Disassembling Front Spring Strut

Information 

The pictures shown in this document may differ from the original.

Information 

The air-spring strut is empty if the rubber bellows can be pressed in slightly.

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Checking air bellows (shown as an example)

1. Push both grommets on the connector cable aside.

   Information 

   Note the cable routing in the connector so that the cables can be inserted at the same position again during re-installation.

2. Loosen the locking mechanism in the connector and unpin both cables from the connector. > Nr.155 Pos.1 - Press-out tool set can be used to pull off the connector.
3. Remove the grommets by opening the grommets slightly using commercially available Seeger circlip pliers. This makes it easier to pull the pins through the grommets. > Opening grommet slightly using Seeger circlip pliers 

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   Opening grommet slightly using Seeger circlip pliers

   Information 

   If the shock absorber needs to be replaced, the shock absorber mounting can remain fitted.

4. To make assembly easier, mark the spring strut using chalk for example. Make the marking on the cover, air spring and shock absorber. > Marking air-spring strut before disassembly 

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   Marking air-spring strut before disassembly

5. Use a > 3186 - socket-wrench insert to loosen the nut on the piston rod.
6. If you intend to use the shock absorber again, slide a piece of hose (shop-made) over the cable. This prevents damage to the PASM cable during removal. > Removing/fitting hose (shop-made) 

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   Removing/fitting hose (shop-made)

   1. 6.1 Slide the hose (shop-made) onto the hexagon on the piston rod. > Hose (shop-made) 

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   Hose (shop-made)

7. Carefully clamp the air-spring strut at the lower mounting point (use aluminum protective jaws -A-  ).

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   Lower mounting point for air-spring strut (shown as an example)

8. Only if replacing the shock absorber mounting:  Loosen the four fastening screws on the cover uniformly and remove the cover.
9. Loosen and remove the clamp. -arrow- 

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   Clamp on boot/bellows (shown as an example)

10. Pull off the boot: Take care not to damage the outer guide on the air spring. Insert a screwdriver carefully between the air spring housing and boot/bellows if necessary. Pull the boot down as far as possible. This makes fitting easier for the next steps.

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    Pulling off boot

11. > Nr.121 Pos.1 - Spring compressor with > Nr.121-1 Pos.2 - tensioning plate at the bottom and > Nr.121-1 Pos.5 - tensioning plate at the top must be used.
    1. 11.1 Place the lower tensioning plate on the shock absorber prongs.
    2. 11.2 Protect the upper tensioning plate on the rolling piston on the air spring with a lint-free cloth, for example, and insert it. -inset- 

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       Inserting spring compressor

    3. 11.3 A second mechanic is required: Holding the air spring at the top cover prevents the rolling piston from becoming inverted. Carefully screw the spring compressor apart until the rolling piston slips off the safety catch on the shock absorber.

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       Pressing air spring with rolling piston off the shock-absorber safety catch

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       Pressing air spring with rolling piston off the shock-absorber safety catch; safety catch visible

    4. 11.4 Remove the air spring -2-  , slide the bellows down and secure it (second mechanic required!). Grasp the rolling piston -1-  and remove it upward from the shock absorber by turning it slightly to the left/right.

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Rolling piston for air-spring strut