Manual Service

Repairs and maintenance
suspenslon, 240/260,DL GL. GT, G LT, GLE,COUPE 1 DTESEL975-

,

Contents
Opor.tions Pa96 2 2

Specificntions.
Special tools Group 65

Replacing the reaction rod and,/or bushings

A 1 - A 5 . . . . . . . . . .3

Replacing the track rod and/or bushings.. ........ .. . 8r 86... ...... 5 ... Replacing the trailing arm and/or bushings ...... cr cr 3 7

Noio: Torque specitications this manual cover I975 8t in models. Refer to appropriatenew modeLliteraturetor subsequentspecif ication changes.

Oid€rNo.TP 30125/2.
We rese.vethe right to make aherations

Specifications
Nm WheelnJts . .. c - a ' ; o 1 ' o d ( b o d ya r a c h m e . r ) ( a r l ed t L ar, m " 4 t . T l d , l , F o o l b o o ya r r a L l a e rr , ( a r l ea l l a L h r e l L ) T a , l , r 9d - s ( b o d yd r r a c h m e l r ) ( a r l ea r ' a c h - e . r ) F e a r5 0 , a g r u r u p p p r. S h o c l a b s o r b " r u p p e ra r d l o ^ . r 1 u t s 1 15::l:15 85 85 85 60 115 115 45:!1O 20 85

85a11 65 65 65 85 85 357.7 t5 65

Special tools
999 2706 2731 2733 5078 5079 5046 5047 5048
DiiltDriftCountorholdPrBs toolSpacersleoveDriftSlesveDritln g a n d n s l a l l i n gr a c kr o d b u s h i n g l n g a n d n s l a l l i n gr a c kr o d b u s h r n g l n g t r a c kr o d b u s h i n g n g l r a l l i n ga r m b u s h i n g ng tralling m bushing a ng reactionrod bushing ng reactionrod bush ng ng reactionrod bush ng

rep rep rep rep rep rep

;ilr
2731,2733 5078,5079

5086,50a7

5047,5044

Group 65 Rear wheel suspension

Replactngthe rcactrcnrcd and/ot bushings

Group65
A. Replacingthe reaction rod and/or bushings
Special tools: 5O86 5087 Drift Sleeve

A1

o

Jack up the real end P acesuppofts Jroniofthereafjackattachments ln

A2

Remove reaction rod

A3

Replacing bushings P r e s sb u s h i n g s u t ( o r i n ) w t h s p e c i a lt o o 5 0 8 6 o counlerhold 087. 5 Note! Pos r on the bushings in the react'on rod so t h e f l a t s d e sa r e p a r a l l e l t o h e r o d t

Gtoup 65 Rear wheel suspension

3

-TRepladng the teact'on rcd dnd ot bushtngs

T h r e ed i l e r e n lr o d e . g t h s a v a l l a b l e 1 4O2 mm (1s 839") standard 1 2 397 mm(1s 641") 5mmshorter(0 97") ') 3 3 9 2 m m 1 1 5 4 4 s " ) - 1 0 m m s h o n e .( O . 4 0 v o R o d s2 a n d 3 a r e u s e d1 0l e s s e n b r a t i o n n t a k eo f f

A5

In$alling

the reaction lod Lower the

Insiall the reaclion rod bu do not tighten

Not€: Do not lightenthe nuls u.til the car has b€en o w e r e da n d s e t t l € sT h i sa v o d s s v a i n i n gt h e b u s hn g s T i g h t e nn g t o r q u e r 8 5 N m ( 6 5 1 t l b s ) b o t h f r o n t a n d

Replacing stabili2el R e m o v et w o r e a r r e t . i n i n gb o h s ( h e x l 9 m m ) o n e a c h R e m o v e w o f r o n i r e t an i n g b o t s ( h e x 1 7 m m ) o n e a c h t

o

T l g h t e n i n go r q u e s l:r o n l a f t a c h m e . t8 5 N m ( 6 5 i t L b s ) t rear allachment45 Nm (3O fr lbs)

4

Group64 Reatwheelsuspensian
IL

ReplacingtQck rod and/or bushings

B. Replacingtrack rod and/or bushings
Specialtools 2706 2731 2 733
Drift Drift

B1

Jack up the rear end
Placesupporrsin front of rearlack attachmenis

B2

Remove fack rod

B3

Replacing bushings P r e s so u t r e a r a x e e n d o { b u s h n g w i r h s p e o a l t o o l 2 7 3 1 a n d s l e e v e 7 3 3 u s e da s c o u n l e r h o l d n d t u r n e d 2 a a s s h o w ni n i l l u s t r a l i o n Pressin new bushlng w th the same lools but w th coun

Gtoup 64 Rear wheelsuspension

5

Replacingtrack rod and /or bushings

B4

Pressout body side of bushing with spec al tool 2705 and seeve 2733 usedas counterhold nd turned .s a show. n uslralion P r e s s n n e w b u s h i n g h h r h e s a m eb o L sb u t w i l h c o u n I w (lJsea soapysolutlon as a lubr cant to assrst n this oper

B5

Note:
T h e b o d y s L d eo l b u s h i n g h a s b e e n r e p l a @ d type lt can be litted without the necessity to

4 0 m m : 1 5 7 4 " ( 19 / I 6 " ) 3 4m m: 1 3 3 8 ' ( 1 5 / 1 6 " )

o
B6

Replace track lod Feplace the irackrod but do not tighten.Lower car Note: Do not lighten the nuts until the car has been lowered settles. s avods slraningthe bushi.gs and Th atlachment 60 Nm (45i1lbs) axle bodyattachmenl 85 Nm (65 ft bs)

6

Gtoup 64 Rear wheel suspension

ReplacingtBiling arm and/ot bushtngs

G. Replacingtrailing arm and/or bushings
Specialtaols 5078 5079 5087
Spacer sleeve Sleeve Drift

sOBB

C1

Jack up the iear end Placesuppo.ts in lront ol rear lack a n a c h m e n l sJ a c k u p r e a ra x e s l i g h t l y t oo f f o a d s p r n g and shock absorber

c2

,o

Remove lowel shock absorber attachment bolt (1) and spring bottom nut (2) Lower andremove spring tack

C3

Removetrailing arm Replacement ot t.ailing o n l y ,s e eo p e r a to n C 1 1 arm

'].

.rii

Group64 Rearwheelsuspenston

7

Replacingttailing atm and/or bushings

C4

Replacing bushings Replacelsading bushing(fronr). ljse speciatool 5O8aandcounterhold 5087

c5

L€adingbushing (tront)
lJ ear y iype bushlngs are ffacked or worn and need replacement bolh sldes must be replaced wilh the later

C6 Replacetrailing bushing (rear)
Note: The tools are stamped with dentfrcation marks A , B ,c o r D U s es p e ca l l o o 5 0 7 8 a n d s p a c e 5 0 7 9 r P l a c e p a c e 5 0 7 9 ( 1 ) r o u n db u s h i n g . s r I n s e r t h r e a d e d o l t ( 2 ) t h r o u g hb u s h l n g r o m i n s i d e b f 'c (3) l r s r a l la d " p L . ' a n d r u r ( 4 ) o 1 r l . eo u r s , d e 'C (3) Cenve adapter belore t ghtening t secur€lywilh boh (2)

c7
Removingbushing
P l a c e s l e e v e ' 8 " ( 1 )a g a n s t b . a c k e t . " P l a c e d a p t e r A ( 2 ) a n dn u t ( 3 ) o n t h . e a d e d o l t a b C e n l r ea d a p t e r" A " ( 2 ) a s a i n s ts L € e v e B " ( 1 ) b e f o r e W i l h d r a wb u s h i n gu s i n ga n i m p a d w r e n c h

8

Gtoup 65 Rear wheelsuspension

ReplacingtQiling arm and/or bushings

CA

Installing bushing P l a c ea d a p t e r" D " ( 1 ) a g a i n s tf l a t e n d centre adapteragainstbushing hole. I n s e r t h r e a d e d o k ( 3 ) t h r o u s hb u s h i n s(2) b 'D' F i l n u t o n b o l t a n d t g h t e nu p a d a p t e r (1)withbolt.

o
Install bushing in blacket from insid€

C9

o

l l \ l o t e : T h e b u s h i n gh a s r e c e s s e(s ) w h i c h s h o u L d e r n b a honzontal ({or€ and aft) Dositionwhen installed- a so note that the recesses ollset towards the top; larger are rubber area (2) should be at bottom lbelow centre ne)

cl0

A i g n a d a p t e .' A ' ( 2 ) a n d t i g h t e nnut 11) pull bushins 1o R e m o v eo o l a n d s p a c e r . l

cl l

Installing tlailing

arm

F t t r a i l i n ga r m , t o l r o n l a n d t h e n t o r e a ra t t a c h m e ntto , gether w th stabl zer attachmenl Noie: Do noi tghten the nuts unti the car has been r o w e r e d n d s e t r l e sT h i sa v o i d s t r a i n i n gh e b u s h i n g s . a . s t

Group 65 Rear wheelsuspension

9

Feplacing trailing am and/o. bushings

nut (2).

cl2 Place springon trailingarmandinstallbottorn

n a s e i a c ka n d g u i d ei h e s p r i n gi n t o p o s i t i o n . Reconnectshock absorber boitom attachment stabili?er attachm6nticenain mode sl. Nois: Spacersleeveshould lie on inside. Do not tighten before lhe car has been lowered and bounced a tew

Shock absorber upper and lower nuts 8 5 N m ( 6 5 f t l b s ) S p r i n gn u t 45 Nm (3O ft lbs) 20 Nm (15 ft lbs) Trailing arrn body attachment I 1 5 N m ( 8 5f t l b s ) axteattachment 1 1 5 N m ( 8 5 1 tl b s )

cl3

Install wheel and low€r car Tighlenins torque {wheel nuts): 1I5 Nm (85 ft lbs)

10

Group65 Rearwheelsuspension