Disassembling And Assembling Front Air-Spring Strut

Information 

The spring plate -1-  can become detached from the suspension cylinder when depressurized.

This is not critical as the suspension cylinder will be attached again when filling the air spring.

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Spring plate

1. Unscrew nut -1-  from the air-spring strut using > T10001 - shock absorber set  . Counter using multiple-tooth screw on the piston rod at the same time.

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   Mounting for air spring on shock absorber

2. Remove press-on plate -1-  and O-ring -2-  .

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   Press-on plate and O-ring

3. Carefully lever out the spring plate -1-  using a small screwdriver.

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   Spring plate

4. Carefully lift suspension cylinder -1-  off the shock absorber -2-  .

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   Lifting off suspension cylinder

   Information 

   Do not damage/scratch the shock absorber pipe and piston rod.

5. Carefully remove the shock absorber cap -1-  from the shock absorber using a plastic hammer.

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   Removing shock absorber cap

   WARNING: High pressure can cause the piston rod to become detached from the shock absorber pipe. 

   • Risk of injury or bruising 

     → Do not reach into the piston rod area.

     → Dispose of shock absorber immediately.

6. Check projection -A-  of shock absorber guide unit -1-  with respect to the shock absorber pipe -2-  .
   • If projection -A-  < 1 mm, the shock absorber can be re-used.
   • If projection -A-  >= 1 mm, dispose of the shock absorber immediately and replace it. High pressure can cause the piston rod including shock absorber guide unit -1-  to become detached from the shock absorber pipe -2-  .

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   Projection of shock absorber guide unit

7. Replace O-rings -1-  and support ring -2-  . Coat O-rings -2-  with assembly grease "Synthesis Glep 1".

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   O-rings and support ring

   Information 

   Do not damage/scratch the shock absorber pipe and piston rod.

   Information 

   Do not fit the stop cap at an angle!

8. Carefully fit the shock absorber cap -1-  on the shock absorber using a plastic hammer.

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   Fitting shock absorber cap

9. Carefully fit suspension cylinder -1-  on the shock absorber -2-  .

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   Fitting suspension cylinder

10. Fit new O-ring -2-  between supporting mount and piston rod and fit press-on plate -1-  .

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    Press-on plate and O-ring

11. Align suspension cylinder with the shock absorber.

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    Aligning suspension cylinder with shock absorber

    1. 11.1 The air connection -1-  must be on the opposite side of the electric connections -2-  .
    2. 11.2 The bore -3-  on the supporting mount must be flush with the bore -4-  in the shock absorber fork.
12. Tighten nut -1-  using > T10001 - shock absorber set  > Tightening torque 55 Nm (41 ftlb.)  . Counter using multiple-tooth screw on the piston rod at the same time.

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    Mounting for air spring on shock absorber