204-02-1

Rear Suspension 204-02-1

Section 204-02 Rear Suspension

Applicable Model: Boomday

CONTENTS PAGE
Specifications
Specifications.................................................................................................................................204-02-2
Descriptions and Operations
Rear Suspension............................................................................................................................204-02-3
Diagnosis and Testing
Rear Suspension............................................................................................................................204-02-5
Removal and Installation
Shock Absorber..............................................................................................................................204-02-6
Leaf Spring.....................................................................................................................................204-02-7

2009.06 Boomday
 Rear Suspension
204-02-2 204-02-2
Specifications

Torque Parameters

Item Nm
Upper retaining nut of shock absorber 40 ± 5
Lower retaining nut of shock absorber 40 ± 2
U-bolt retaining nut 40 ± 2
Retaining nut for front pin shaft of leaf spring 155 ± 15
Retaining nut of leaf spring shackle assembly 100 ± 20
Central bolt of leaf spring 30 ± 2
Bumper block bolt 38 ± 9

2009.06 Boomday
204-02-3
Rear Suspension 204-02-3
Descriptions and Operations

Rear Suspension
  TTENTION: The suspension fasteners
A
are critical parts which may influence
the vehicle performance. Their failure
will cause high maintenance costs. Use
components of identical part drawing
number when replacement is necessary
during maintenance. Do not use
substitutive parts or parts of poor quality.
During assembly, strictly tighten the
components up to the given torque so as
to guarantee that they are under correct
holding force.
The rear suspension system is composed of the
following components:
● Shock absorber
● Leaf spring
● Rear bumper block
Shock absorber
Rear shock absorber provides necessary dam-
ping control for the suspension system.
The rear shock absorber is in the type of hydraul-
ic two-way cylinder.
Leaf spring
Adopt semi-ellipse, leaf-shaped spring.
Rear bumper block
It is used to prevent metallic impact of sheet metal
parts between rear axle and frame.

2009.06 Boomday
 Rear Suspension
204-02-4 204-02-4
Descriptions and Operations

Rear Suspension System – Parts Illustration

Item Description Item Description

1 Leaf spring shackle 9 Upper plywood
2 Rubber bushing 10 Lower bracket
3 Shackle plate 11 U-bolt connecting nut (four)
4 Shackle connecting nut (two) 12 Front shaft pin
5 Rear bumper block 13 Shaft sleeve
6 Retaining nut of hock absorber (two) 14 connecting nut of front shaft pin
7 Rear shock absorber 15 Leaf spring
8 U–bolt (two)

2009.06 Boomday
204-02-5
Rear Suspension 204-02-5
Descriptions and Operations

Rear Suspension
Refer to section 204-00 for more information.

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 Rear Suspension
204-02-6 204-02-6
Removal and Installation

Shock Absorber
Removal and Installation
  TTENTION: The following operations
A
are for components on the right side, and
those for components on the left side are
similar.
1. Place the vehicle on the lift.
For more information, refer to section 100-02.
2. Remove the upper end nut of shock absorber.
● During installation, tighten it up to 40 ± 5 Nm.

3. Remove the lower end nut of shock absorber.

● During installation, tighten it up to 40 ± 2 Nm.

4. Remove the shock absorber.

5. For installation, reverse the removal procedures.
●  heck the condition of the shock absorber,
C
and replace it with a new one if necessary.

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204-02-7
Rear Suspension 204-02-7
Removal and Installation

Leaf Spring
Removal 4. Remove four U-bolts mounting nuts, lower
bracket, and two U-bolts.
 TTENTION: The following operations
A
are for components on the right side, and 1 Remove the four nuts.
those for components on the left side are
similar. 2 Remove the lower bracket.

1. S
 hift the vehicle to the neutral gear and 3 Remove two U-bolts.
prop up the rear axle with a jack.

5. R emove the mounting nut of leaf spring

2. R
 emove the lower end nut of shock absorber. shackle, shackle plate, and shackle.
1 Remove two nuts.
2 Remove the shackle plate.
3 Remove the shackle.
●  etach the rubber bushing and knock
D
out the shackle with a copper bar and
hammer.

3. R
 emove the two bolts, and remove the
parking brake cable and wheel speed
sensor wire.

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 Rear Suspension
204-02-8 204-02-8
Removal and Installation

6. Remove the leaf spring assembly. ● Force the bushing in with a bench press.

1 Remove the front pin shaft and nut pf leaf
spring.
● K
 nock out the front pin shaft with a copper
bar and hammer.
2 Remove the leaf spring assembly.

2. Locate the leaf spring and install the front

pin shaft and nut to proper positions. Do
not tighten up the nuts here.
3. Install the rubber bushing, leaf spring
shackle, shackle plate, and nut to proper
positions, and do not tighten up the nut here.
7. Remove the bushing from the leaf spring. ●  pply rubber grease inside the rubber
A
bushing.
● Force the bushing out with a bench press.

ATTENTION: The rubber bushing flange
should sit against the outer edge of the
leaf spring and shackle bracket.
4. Locate and place the upper plate, install the
u-bolt, lower bracket, and nut; adjust U-bolt
to make it vertical as far as possible, and
screw up the nut to a proper position.
5. Lower the vehicle height to make the susp-
ension at the height of unloaded state.
6. Tighten the front pin shaft mounting nut up
to 155 ± 15 Nm.
Installation

CAUTION: When the suspension is at the
height when the vehicle is in the unloaded
state, finally tighten up the leaf spring
fastener.
1. Install the shaft sleeve.

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204-02-9
Rear Suspension 204-02-9
Removal and Installation

7. Tighten
 the shackle nut up to 100 ± 20 Nm.

8. Tighten
 the U-bolt mounting nut up to 67 ±
6 Nm in X-shape.

9. Install
 the lower end washer and nut of
shock absorber.
● Tighten them up to 40 ± 2 Nm.

10. Install
 the parking brake cable and wheel
speed sensor wire.

2009.06 Boomday