a spanner or socket. They look nice too! John K 4

5 HINTS & TIPS You can tell if you have wide track suspension car by looking at the dampers. Wide track has a 5 long hexagonal spacer between the top spring retainer and the mounting bush. Matt T Thread lock is used to stop something coming undone, but it only needs a little drop on the thread to be effective. Jamie A A bolt size is described by its diameter (eg M0=0) by the length not including the head (eg 65). James A Generally, metric Nyloc nuts have a blue nylon insert and imperial ones a white nylon insert. Grant P Teabag, boiling water, then the milk, in that order. Simon L Left and right are as viewed from the driver s seat. Harrison P

6 SERIAL KEY S Y M B O L S AA AJ AM Item number Fixing item S / R specific instructions Advice from factory professionals Nm Required torque (where applicable) S3 S5 S3 / S5 chassis specific instructions Repeat on both sides F I X I N G S A 44 PACK 30F05B FRONT SUSPENSION DeDION CARS (METRIC) BASIC PART QTY DESCRIPTION USED ON BASIC DESCRIPTION PART QTY USED ON Bolt M x 00 AA BMX00 Bolt M x 00 AA BMX00 Bolt M x 65 AB BMX65 Bolt M0 x 65 3 AC BM0X65 Bolt M0 x 60 4 AD BM0X60 Bolt M8 x 40 5 AE BM8X40 4 x4 (Indicates number of each fixing required) Plain Nut M4 6 AF NMPH4 x.5 thread Temporary use to help lock upper wishbone ball joint 7 AG Nyloc Nut M NMYF 8 AH Nyloc Nut M0 NMYF0 4 9 AJ M WPCM 8 Chamfered 0 AK M8 WPHM8 4 AL ⅜" x ¾" WPH3/8 Brake pipe Drawings are for illustrative purposes only and are not to scale. Page of (Greyed out area indicates fixings are not required for current step)

KEY T O O L S LO Grease Pop rivet gun Socket wrench Assistance Haer Power adhesive Socket wrench (allen) Torque wrench Axle stand Heat gun Pozidrive screwdriver Spirit level Trolley jack Combination

7 KEY T O O L S LO Grease Pop rivet gun Socket wrench Assistance Haer Power adhesive Socket wrench (allen) Torque wrench Axle stand Heat gun Pozidrive screwdriver Spirit level Trolley jack Combination spanner Junior hacksaw Pozidrive screwdriver (stubby) Spray lube WD40 Reading manual Stanley knife Tool Sticky tape Tool Super glue Tool tex Latex gloves UAL MAN E S VE GLO La IT Copper slip CT + Allen key Thread lock Drill Long nose pliers Scissors Drill bit Mallet Side cutters Flat dzuz screwdriver Marker pen Silicon Tap wrench Tool Flat head screwdriver Muscle Silicon gun Tape measure Tool R PE E S UGLU 3

8 LETS GET READY PARTS T O O L S x3 F I X I N G S T I P S When deciding how high your axle stands should be (the higher the better for working on), don t forget that a complete car will need to come down off them, so make sure your trolley jack can reach and lift the height you set them too! Mick F Some tape or foam on the top of the axle stands will stop them scratching the chassis. Matt T 4

9 LETS GET READY 5

10 SERIAL START WITH THE SUSPENSION WISHBONES PARTS T O O L S 3 Wishbone bush sleeve F I X I N G S T I P S A PACK 30F05B FRONT SUSPENSION DeDION CARS (METRIC) BASIC PART QTY USED ON DESCRIPTION Bolt M x 00 AA BMX00 44 A BASIC DESCRIPTION PART QTY Spring Washer AM WSHM M FRONT SUSPENSION DeDION CARS (METRIC) USED ON SERIAL 44 PACK 30F05B For now, only tighten the nuts/bolts lightly and then torque them up when the car is finished and on the ground. This sets the bushes correctly and ensures the best handling. Harrison P Bolt M x 65 AB BMX65 Spring Washer 3 AN WSHM8 6 M8 & upper damper mount Bolt M0 x 65 3 AC BM0X65 Washer ⅜" 4 AP WSS3/8 Brake pipe Shake-proof Bolt M0 x 60 4 AD BM0X60 Nyloc Nut ½" 5 AR NFYH/ Wing stay Half height Bolt M8 x 40 5 AE BM8X40 4 Nyloc Nut ½" 6 AS NFYF/ Full height Front brake, upright mounting (std track ONLY) Temporary use to Plain Nut M4 6 AF NMPH4 help lock upper x.5 thread wishbone ball joint 7 AG Nyloc Nut M NMYF 8 AH Nyloc Nut M0 NMYF0 4 9 AJ M WPCM 8 Chamfered x4 x4 Drawings are for illustrative purposes only and are not to scale. Page of 0 AK M8 WPHM8 4 AL ⅜" x ¾" WPH3/8 Brake pipe Drawings are for illustrative purposes only and are not to scale. Page of 6

11 START WITH THE SUSPENSION WISHBONES AD AH 34Nm AC AH 34Nm 3 AA AJ AG 8Nm AB AJ AM 8Nm 7

12 SERIAL NOW FOR THE STEERING RACK PARTS T O O L S Steering rack Rack clamps Column universal joint Track rod end IVA cover 3 ¾" F I X I N G S T I P S B BASIC DESCRIPTION PACK 30S003B STEERING DeDION CARS (METRIC) PART QTY USED ON Caphead Bolt BA M6 x 70 BMCH6X70 4 Rack clamps DIN 9 55 x4 Finding the right IVA cover isn t obvious because it is effectively a long cap. To use it, you cut the closed end off. Jamie A BB Bolt ¼" x ½" BF/4X./ Column clamp Bolt M8 x 3 BC BM8X Grade 8.8 Column to rack universal joint Nyloc Nut ½" 4 BD NFYH/ Steering wheel boss Half height 5 BE Plain Nut ½" NFPF/ Track rod lock nut Plain Nut ⁷ ₁₆" 6 BF NFPFH7/6 Half height Column clamp grubscrew locknut 7 BG Nyloc Nut M8 NMYF8 8 BH Nyloc Nut M6 NMYF6 4 Column to rack universal joint Steering rack clamps x4 9 BJ ½" x ⅛" WPH/ Steering wheel boss Chamfered 0 BK ¼" WPH/4 6 Rack clamps and column clamp x4 Spring Washer ¼ BL WSH/4 Column clamp Drawings are for illustrative purposes only and are not to scale. Page of 8

13 NOW FOR THE STEERING RACK 3 BC BG 0Nm 7 7 BA BH BK Nm 5 4 BE 9

14 SERIAL AND THEN THE DAMPERS PARTS T O O L S Spring / damper Lower damper eyelet 6 3 Upper damper eyelet 6 F I X I N G S T I P S A PACK 30F05B FRONT SUSPENSION DeDION CARS (METRIC) BASIC PART QTY USED ON DESCRIPTION Bolt M x 00 AA BMX00 Bolt M x 65 AB BMX65 44 A BASIC DESCRIPTION PART QTY Spring Washer AM WSHM M Spring Washer 3 AN WSHM8 6 M8 FRONT SUSPENSION DeDION CARS (METRIC) USED ON & upper damper mount SERIAL 44 PACK 30F05B Put the top of the damper on first. Grant P The bottom can be a tight fit! Mick F Bolt M0 x 65 3 AC BM0X65 Washer ⅜" 4 AP WSS3/8 Brake pipe Shake-proof Bolt M0 x 60 4 AD BM0X60 Nyloc Nut ½" 5 AR NFYH/ Wing stay Half height Bolt M8 x 40 5 AE BM8X40 4 Nyloc Nut ½" 6 AS NFYF/ Full height Front brake, upright mounting (std track ONLY) Plain Nut M4 6 AF NMPH4 x.5 thread 7 AG Nyloc Nut M NMYF Temporary use to help lock upper wishbone ball joint Drawings are for illustrative purposes only and are not to scale. Page of Other fixings provided in chassis & wishbone. 8 AH Nyloc Nut M0 NMYF0 4 9 AJ M WPCM 8 Chamfered 0 AK M8 WPHM8 4 AL ⅜" x ¾" WPH3/8 Brake pipe Drawings are for illustrative purposes only and are not to scale. Page of 0

15 AND THEN THE DAMPERS AN 0Nm Nm

16 SERIAL IT S TIME FOR THE WINGSTAYS PARTS T O O L S Wingstay Front brake & upright assembly ¾" F I X I N G S T I P S A PACK 30F05B FRONT SUSPENSION DeDION CARS (METRIC) BASIC PART QTY USED ON DESCRIPTION Bolt M x 00 AA BMX00 Bolt M x 65 AB BMX65 Bolt M0 x 65 3 AC BM0X65 Bolt M0 x 60 4 AD BM0X60 Bolt M8 x 40 5 AE BM8X40 4 Temporary use to Plain Nut M4 6 AF NMPH4 help lock upper x.5 thread wishbone ball joint 7 AG Nyloc Nut M NMYF 8 AH Nyloc Nut M0 NMYF0 4 9 AJ M WPCM 8 Chamfered 44 A BASIC DESCRIPTION PART QTY Spring Washer AM WSHM M Spring Washer 3 AN WSHM8 6 M8 USED ON & upper damper mount Washer ⅜" 4 AP WSS3/8 Brake pipe Shake-proof Nyloc Nut ½" 5 AR NFYH/ Wing stay Half height Nyloc Nut ½" 6 AS NFYF/ Full height FRONT SUSPENSION DeDION CARS (METRIC) Front brake, upright mounting (std track ONLY) Drawings are for illustrative purposes only and are not to scale. Page of SERIAL 44 PACK 30F05B The drilled hole is for the side repeater earth that we ll fit later. It s easier to drill from the top and down through both sides of the tube, rather than through one side from the bottom (where the earth will be fixed). Tiago O Some of the fixings required and shown on the drawings, such as the ball joint nut, are already on the part and not in the fixing pack. Anthony L Use the plain nut to pull the top ball joint home before using a nyloc, otherwise the thread will spin. Chris N Put the upright into the lower wishbone joint then attach the steering before tightening the bottom nut. This stops it all swinging around the hitting the side of the chassis. John S 0 AK M8 WPHM8 4 AL ⅜" x ¾" WPH3/8 Brake pipe Drawings are for illustrative purposes only and are not to scale. Page of

17 IT S TIME FOR THE WINGSTAYS x/8 x/8 AR WIDE TRACK AS 54Nm (STANDARD TRACK ONLY) 3

18 SERIAL LAST PART OF THE FRONT SUSPENSION: CONNECTING THE TWO SIDES TOGETHER PARTS T O O L S bracket 3 3 rubber 4 ball 5 dust cover LOCTITE LOCTITE F I X I N G S T I P S A PACK 30F05B FRONT SUSPENSION DeDION CARS (METRIC) BASIC PART QTY USED ON DESCRIPTION Bolt M x 00 AA BMX00 Bolt M x 65 AB BMX65 Bolt M0 x 65 3 AC BM0X65 Bolt M0 x 60 4 AD BM0X60 44 A BASIC DESCRIPTION PART QTY Spring Washer AM WSHM M Spring Washer 3 AN WSHM8 6 M8 FRONT SUSPENSION DeDION CARS (METRIC) USED ON & upper damper mount Washer ⅜" 4 AP WSS3/8 Brake pipe Shake-proof Nyloc Nut ½" 5 AR NFYH/ Wing stay Half height SERIAL 44 PACK 30F05B x4 Check that the colour of the mounting rubbers matches the colour spot on the bar. John K Grease the balls and cups generously. Matt T Getting the assembled anti-roll bar fully into both cups on the upper wishbone can be a bit of a fight. It s made of springy stuff, so don t worry that you are bending it. Jamie A Use four small cable ties to secure the dust cover. Mick F Bolt M8 x 40 5 AE BM8X40 4 x4 Nyloc Nut ½" 6 AS NFYF/ Full height Front brake, upright mounting (std track ONLY) Plain Nut M4 6 AF NMPH4 x.5 thread Temporary use to help lock upper wishbone ball joint Drawings are for illustrative purposes only and are not to scale. Page of 7 AG Nyloc Nut M NMYF 8 AH Nyloc Nut M0 NMYF0 4 9 AJ M WPCM 8 Chamfered 0 AK M8 WPHM8 4 x4 AL ⅜" x ¾" WPH3/8 Brake pipe Drawings are for illustrative purposes only and are not to scale. Page of 4

19 LAST PART OF THE FRONT SUSPENSION: CONNECTING THE TWO SIDES TOGETHER AE 4 AK AN 0Nm

RHINO SUSPENSION SYSTEM INSTALLATION INSTRUCTIONS

RHINO SUSPENSION SYSTEM INSTALLATION INSTRUCTIONS PARTS INCLUDED: 2 FRONT UPPER A-ARMS 2 FRONT LOWER A-ARMS 2 UNI-BALL JOINTS 2 UNI-BALL JOINT STUDS 2 UNI-BALL JOINT CAPS 2 RETAINING RINGS 1 FRONT SHOCK ASSEM. 2 DELRON STEERING STOPS 2 SHOCK MOUNT SPACERS