Front Suspension

Front Suspension Assembly.............. 21-1

Overview ......................................... 21-1
Cautions .......................................... 21-2
Working principle of the system ...... 21-3
List of failure symptoms................... 21-4
Component drawing ........................ 21-5
Detection and adjustment................ 21-7
Front Shock Absorber....................... 21-10
Overhaul ........................................ 21-10
Front Leaf Spring............................... 21-12
Overhaul ........................................ 21-12
Front Stabilizer Bar........................... 21-15
Overhaul ........................................ 21-15
 Front Suspension - Front Suspension Assembly 21-1

Front Suspension Assembly

Overview
The role of front suspension system is to maximize the frictional force between tires and
road surface, and provide excellent steering actuation capabilities and stability as well as
providing passengers with comfort. It can absorb the energy of the vertical accelerating
wheel and enable the auto frame and the auto body to go undisturbed when the wheel
is bumping up and down along the road. Front suspension is made up of the leaf spring,
shared connecting shaft, shock absorber, damper rubber and stabilizer bar. Among them,
there are 9 pieces of leaf spring. The front end of the leaf spring is linked directly to the
spring carrier through the spring pin. The back end of the spring passes through the hook 21
ring through the hook ring pin. The hook ring is used to buffer the distance changes caused
by leaf spring warping. The leaf spring is linked to the front axle through the clamp plate (the
intermediate and upper parts) and bracket (the intermediate and lower parts). The shock
absorber and stabilizer bar are installed between front axle and chassis bracket to ensure
more comfortable and smooth of driving.
 21-2 Front Suspension - Front Suspension Assembly

Cautions
1. Cautions for suspension system operation
(a) When replacing parts, be sure to follow the instructions of this manual with care.
(b) Incorrect operation may influence the performance of steering system, and even en-
danger the personal safety.
(c) For special requirements, be sure to follow strictly the operating specifications.

21
 Front Suspension - Front Suspension Assembly 21-3

Working principle of the system

1. The shock absorber
Through the damping process, the shock absorber controls the undesirable spring move-
ment. The shock absorber can slow and weaken the vibration magnitude by converting the
kinetic energy of the suspension movements into thermal energy released by the hydraulic
oil consumption. The upper bracket of the shock absorber is linked to the frame (sprung
mass), and the lower bracket of the shock absorber closing to the wheel is linked to the
axle (non-sprung mass). In the twin-cylinder design, one of the most common types of
shock absorbers is the upper bracket linked to the piston rod, which is linked to the piston,
and the piston is located in the vessel full of hydraulic oil. The internal cylinder is called
pressure vessel, and external cylinder is called oil reservoir. The oil reservoir stores the 21
extra hydraulic oil. When the wheel gets on a bumpy road, the spring is compressed and
extended. The energy of the spring is transferred to the shock absorber through the upper
bracket and transferred down to the piston through the piston rod. There are holes in the
piston. When the piston is moving up and down inside the pressure vessel, the hydraulic
oil can leak from these holes. Because these holes are very tiny, only a very small amount
of hydraulic oil can go through under very heavy pressures. In this way, the moving speed
of the piston is slowed to make the spring movements slow down. There are two cycles
of the shock absorber operations - the compression cycle and the extension cycle. The
compression cycle is when the piston is moving downwards to compress the hydraulic oil
underneath. The extension cycle is when the piston is moving upwards to the pressure
vessel ceiling to compress the hydraulic oil above. For a typical car, the resistance of the
extension cycle is greater than that of the compression cycle. It should also be noted that
the compression cycle controls the movement of the non-sprung mass of the vehicles.
The extension cycle controls the movement of the heavier sprung mass of the vehicles. All
the modern shock absorbers have the speed sensing functions - the quicker the moving
speed of the suspension, the greater resistance the shock absorber provides. This enables
the shock absorber to make adjustments based on the road conditions and control all the
possible movements of the vehicles which are undesirable, such as jumping, overturning,
brake dive and accelerated crouching etc.
2. Stabilizer bar
The coordinated operation of stabilizer bar and shock absorber provides added steadiness
for the running vehicles. The stabilizer bar is a metal bar across the entire axle which ef-
fectively links together both sides of the suspension. When the suspension of one wheel
is moving up and down, the stabilizer bar will transfer the movement to other wheels. This
can make the driving more steady and smooth and reduce the tilting degree of the vehicle.
Especially, it can offset the overturning trends of vehicles on the suspension when turning.
3. Leaf spring
The intermediate section of the leaf spring is fastened to the axle through the U-shape bolt
(also called U-bolt). Both ends of the spring are linked to the auto frame bracket through
the pin hinge. In this way, the axle and auto body are linked together through the leaf
spring which serve the buffer, shock absorption and force transfer functions. The steel
plates of the multi-piece leaf spring are combined into an inverted triangle shape. The up-
permost steel plate is the longest and the lowermost steel plate is the shortest. The num-
ber of steel plates is related with the weight of the vehicle supported and the shock absorb-
ing effects. The more, the thicker and shorter the steel plates, the greater the stiffness of
the springs.
 21-4 Front Suspension - Front Suspension Assembly

List of failure symptoms

Using the following list will help you to locate the fault; serial number means the sort of
possible reason; check each section according to that sequence, and replace if necessary.

Failure Symptom Suspected Part Refer To

Goods are loaded based on the supporting

1. Vehicles (overload)
capacity

Chapter 21 Front Suspension - Front Leaf

Body sinking 2. Leaf spring (no force applied)
Spring, Overhaul

Chapter 21 Front Suspension - Front Shock

21 3. Shock absorber (wear)
Absorber, Overhaul

Chapter 23 Tire and Wheel - Front Tire and

1. Tire (wear or improper infla- Wheel Assembly, Overhaul; Chapter 23 Tire
tion) and Wheel - Rear Tire and Wheel Assembly,
Overhaul

Chapter 23 Tire and Wheel - Tire and Wheel

2. Tire (imbalanced)
Assembly, Detection and Adjustment

Chapter 21 Front Suspension- Front Leaf

3. Shock absorber (wear)
Swing/ Tilt Spring, Overhaul

4. Leaf spring pin, bush, lifting Chapter 21 Front Suspension- Front Leaf
lug (excessive Wear) Spring, Overhaul

Chapter 21 Front Suspension- Front Leaf

5. U-shape bolt (loosen)
Spring, Overhaul

6. Leaf spring (elastic force

Chapter 21 Front Suspension- Front Leaf
declined or inconsistent stiff-
Spring, Overhaul
ness)

1. Lubricating oil (excessive) Adjusting lubricating oil

2. S e a l e l e m e n t s ( f a i l e d o r
Oil leaks of shock Replace seal elements
broken)
absorber
Chapter 21 Front Suspension - Front Shock
3. Shock absorber (failed)
Absorber, Overhaul

Chapter 21 Front Suspension - Front Shock

1. Shock absorber (failed)
Absorber, Overhaul

2. Leaf spring (worn or dam- Chapter 21 Front Suspension- Front Leaf

aged) Spring, Overhaul

Chapter 21 Front Suspension- Front Leaf

Noise of the suspen- 3. Bush (worn or damaged)
Spring, Overhaul
sion part
4. Shock absorber and leaf spring
Chapter 21 Front Suspension--- Front Shock
assembly fixing bolts and nuts
Absorber, Overhaul
(loosen or damaged)

Chapter 21 Front Suspension - Front Stabi-

5. Stabilizer bar bush wear
lizer Bar, Overhaul
 Front Suspension - Front Suspension Assembly 21-5

Component drawing

23 4 19
14
13
9 6
9

18 3 20

8
24 6

18
4

9
16
6 21
25 2
9
15
5
8

11

12
4
3 17
21
2 21
7
2 22 22
3
11
4
12 20
1
33
51 54
6
39
5
50
52 6
29

49
46 53
28 43
48
26 44
31
45
27

33
41 20
20 38
33 32 40
42
30

37
40

33
20

34
6 10 36

35
 21-6 Front Suspension - Front Suspension Assembly

1 Front stabilizer bar hanger seat 28 Base plate weldment assembly

2 Upper connecting bolt 29 Nut

3 Front stabilizer bar bushing 30 Hexagon head bolt - fine thread

4 Hanger bracket of front stabilizer bar 31 Hexagon head bolt

5 U-connecting plate 32 Buffer block assembly

6 Hexagon bolt - fine thread 33 Flat washer

7 Leaf spring assembly 34 All-metal hexagon locknuts, style 2

21 8 Self-locking nut 35 Bolt

9 Flat washer 36 Shock absorber bracket

10 Hexagon head bolt 37 Reinforced plate

11 Reinforced plate 38 Connecting bolt of bar ends

12 Ingot beam 39 Spring washer

13 Hexagon head bolt - fine thread 40 Flat washer

14 Front U-bolt 41 Spherical washer

15 Hexagon head bolt - fine thread 42 Self-locking nut

16 Hexagon head bolt - fine thread 43 Hexagon bolt - fine thread

17 Hexagon head bolt - fine thread 44 Shaft elastic snap ring

18 Self-locking nut 45 Connecting shaft in common

19 Hexagon head bolt - fine thread 46 Spring washer

20 Rear bracket of front leaf spring 47 Front leaf spring assembly

21 Front leaf spring lifting lug 48 Front bracket of front spring

22 Leaf spring pin shaft 49 Hexagon head bolt - fine thread

23 Bent lubricating nipple 50 Hexagon head bolt - fine thread

24 Adjusting shim 51 Front stabilizer bar assembly

25 Front shock absorber assembly 52 Hexagon head bolt - fine thread

26 Shock absorber crossover 53 Spring washer

27 Bolt 54 Hexagon nut - fine thread

 Front Suspension - Front Suspension Assembly 21-7

Detection and adjustment

1. On-board inspection
(a) Visual measure the shock absorber is not leaking; the bush is cracking.
(b) Check the U-bolts are not deformed, cracked, and the threads are not damaged. Re-
place with new one if necessary.
(c) The fastening of U-bolts should adopt the uniform crossover tightening method, gradu-
ally increase the tightening torque to the specified value. When full loaded, because
the leaf spring is tightly fit, at this time, the U-shape bolts and nuts must be tightened
once again. When fastening the nuts, prevent the inability of the leaf spring from being
compressed tightly due to the rust and corrosion of the bolts and nuts, and result in a 21
illusion that the torque is artificially enlarged. If necessary, the tapping machine should
be used for tapping so that the bolts and nuts can match perfectly.
(d) Measurement of buffer clearance
Standard value: 124mm
Limit value: 118 - 130mm
Note:
Measurement should be conducted at no-load.
If the buffer clearance is significantly reduced,
fhwx210002 the leaf spring and buffer block may be dam-
aged (cracking or poor elasticity).

2. Inspection of shock absorber

(a) Check the shock absorber for oil leaks.
 21-8 Front Suspension - Front Suspension Assembly

(b) Check the connecting rod, rubber bushing

and other connecting parts of the shock ab-
sorber is not damaged, and replace it if dam-
aged.
(c) Press and pull the reciprocating shock ab-
sorber for 2 to 3 times. If the whole process
of reciprocating stroke is normal and uniform,
fhwx210003
without obvious non-cutting stroke, without
getting stuck and suddenly overlooked.
(d) After loading, driving about 10 Km in a bumpy
road and parking, touch the surface of the
21
shock absorber by hand. If there is a big dif-
ference in temperatures of the two shock
absorbers, the difference in resistance levels
between the two is also larger. The resistance
level of the low-temperature shock absorber
is low. If the surface temperature of the shock
absorber is not higher than the air tempera-
ture, the shock absorber has no level of re-
sistance and has lost its functions.
△ Hint:
Replace the shock absorber if any fault oc-
curs, refer to Chapter 21 Front Suspension -
Front Shock Absorber, Overhaul.

3. Inspection of leaf spring pin shaft

(a) Measure the outer diameter of leaf spring pin
shaft using micrometer.
Standard value: φ30mm
Limit value: φ29.93 - 29.97mm
Note:
fhwx220004 If exceeded the limit value, replace the leaf
spring pin shaft.

(b) Measure leaf spring camber using measuring

tape.
Standard value: 105mm
Limit value: 99 - 111mm
Note:
The camber deviations of the two front leaf
springs shall be no more than 4mm, other-
wise, it may cause inclination of vehicle.
Front Suspension - Front Suspension Assembly 21-9

4. Measure the inner diameter of front-end

leaf spring pin bushng
(a) Measure the inner diameter of leaf spring pin
shaft bush by vernier caliper
Standard value: φ30mm
Limit value: φ30.11 - 30.194mm
fhwx210005 Note:
Select three locations and measure.

5. Inspection of the internal bush of the sta- 21

bilizer bar
(a) Check the casing for excessive wears or fis-
sures, etc.

fhwx210006
 21-10 Front Suspension - Front Shock Absorber

Front Shock Absorber

Overhaul
Component drawing, refer to Chapter 21 Front Suspension - Front Suspension Assembly,
Component drawing
1. Lifting Cabin
Note:
Confirm the locking mechanism of the cabin is reliable.
2. Remove the front shock absorber assem-
21 bly
(a) Remove the upper fixing bolts of front shock
absorber

fhwx210007

(b) Remove the lower fixing bolts of front shock

absorber, and remove the front shock absorb-
er

fhwx210008

3. Check the shock absorber, refer to Chapter 21 Front Suspension - Front Suspen-
sion Assembly, Detection and Adjustment
 Front Suspension - Front Shock Absorber 21-11

4. Install the left front shock absorber as-

sembly
(a) Install the lower fixing bolts of front shock ab-
sorber.
Torque: 221±22N•m

fhwx210008

(b) Install the upper fixing bolts of front shock ab-

sorber. 21
Torque: 221±22N•m
△ Hint:
Overhaul of the front right shock absorber, re-
fer to the Overhaul of front left shock absorb-
er.

fhwx210007

5. Tilting cabin
 21-12 Front Suspension - Front Leaf Spring

Front Leaf Spring

Overhaul
△ Hint:
Component drawing, refer to Chapter 21 Front Suspension - Front Suspension As-
sembly, component drawing
1. Jack up the left front beam, and support by stirrup, refer to Chapter 1 Introduc-
tion - Repair Guide, Vehicle Jacking and Supporting Position
2. Remove the tire
21 3. Disconnect the air tube of front left brake air chamber, refer to Chapter 26 Serv-
ice Braking - Front Brake Chamber, Overhaul
4. Remove the left front shock absorber, refer to Chapter 21 Front Suspension -
Front Shock Absorber, Overhaul
5. Remove the left front leaf spring assembly
(a) Jack up the front axle, and remove the front
left leaf spring U-shape joint nut and 4 joint
nuts of front Axle.
(b) Remove the U-bolts and front leaf spring
pressure plate sequentially.
(c) Slowly loosen the jack to allow smooth de-
fhwx210009
scending the front axle.
Note:
Be sure to jacking up the front part of the vehi-
cle when loosening the front axle jack.

(d) Remove the fixing bolt 1 of front leaf spring

pin shaft.
1 (e) Pull out the front leaf spring pin shaft 2 by us-
ing drawing machine.

fhwx210010
 Front Suspension - Front Leaf Spring 21-13

(f) Remove the fastening bolt 1 of rear leaf

2 spring pin shaft.
(g) Pull out the rear leaf spring pin shaft 2 by us-
ing drawing machine.

fhwx210011

(h) Remove the left front leaf spring.

21

fhwx210012

6. Inspect front leaf spring combination; refer to Chapter 21 Front Suspension -

Front Suspension Assembly, Detection and Adjustment
7. Install the left front leaf spring assembly
(a) Install the left front leaf spring onto the front
bracket 1 of front leaf spring and the left lifting
lug of front leaf spring.

fhwx210013

(b) Install the rear leaf spring pin shaft 2.

2 (c) Install the fastening bolt 1 of rear leaf spring
pin shaft.
Torque: 84±8N•m
△ Hint:
1
Applying one layer of grease to the leaf spring
fhwx210011
pin shaft. Grease: No. 2 base grease.
 21-14 Front Suspension - Front Leaf Spring

(d) Install the front leaf spring pin shaft 2.

(e) Install 2 fastening bolts of front leaf spring pin
1 shaft.
Torque: 84±8N•m
△ Hint:
2
Applying one layer of grease to the leaf spring
fhwx210010 pin shaft. Grease: No. 2 Lithium Grease

(f) Slowly jacking up the front axle to make the

head of leaf spring center bolt entering the
21
front axle locating hole.

(g) Install front leaf spring pressure plate, U-bolts

and nuts in turn.
• Tightening the 4 fastening nuts.
Torque:280±20N•m

fhwx210009

8. Install the left front shock absorber assembly; refer to Chapter 21 Front Suspen-
sion - Front Shock Absorber, Overhaul.
9. Install the air tube of front left brake air chamber; Chapter 26 Service Braking -
Front Brake Chamber, Overhaul
10. Install the tire
△ Hint:
Overhaul of right front leaf spring assembly, refer to the servicing procedure of left
front leaf spring.
 Front Suspension - Front Stabilizer Bar 21-15

Front Stabilizer Bar

Overhaul
△ Hint:
Component drawing, refer to Chapter 21 Front Suspension - Front Suspension As-
sembly, component drawing
1. Remove the front stabilizer bar assembly
(a) Remove the U-shape connecting plates on
both sides.
• Unscrew the fastening nuts on both 21
sides, and remove the bolts.
(b) Remove the U-shape connecting panels, the
front stabilizer rubber pad in turn.
fhwx210014

(c) Disconnect the left stabilizer bar and head

connector of stabilizer bar.
• Unscrew the fastening nuts, and remove
the bolts.

fhwx210015

(d) Disconnect the right stabilizer bar and head

connector of stabilizer bar.
• Unscrew the fastening nuts.
(e) Remove the stabilizer bar assembly.

fhwx210016

2. Check the stabilizer bar assembly

(f) Whether the stabilizer bar is not deformed or worn.
(g) Whether the stabilizer bar rubber pad is not damaged or fissured.
(h) Whether the U-shape connecting panel and the front stabilizer bar are not deformed.
Torque: 84±8N•m
 21-16 Front Suspension - Front Stabilizer Bar

3. Install stabilizer bar assembly

(a) Connect the stabilizer bar with its connecting
part, and install the bolts.
Torque: 140±14N•m
Note:
The bolts can be tightened until the U-shape
fhwx210016 connecting plate of stabilizer bar is installed
completely.

(b) Connect the left stabilizer bar with its connect-

21 ing part, and install the bolts.
Torque: 140±14N•m
Note:
The bolts can be tightened until the U-shape
connecting plate of stabilizer bar is installed
completely.
fhwx210015

(c) Install stabilizer bar rubber pad, U-shape con-

necting plate into the stabilizer bar assembly
in turn.
(d) Tighten the bolts.
Torque: 84±8N•m

fhwx210014