Maintenance Manual of Single Rear Axle Suspension

Table of contents
I. General .................................................................................................................................................1
(I) Structure of rear suspension .........................................................................................................1
(II) Structure of transverse stabilizer bar ...........................................................................................2
(III) Technical parameter ...................................................................................................................3
(IV) Fault diagnosis ...........................................................................................................................3
II. Maintenance of rear suspension.......................................................................................................4
(I) Dismounting ..................................................................................................................................4
(II) Inspection ....................................................................................................................................5
(III) Reassembling .............................................................................................................................6
Maintenance Manual of Single Rear Axle Suspension
 Maintenance Manual of Single Rear Axle Suspension

I. General
(I) Structure of rear suspension
The rear suspension system is composed of main spring and auxiliary spring which are made of few-leaf
spring and rear transverse stabilizer bar.
The auxiliary spring is fitted with cover plate. In the middle of two springs, the leaf spring assembly is
fixed on axle through U-bolt and U-bolt base plate. The main spring front spring eye is connected to the
frame via fixed end bracket and lug pin to form a fixed rotating support end while its rear spring eye is
connected to the frame via leaf spring pin, lug pin and hanger end bracket to form a swinging support
end.
For the rear suspension system, the leaf spring assembly and transverse stabilizer bar are used to
receive and transmit the force and torque along various directions. This rear suspension is fitted with
removable auxiliary spring sliding plate which is easy to be replaced when it is worn out. The U-bolt base
plate is inclined base plate and its direction is not inverse. The spring pin and lug pin of this rear
suspension are fixed by bracket and hanger single side cutting and bolt clamping means. A stop block is
mounted above rear axle.

1. Auxiliary leaf spring assembly 5. U-bolt

2. Auxiliary spring bracket—rear suspension 6. Main leaf spring assembly
3. Leaf spring pin 7. Fixed end bracket—rear suspension
4. lifting lug

General 1
Maintenance Manual of Single Rear Axle Suspension

(II) Structure of transverse stabilizer bar

When the vehicle runs normally and the left and right wheels run out at same direction and amplitude,
the transverse stabilizer bar will be out of function. When the left and right wheels have relative
displacement vertically, the stabilizer bar will be in torsion to play a role of elastic component. If an
appropriate total roll rate of front and rear suspensions is selected, the complete vehicle may obtain
certain under-steering characteristics. Be sure that the transverse stabilizer bar is often mounted in front
and rear suspension systems of vehicle or only in front suspension system. If it is mounted in rear
suspension only, it may cause the over steering of vehicle to affect adversely the running. The
transverse stabilizer bar is connected to the axle at its one end and to the frame at its other end and the
connecting point is supported with rubber for vibration isolating and noise reducing purpose.

2 General
 Maintenance Manual of Single Rear Axle Suspension

(III) Technical parameter

Item Type
With main and auxiliary leaf springs of two rigidity grades, and
Type of suspension
rear transverse stabilizer bar
Type of leaf spring Taper-leaf spring assembly, few-leaf spring

(IV) Fault diagnosis

Fault diagnosis table

Symptom Cause analysis Solutions

The leaf spring is broken along Replace the component, tighten it as
The U-bolt is loose for long.
center hole. required and periodically check it.
Overload Normal service
The leaf spring is of early
The cushion block falls off. Mount it in time.
breakage.
Overload Normal service
The leaf spring bushing and lifting Fail to fill the lubricating Conduct maintenance and
lug bushing are of early abrasion. grease as required. lubrication as required.
The tandem suspension shaft and Fail to fill the lubricating Conduct maintenance and
bush are of early abrasion. grease as required. lubrication as required.
The steering wheel beats hand
The shock absorber is in Replace or repair the shock
and the driver cab vibration
failure. absorber.
doesn’t fall.
There is severe impact when The shock absorber is Replace or repair the shock
running on rugged road. blocked. absorber.

Fault predication of shock absorber

1. After the vehicle passes the drop pit or convex hull, if
the vibration continues and has no attenuation for long,
the shock absorber may be in failure. At this time, it is
necessary to dismount the shock absorber and push
downwards or pull upwards the shock absorber pull bar
(see the right figure). If there is very large and even
resistance between upper and lower two strokes, this
shows the shock absorber is good; if no resistance, this
shows the shock absorber is in failure and shall be
repaired or replaced. If it is found that some positions are
first easy and then resistive, this shows the shock
absorber oil is inadequate and the oil shall be added.
2. After a vehicle runs for 10km on a bad road and then stops, when touching the shock absorber with
hand and finding that its temperature not greater than air temperature, this shows the shock absorber
has no resistance and is out of function; when the temperature of two shock absorbers are one high and
one low with large difference, this shows the resistance of low-temperature shock absorber is much less
than that of high-temperature shock absorber.
3. If there is severe impact when the vehicle runs on rugged road, it is allowed to dismount the shock
absorber and put it upright. If it cannot be pulled, this shows the shock absorber is blocked and the repair
and replacement are necessary. The oil leakage is mainly caused by severe abrasion of oil seal of
connecting rod and bad sealing performance. Be sure to replace them in time. When the connecting rod
guide seat seal ring is aged, the oil will leak from oil reservoir wall. If it is found that there is oil leakage
from oil reservoir wall or oil stain on oil reservoir, it is necessary to use a special spanner to tighten the
top cover with the torque of 98 N·m above. If there is still oil leakage but is not severe after the top cover
is tightened, it is allowed to continue the use. If the oil leakage is severe to cause the obvious resistance
of resistance, the repair or replacement is necessary.

General 3
Maintenance Manual of Single Rear Axle Suspension

II. Maintenance of rear suspension

(I) Dismounting
Notice: Before dismounting, be sure to clean the suspension system of silt and greasy filth,
place the parking brake control valve handle at brake position and fix the front and rear wheels
with triangle timber wedge.

1. Loosen the U-bolt, take off the U-bolt, cover

plate and base plate.
2. Jack up the rear axle with jack, support the
frame with reliable bracket, put down the jack,
make and hold the spring at free state, and
dismount the auxiliary spring assembly and base
plate.

3. Dismount the spring rear end.

1) Dismount the rear fixing bolt from leaf spring.

2) Dismount the rear pin and side washer from

leaf spring.

4 Maintenance of rear suspension

 Maintenance Manual of Single Rear Axle Suspension

4. Dismount the rear leaf spring front pin fixing

bolt, and then remove the rear leaf spring front pin.

5. Put down the jack, and remove the rear leaf

spring.
6. Dismount the lifting lug fixing bolt and then lug
pin, lifting lug and side washer.

(II) Inspection
1. Measure the thickness of each leaf spring. If the wear extent exceeds 15% of normal thickness,
replace the spring.

2. Spring pin and lug pin

Measure the external diameter of spring pin and
lug pin.
Wear limit: 34.7mm

Maintenance of rear suspension 5

Maintenance Manual of Single Rear Axle Suspension

3. Spring pin and lug pin bushing

Measure the internal diameter of bushing.
Wear limit: 36mm
4. Calculate the clearance between the spring
pin and lug pin and their bushings.
Clearance between spring pin and bushing
Maintenance standard: 0.015~0.32mm
Clearance between lug pin and bushing
Maintenance standard: 0.04~0.155mm

(III) Reassembling
Notice: Before reassembling, apply a layer of lubricating grease onto spring bushing and hanger
bushing hole.

1. Mount the hanger on hanger bracket, mount

the side washers at the sides of hanger, drive
down the lug pin, and then mount the locking bolt.
Notice: When driving down the lug pin, the
groove of lug pin shall align with the locking
bolt.
Tightening torque: 55~70N m
2. Place the rear spring on rear axle, jack up the
rear axle with jack.

3. Align the fixed end bracket hole with the

spring eye hole, and insert the spring pin in place.
Notice: Align the groove of spring pin with the
locking bolt.
4. Mount the fixing bolt.

6 Maintenance of rear suspension

 Maintenance Manual of Single Rear Axle Suspension

5. Mount the spring rear end, lug hole, spring

eye hole and make the side washer holes at two
sides align each other, insert the spring pin in
place, and mount the locking bolt.
Tightening torque: 55~70N m
6. Place the auxiliary spring base plate, auxiliary
spring and cover plate on rear spring, mount the
U-bolt temporarily.
7. Jack up the rear end with jack, take off the
bracket on frame, and put down the jack.
8. Mount the U-bolt base plate.
9. Tighten the U-bolt nut.
Tightening torque

Reference
tightening
Specification of screw thread torque
(N·m)

M27(29Z33-04133) 860-1000

M24 450-500

M22 400-450

M20 350-400

M18 280-350

M16 220~280

Warning: Be sure to tighten really the U-bolt nut of leaf spring. This has an important bearing
upon the service life of leaf spring.

10. Apply lubricating grease onto the leaf spring

pin and lug pin.

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Maintenance Manual of Single Rear Axle Suspension

8 Maintenance of rear suspension