Suspension Spring ( Coil / Leaf ): Service and Repair

LEAF SPRING






Removal and Installation

CAUTION: When installing the components with rubber bushings, the final nut tightening must be carried out under unladen* conditions with the tires on level ground.
* (Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.)

REMOVAL
1. Support the rear final drive assembly with a suitable jack to relieve the tension from the leaf spring.
^ The axle weight should be supported, but there should be no compression in the spring.





2. Remove the shock absorber lower nut and bolt using power tool.





3. Remove the four rear spring clip U-bolt nuts using power tool, then remove the rear spring pad.





4. Remove the rear spring shackle lower nut and bolt using power tool.
^ If removing the LH rear leaf spring, remove the storage box if equipped, to access the rear spring shackle lower nut and bolt.





5. Remove the rear leaf spring front nut and bolt using power tool.
6. Remove the rear leaf spring.
7. Remove the rear spring shackle from the rear leaf spring as necessary, using power tool.

INSPECTION AFTER REMOVAL
^ Check the rear leaf spring for any cracks or damage. Replace the rear leaf spring if necessary.
^ Check the rear spring shackle, rear spring clip U-bolts, bumper, and rear spring pad for excessive wear, cracks, straightness, and damage. Replace any components if necessary.
^ Check all bushings for deformation and cracks. Replace any bushings if necessary.

INSTALLATION
1. Apply soapsuds to all of the rubber bushings.
2. Install the rear spring shackle and rear leaf spring front nut and bolt. Finger-tighten the nuts.
3. Install the rear spring clip U-bolts and bumper on top of the rear leaf spring.
4. Install the rear spring pad, and new rear spring clip U-bolt nuts under the rear final drive axle case.

CAUTION: Use new rear spring clip U-bolt nuts for installation.

5. Tighten the rear spring clip U-bolt nuts diagonally and evenly using the following sequence:





a. Tighten the rear spring clip U-bolt nuts until the rear spring pad contacts the rear final drive axle case.
b. Tighten the rear spring clip U-bolt nuts diagonally and evenly to 50 Nm (5.1 kg-m, 37 ft. lbs.).
c. Tighten the rear spring clip U-bolt nuts to specification so the lengths of all the exposed rear spring clip U-bolt threads under the rear spring pad are equal in length as shown.
6. Install the shock absorber, and finger-tighten the nuts.





7. Remove the jack supporting the rear final drive assembly and bounce the rear of the vehicle to stabilize the suspension. (unladen)
8. Tighten the rear spring shackle nuts, rear leaf spring front nut and shock absorber nuts to specification.

CAUTION: When installing the components with rubber bushings, the final nut tightening must be carried out under unladen* conditions with the tires on level ground. * (Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.)