Models Hardtop (Hardtop) and Universal (Station Wagon)
Removing
1. Loosen the front wheel nuts.
2. Jack up the front of the car and place it on jack stands placed under the frame members. Remove the front wheels.
3. Remove the drain plug and drain the oil from the front axle housing.
4. Mark the position of the front propeller shaft in relation to the drive gear flange and the front drive flange of the transfer case. Disconnect the propeller shaft and remove it from under the vehicle.
5. Release a collar and disconnect from a case of the forward bridge a ventilating hose.
6. Disconnect a brake tube from a flexible brake hose, release a fixing clip and release a hose from a basic arm. Seal the open ends of the tube and hose to prevent dirt from entering the hydraulic brake system.
7. Remove the cotter pin and unscrew the castle nut securing the tie rod pendulum arm ball joint to the knuckle swing arm. Release the ball joint pin from the pivot arm by pressing the head of the hammer against the back side of the tie rod mounting ear and hitting from the opposite side with the second hammer. Using a piece of wire, tie the tie rod pendulum arm to the left side member of the chassis.
8. Give the fixing nuts, remove the washers and disconnect the lower shock absorber supports from the front axle housing.
9. Give the nut, remove the washer, then, prying with a lever, separate the transverse jet rod from the axle housing. Tie the rod to the front suspension element with a piece of wire.
10. Remove the front coil springs.
11. Using two stands or jacks, support the bridge in a horizontal position.
12. Give nuts and take out bolts of fastening of a case of the bridge to longitudinal levers, then by means of the assistant take out the bridge from under the car.
Installation
Installation is in the reverse order.
1. Move the front axle assembly into position, then insert the trailing arm mounting bolts, but do not tighten the nuts at this stage.
2. Reinstall the coil springs, transverse torque rod, and shock absorbers, but do not tighten the mounting nuts at this stage.
3. Connect the tie rod pendulum arm and tighten the slotted nut to 46÷54 Nm. Insert new pin.
4. Install the cardan shaft (sliding joint to the front axle). Follow the correct alignment of the landing marks applied during the dismantling process. Tighten the fixing nuts and bolts with a force of 78÷88 Nm.
5. Connect the vent hose and brake pipe, bleed the hydraulic system.
6. Pour the required amount of oil of the required grade into the axle housing.
7. Lower vehicle to ground and tighten to specification (see tables of sizes and adjustments at the end of the guide) by the force of the nuts for fastening the trailing arms, shock absorbers and transverse torque rod.
Utility Models (Van) and mini truck (Cab Chassis)
Removing
1. Loosen the front wheel nuts.
2. Jack up the front of the car and place it on jack stands placed under the frame members. Remove the front wheels.
3. Remove the drain plug and drain the oil from the front axle housing.
4. Mark the position of the front propeller shaft in relation to the drive gear flange and the front drive flange of the transfer case. Disconnect the propeller shaft and remove it from under the vehicle.
5. Release collars and disconnect from a case of the forward bridge a ventilating hose.
6. Disconnect a brake tube from a flexible brake hose, release a fixing clip and release a hose from a basic arm. Seal the open ends of the tube and hose to prevent dirt from entering the hydraulic brake system.
7. Give fixing nuts, remove washers and disconnect the bottom support of shock-absorbers from basic plates of springs.
8. Give nuts and disconnect racks from a bar of the stabilizer of cross stability.
9. Remove the cotter pin and unscrew the castellated nut securing the tie rod ball joint to the connecting rod. Release the ball joint pin from the tie rod by pressing the head of the hammer against the back side of the tie rod mounting ear, and with a second hammer, strike from the opposite side of it. Using a piece of wire, tie a longitudinal link to the left side member of the chassis.
10. Give nuts of U-shaped bolts of step-ladders of springs and remove basic plates. Lower the front ends of the springs to the ground.
11. Support the front axle horizontally with two stands or jacks.
12. Give fixing nuts and, supporting springs, remove plates and fingers of earrings from their forward ends.
13. With the help of an assistant, remove the axle assembly from under the vehicle.
Installation
Installation is in the reverse order.
1. Track the correct placement of the axle housing on the central bolts of the springs.
2. Install the pins, bushings and spring shackle plates, but do not tighten the mounting nuts at this stage.
3. Install the U-bolts and support plates of the spring ladders, tighten the fixing nuts with a force of 108÷147 Nm.
4. Install the anti-roll bars and tighten the fixing nuts with a force of 20÷23 Nm.
5. Connect the tie rod to the connecting rod, tighten the nut to 88÷113 Nm and install a new cotter pin.
6. Connect shock absorbers, but do not tighten nuts at this stage.
7. Install the cardan shaft (sliding joint to the front axle). Follow the correct alignment of the landing marks applied during the dismantling process. Tighten the fixing nuts and bolts with a force of 78÷88 Nm.
8. Connect the vent hose and brake pipe, bleed the hydraulic system.
9. Pour the required amount of oil of the required grade into the axle housing.
10. Lower the vehicle to the ground and tighten to specification (see tables of sizes and adjustments at the end of the guide) by the force of the nut for fastening the fingers of the springs and shock absorbers.