Subsection 0 (TABLE OF CONTENTS) TABLE OF CONTENTS 0 FRONT SUSPENSION... 08-02- GENERAL... 08-02-2 STRUT-TYPE FRONT SUSPENSION... 08-02-2 LOWER SUSPENSION ARM PROTECTOR... 08-02-3 LOWER SUSPENSION ARM... 08-02-4 BALL JOINT... 08-02-5 REAR SUSPENSION... 08-03- GENERAL... 08-03-2 REAR SHOCK... 08-03-2 TORSION BAR... 08-03-3 TRAILING ARM... 08-03-4 TRAILING ARM BEARINGS... 08-03-5 VMR2004_54_08_0ATOC.FM 08-0-
Subsection 02 (FRONT SUSPENSION) FRONT SUSPENSION 0 6 5 4 55 N m (4 lbf ft) 3 Loctite 243 7 3 Loctite 243 4 55 N m (4 lbf ft) 5 2 2 (35 lbf ft) 80 N m 4 X 4 Models only (59 lbf in) 4 N m (35 lbf in) Synthetic grease 2 80 N m (59 lbf ft) 4 2 (35 lbf ft) 23 N m (7 lbf ft) 3 (35 lbf ft) 4 X 4 Models only 4 N m (35 lbf in) (35 lbf ft) 0 5 V07J0GS 9 (35 lbf ft) 4 X 4 Models only 8 (35 lbf ft) 9 4 X 4 Models only 23 N m (7 lbf ft) 4 VMR2004_47_08_02A.FM 08-02-
Subsection 02 (FRONT SUSPENSION) GENERAL The procedure explained below is the same for the RH and LH sides unless otherwise noted. During assembly/installation, use the torque values and service products as in the exploded view. Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete procedure WARNING Torque wrench tightening specifications must strictly be adhered to. Locking devices (ex.: locking tabs, elastic stop nuts, self-locking fasteners, etc.) must be installed or replaced with new ones where specified. If the efficiency of a locking device is impaired, it must be renewed. STRUT-TYPE FRONT SUSPENSION Loosen wheel nuts. Lift front of vehicle until front struts no. are fully extended then install a jack stand under the frame to support the vehicle off the ground. Remove: wheel front rack bolts no. 2 retaining strut to the knuckle circlip no. 3 strut nut no. 4. V07J03A 2. Circlip 2. Strut nut NOTE: To unscrew the strut nut, use the 4 mm socket for Traxter swing arm nut. Separate strut from knuckle. Disassembly For shock spring disassembly use shock spring remover (P/N 529 035 504) and adaptor kit (P/N 529 035 928) in a vise. Install the adaptor kit on shock spring remover or if the kit is already installed, place the right spring support outside of support arm. V07J02A TYPICAL 08-02-2 VMR2004_47_08_02A.FM
Subsection 02 (FRONT SUSPENSION) 2 A skip or hang up when reversing stroke at mid travel. Seizing or binding conditions except at extreme end of either stroke. A gurgling noise after completing one full compression and extension stroke. Replace strut if any of these conditions are found. For assembly, reverse the disassembly and removal procedures. NOTE: Do not interchange left and right tires. The tires are directional and their rotation must be kept in a specific direction for proper operation. V07J04A. Right spring support 2. Support arm Place the vertical lever in the second handle hole. V07J06A V07J05A 2. Vertical lever 2. Handle Mount shock in it and turn shock so that spring coils matches spring compressor. Close and lock the bar. Adjust the handle horizontal position by changing the position of the clevis pin. Push down on the handle until it locks. Remove spring stopper no. 5 and no. 6 then release handle. Inspect the spring no. 7 for damage. Replace if necessary. Inspect strut for oil leakage. Extend and compress the piston several times over its entire stroke. Check that it moves smoothly and with uniform resistance with rod up. Any of the following conditions will denote a defective strut: DIRECTION OF ROTATION Torque wheel nuts to 70 N m (52 lbf ft) in a crisscross sequence. LOWER SUSPENSION ARM PROTECTOR 4 X 4 Models Only Check protector no. 8 for cracks or other damages. Replace if necessary. Remove screw no. 9 then the protector. The installation is the reverse of removal procedure. VMR2004_47_08_02A.FM 08-02-3
Subsection 02 (FRONT SUSPENSION) LOWER SUSPENSION ARM Check lower suspension arms no. 0 for distortion or damage. Replace suspension arms if necessary. Move suspension arm from side to side. There should be no noticeable loose. Replace bushings if necessary. Move suspension arm up and down. There should be no noticeable loose. Replace bushings if necessary. The following items are performed when the suspension arm is removed. Inspect pivot bushings no. for wear or damages. Replace bushings if necessary. V07J08A 2 3 4 TYPICAL. Lower suspension arm 2. Ball joint bolt 3. Ball joint 4. Knuckle Separate lower suspension arm from knuckle. Remove bolts no. 3 retaining lower suspension arm to frame. V07J07A TYPICAL. Pivot bushing Check ball joint rubber on lower suspension arm for cracks or any other damage. Inspect ball joint end for damage. Ensure it s moving freely. Replace ball joints as required, see below for procedure. Remove wheel. Remove bolt no. 2 retaining lower suspension arm no. 0 to the knuckle. V07J09A 2 2 TYPICAL. Lower suspension arm 2. Remove bolts Remove lower suspension arm from vehicle. For assembly, reverse the disassembly procedure. However, pay attention to the following. Install lower suspension arm to frame. Attach lower suspension arm no. 0 to knuckle. Install wheel. 08-02-4 VMR2004_47_08_02A.FM
Subsection 02 (FRONT SUSPENSION) NOTE: Do not interchange left and right tires. The tires are directional and their rotation must be kept in a specific direction for proper operation. Remove: wheel lower suspension arm from knuckle bolts no. 5 retaining ball joint to lower suspension arm. V07J06A DIRECTION OF ROTATION Torque wheel nuts to 70 N m (52 lbf ft) in a crisscross sequence. BALL JOINT Check ball joint no. 4 for damage, pitting, looseness and roughness. If so, replace ball joint. Check ball joint rubber boot for cracks. Change if necessary. V07J0AA Extract the ball joint by pulling it out of lower suspension arm. The installation is the reverse of removal procedure. VMR2004_47_08_02A.FM 08-02-5
REAR SUSPENSION 0 8 4 9 0 6 7 Loctite 243 3 8 2 4 2 3 5 6 9 4 (35 lbf ft) 3 Loctite 243 4 (35 lbf ft) Loctite 27 2 Loctite 27 90 N m (40 lbf ft) 6 0 Loctite 243 4 9 7 8 V07HYS VMR2004_48_08_03A.FM 08-03-
GENERAL The procedure described below is the same for the RH and LH sides, unless otherwise instructed. During assembly/installation, use the torque values and service products as in the exploded views. Clean threads before applying a threadlocker. Refer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for complete procedure. WARNING Torque wrench tightening specifications must strictly be adhered to. Locking devices (ex.: locking tabs, elastic stop nuts, self-locking fasteners, etc.) must be installed or replaced with new ones where specified. If the efficiency of a locking device is impaired, it must be renewed. Disassembly Use shock spring remover (P/N 529 035 504) and put it in a vise. Mount shock in it and turn shock so that spring coils no. 9 match spring compressor. Close and lock bar. Adjust handle horizontal by changing position of clevis pin. Push down on handle until it locks. Remove spring stopper and cap then release handle. 2 REAR SHOCK Lift rear of vehicle until rear shock absorbers no. are fully extended. Install jack stands or blocks under the frame to support the vehicle. Remove upper no. 2 and lower no. 3 bolts and nuts no. 4 retaining shock absorbers each side. A0B4LA. Clevis pin 2. Bar 3. Handle 3 At installation, cap opening no. 5 must be 80 from spring stopper opening no. 6. Secure the shock body end no. 7 in a vise with its rod upward. A4F0BA TYPICAL. Clamp here V07HCA 08-03-2 VMR2004_48_08_03A.FM
CAUTION: Do not clamp directly on shock body. Examine each shock for leaks. Extend and compress the piston several times over its entire stroke. Check that it moves smoothly and with uniform resistance with its rod upward. Pay attention to the following conditions that will denote a defective shock: A skip or a hang back when reversing stroke at mid travel. Seizing or binding condition except at extreme end of either stroke. Oil leakage. A gurgling noise, after completing one full compression and extension stroke. Renew if any faults are present. Assembly and installation are essentially the reverse of disassembly and removal procedures. TORSION BAR Apply parking brake and lift rear of vehicle until rear shock absorbers no. are fully extended. Install a jack stand or blocks under the frame to safely support the vehicle. Remove: rear wheels both footwells protective covers no. 8 clamp no. 4 (discard) NOTE: Heat the elastic nut using a heat gun to facilitate the removal. elastic nuts no. 9 (discard) flat washers no. 0 torsion bar levers no. V07HGA 3 2. Elastic nut 2. Washer 3. Torsion bar lever torsion bar no. 2. Check: torsion bar for cracks, bending or other damages splines for damages (torsion bar and torsion bar lever) torsion bar lever tabs for racking, cracks or other damages. NOTE: If a tab is damaged, check the trailing arm no. 3 for damages. Replace all damaged parts. Clean the torsion bar splines using a heat gun. Apply Loctite 27 (P/N 293 800 005) on both sides of torsion bar splines. Insert the torsion bar into the frame and install the torsion bar lever (one on each side). VMR2004_48_08_03A.FM 08-03-3
NOTE: Ensure lever is aligned with the cut-outs on the swing arm and arrow is pointing up. Frame Side Remove: protective covers no. 8 clamp no. 4 elastic nut no. 9 (discard) washer no. 0 torsion bar lever no. V07HGB Install the washer and a new elastic nut. First torque the right hand side elastic nut to 55 N m (4 lbf ft), then the left hand side to 20 N m (89 lbf ft). Reinstall both torsion bar covers with new clamps. TRAILING ARM Apply parking brake and lift rear of vehicle until rear shock absorbers no. are fully extended. Install a jack stands or a blocks under the frame to safely support the vehicle. Wheel Side Remove: appropriate wheel wheel cap cotter pin (discard) castellated nut washer wheel hub. NOTE: Use the hub puller (P/N 529 035 62) if necessary. V07HIA trailing arm nut no. 6 NOTE: To remove the trailing arm nut, use the spanner wrench (P/N 529 035 925). V07HJA lower bolt no. 3 of shock absorber trailing arm no. 3. 08-03-4 VMR2004_48_08_03A.FM
Check: trailing arms for cracks, bending or other damages bearings for smooth and free operation. Replace all damaged parts. Insert drive shaft end into trailing arm. Install the trailing arm on frame. Install the lower shock absorber bolt to support the trailing arm. Do not torque yet. Frame Side Apply Loctite 243 on trailing arm nut threads. Install the trailing arm nut and torque it to 90 N m (40 lbf ft). Apply a thin coat of Loctite MAXI- COAT (P/N 293 800 05) on the remaining threads. Install circlip, torsion bar lever, washer and a new elastic nut. Torque the elastic nut to 20 N m (89 lbf ft). Install protective cap. Wheel Side Install: wheel hub washer castellated nut. Torque castellated nut to 85 N m (36 lbf ft) and further tighten until its grooves align with the next cotter pin hole. Install a new cotter pin then the wheel cap. NOTE: The longer end of cotter pin must be folded over shaft end. Torque the shock absorber bolt to (35 lbf ft). Install wheel. CAUTION: Always use the recommended wheel nuts (P/N 250 00 039). Using a different nut could cause damages to the rim. TRAILING ARM BEARINGS Check inner race of each bearing no. 7 with your finger. The bearings should turn smoothly and quietly. Remove and discard bearings if race does not turn smoothly or quietly. The same procedure can be used for both bearings. To perform the following, these tools are necessary. TOOLS WHEEL SIDE Trailing arm support 529 035 922 Extractor/Installer 529 035 98 FRAME SIDE Trailing arm support 529 035 922 Extractor/Installer 529 035 920 NOTE: Before extracting the bearing on wheel side, remove the protector by drilling the pop rivets with a 3/6 drill. Remove the circlip no. 8. V07HKA V07HLA WHEEL SIDE VMR2004_48_08_03A.FM 08-03-5
V07HMA FRAME SIDE Place the trailing arm support on the end of trailing arm. V07HOA FRAME SIDE Using a press and the bearing extractor/installer, remove the bearing. V07HNA WHEEL SIDE V07HPA WHEEL SIDE 08-03-6 VMR2004_48_08_03A.FM
V07HQA FRAME SIDE Clean the bearing housing. Using the proper extractor/installer, push the bearing in its location. V07HHA FRAME SIDE Install the circlip. If the circlip is slacked, replace it with a new. V07HRA WHEEL SIDE VMR2004_48_08_03A.FM 08-03-7