Disassembling Front Spring Strut

→ Wear protective goggles.

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.

Fig 1: Checking Air Bellows

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The next sections describe the spring struts with and without PASM.

1. On vehicles with PASM, push both grommets on the connector cable to one side.

   Information 

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

2. Vehicles with PASM: Loosen the lock in the connector and unpin both cables from the connector. Press-out tool set Nr.155 Pos.1  can be used to pull off the connector.
3. Vehicles with PASM: Remove the grommets by opening the grommets slightly using a commercially available Seeger circlip ring pliers. This makes it easier to pull the pins through the grommets. → Opening grommet slightly using Seeger circlip ring pliers 
   Fig 2: Opening Grommet Slightly Using Seeger Circlip Ring Pliers

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   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 
   Fig 3: Identifying Marking On Air-Spring Strut Before Disassembly

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5. Use a socket-wrench insert 3186  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) 
   Fig 4: Removing/Fitting Hose (Shop-Made)

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   1. 6.1. Slide the hose (shop-made) onto the hexagon on the piston rod. → Hose (shop-made) 
      Fig 5: Sliding Hose (Shop-Made)

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7. Carefully clamp the air-spring strut at the lower mounting point (use aluminum protective jaws -A-  ).
   Fig 6: Identifying Lower Mounting Point For Air-Spring Strut

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8. Only if replacing the shock absorber mounting:  Loosen the four fastening screws on the cover evenly and remove the cover.
9. Loosen and remove the clamp. -arrow- 
   Fig 7: Locating Clamp On Boot/Bellows

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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.
    Fig 8: Pulling Off Boot

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11. Spring tensioner Nr.121 Pos.1  with tensioning plate Nr.121-1 Pos.2  at the bottom and tensioning plate Nr.121-1 Pos.5  at the top must be used.
    1. 11.1. Place the bottom tensioning plate on the shock absorber prongs.
    2. 11.2. Protect the top tensioning plate on the rolling piston on the air spring with a lint-free cloth, for example, and insert it. -inset- 
       Fig 9: Inserting Spring Tensioner

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    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 tensioner apart until the rolling piston slips off the safety catch on the shock absorber.
       Fig 10: Pressing Air Spring With Rolling Piston Off Shock-Absorber Safety Catch

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       Fig 11: Pressing Air Spring With Rolling Piston Off Shock-Absorber Safety Catch - Safety Catch Visible

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    4. 11.4. Remove the air spring -2-  , slide the bellows down and secure it (second mechanic required!). Grasp rolling piston -1-  and remove it upward from the shock absorber by turning slightly to the left/right.
       1. Rolling piston
       2. Air spring
          Fig 12: Removing Air-Spring Strut Rolling Piston

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