SAFARI

14 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 (Pt.No. 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 i t wi th new one, i f 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.