Usage:
1. Put tooling (A) in position under the truck frame as shown.
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To prevent personal injury, do not, under any condition, remove valves or plugs from the cylinder unless the rod is fully retracted and all nitrogen pressure is released. Do not stand under the vehicle when it is lifted or lowered. The clearance above your head can decrease suddenly. The vehicle must be empty and on level ground to release the nitrogen pressure. |
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2. Remove bolts (2) and the lockwashers that fasten guard assemblies (1) to the suspension cylinders.
3. Install tooling (B) on the nitrogen valve. Turn the chuck "CLOCKWISE" to loosen the nitrogen valve. Use tooling (A) to lower the vehicle weight on the cylinders until the rods are completely retracted.
NOTE: When the cylinder is completely retracted, the distance between the centers of the pins that hold the cylinder (dimension X) is 73.4 cm (28.9 in).
4. Install a hoist on the suspension cylinder as shown. Remove bolts (3), the nut, lockwasher and two washers (4).
5. Use a hammer and punch to remove pin (5) that fastens the top of the suspension cylinder to the frame.
6. Lower the cylinder to a horizontal position. Support the cylinder at the rod end, and reattach the hoist as shown. Remove bolt (6), the nut, lockwasher and two washers.
7. Use a hammer and punch to remove pin (7) that fastens the suspension cylinder to the differential housing. Remove the rear suspension cylinder. The weight of the cylinder is 152 kg (335 lb).
Install Rear Suspension Cylinders
1. Fasten a hoist to the suspension cylinder as shown, and put the cylinder in position in the differential housing.
2. Lubricate pin (1) with 4C5593 Anti-Seize Compound. Install pin (1) that fastens the cylinder to the differential housing. Install the two washers, nut, bolt and lockwasher that hold the pin in the differential.
3. Fasten a hoist to the top of the rear suspension cylinder as shown, and put the cylinder in position in the frame. Use tooling (A) to make adjustments for vertical alignment.
4. Lubricate pin (2) with 4C5593 Anti-Seize Compound. Install pin (2) that fastens the cylinder to the frame. Install the two washers, nut, bolt and lockwasher that hold the pin in the frame.
NOTE: After the installation of the cylinders, charge the cylinder with oil and nitrogen. See Testing And Adjusting, Form SENR5647, for the correct procedure.
5. Put guard assembly (3) in position, and install the bolts and lockwashers that fasten the guard to the cylinder.
6. Remove tooling (A).
Disassemble Rear Suspension Cylinders
Start By:
a. remove rear suspension cylinders
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To prevent possible personal injury, the suspension cylinder must be completely discharged before it is disassembled. |
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1. Remove the oil from suspension cylinder. Remove the four bolts and cover (3).
2. Put the rear suspension cylinder in position on tool (A) as shown.
3. Remove valve assemblies (1) and (2) from rod assembly (10). Remove valve assembly (4) from cylinder assembly (9).
4. Remove bolts (11) and the two cover assemblies. Remove the O-ring seals from the cover assemblies.
5. Put an alignment mark on head (13) and cylinder assembly (9) so they will be in correct alignment at assembly.
6. Use tool (A) to separate cylinder assembly (9) from rod assembly (10).
7. Remove wear ring (15), plate (7) and check ball (8) from rod assembly (10).
8. Remove rod assembly (10) from tool (A). Remove head (13) from the rod assembly.
9. Remove wiper (12) and ring seals (5) and (6) from the head. Remove the O-ring seal and back-up ring (14) from the head.
Assemble Rear Suspension Cylinders
1. Put clean SAE 10W oil on the ring seals and the wiper. Install ring seals (5) and (6) into head (13). Ring seal (5) (the thin, yellow ring seal) goes next to the outside (atmosphere side) of cylinder. Ring seal (6) (the thick, black ring seal) goes next to the inside (pressure side) of cylinder. Install wiper (12) in the head. Make sure the wiper is installed with the lip toward the outside.
2. Put clean SAE 10W oil on O-ring seal and back-up ring (14) in the groove on the outside of head (13). The back-up ring is installed toward the inside of groove (next to the larger outside diameter of the head).
3. Install head (13) on rod assembly (10). Install the rod assembly on tool (A).
4. Install check ball (8), plate (7) and wear ring (15) on rod assembly (10).
5. Make sure the rod assembly and cylinder assembly are in alignment, and push cylinder assembly (9) onto rod assembly (10).
6. Install the O-ring seals on the two cover assemblies. Install the two cover assemblies and bolts (11).
7. Install valve assemblies (1) and (2) in rod assembly (10). Install valve assembly (4) in cylinder assembly (9). Tighten the three valve assemblies to a torque of 50 ± 10 N·m (37 ± 7 lb ft).
8. Install cover (3) and the four bolts.
End By:
a. install rear suspension cylinder
