SAFARI

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SUSPENSION
4F. REMOVAL/DISMANTLING OF LOWER
WISHBONE (Fig. 8)
l Unscrew and remove 2 screws holding bracket
(torsion bar mounting) to lower wishbone. Take
out the bracket.
l Take out the split pin locking the castle nut of
stub axle bottom ball joint. Properly support the
stub axle. Push out the ball joint from stub axle.
l Unscrew and remove two nyloc nuts of pivot pins
holding lower wishbone with mounting brackets
on frame, using adaptor . 2699 5890 41
01). Push out pivot pins and remove lower
wishbone (Fig.11)
l Unscrew and remove 4 screws holding the ball
joint to lower wishbone. Take out the ball joint.
l Pry out pivot bushes from lower wishbones, if
necessary.
l Pry out pivot bushes from lower wishbone
mounting bracket, if necessary.
5. INSPECTION OF PARTS
l Check the condition of the following for wear,
damage. If necessary replace with new ones.
l Check the condition of antiroll bar for bend, cut,
damage etc. Replace it with new one, if
necessary.
l Check the condition of rubber links and bushes
of antiroll bar. If necessary replace with new ones.
l Check the condition of pivot bushes, washer and
spindle of upper wishbone assembly If necessary
replace with new ones.
l Check the condition of ball joints of upper
wishbone and lower wishbone. Check for
excessive play in ball joints. If necessary replace
with new ones.
l Check the condition of rubber boots of top and
bottom ball joints. If it is damaged, replace the
ball joint.
l Check the condition of shock absorber for leakage
etc. Check the condition of rubber bushes, washer
etc. If necessary replace with new OE shock
absorber
l Check the condition of torsion bar for wear cuts
etc. If necessary replace with new one.
l Check the condition of bump and rebound stopper.
If found worn/damaged replace with new ones.
Fig.14 Lower wishbone assembly
l Check the condition of upper wishbone and lower
wishbone. If found necessary replace with new
ones.
6. ASSEMBLY / INSTALLATION PROCEDURE
6A. ASSEMBLY / INSTALLATION OF LOWER
WISHBONE
l Assemble lower ball joint on stub axle for 4 x 4
version & then on the lower wishbone.
l If 2 halves of pivot bushes removed earlier from
lower wishbone, fit each half from either sides,
using suitable drift.
l Locate lower ball joint on the lower wishbone &
install 2 hex bolt (M12), washer, spring washer,
hex nut and then 2 hex screws (M10), washer,
spring washer, hex nut.Tighten M 12 bolts to 9.7
mkg torque and M10 screws to 6.5 mkg. torque.
l Fit bracket (torsion bar mounting) on the lower
wishbone with 2 hex screws and washers and
tighten hex screws to 9.7 mkg. torque.
l If 2 halves of pivot bushes removed earlier from
mounting bracket of lower wishbone, fit each half
from either sides, using suitable drift.
l Position the lower wishbone on chassis frame.
Align pivot bushes and holes on bracket using
suitable punch.
l Insert the shims to fill the gap at front pivot, Install
pivot pins (serrated pin in the torsion bar mounting
bracket) and nyloc nuts. Tighten nyloc nuts to
14-16 mkg torque, using adaptor (Pt. No. 2699
5890 41 01) with torque wrench.