Front
Removal and installation of front shock absorberNote: The front shock absorbers also serve as a deflection stop for the front wheels. For this reason, detach shock absor her suspension only when the vehicle is resting on its wheels or when the lower control arm is supported.
A safety stop is provided between the upper control arm and the front axle carrier.
In the event of repairs and independent of make, the shock absorbers can be individually exchanged. Only shock absorber versions identified by color code, e.g. 1 lengthwise line red or 1 crosswise line red, must be in agreement.
Removal
1. Loosen hex. nuts (11a) at upper shock absorber suspension, remove cup (11b) and rubber ring (11c).
Wrench For Fastening Shock Absorber:
Attention! When removing gas pressure shock absorbers with separating piston or with piston rod mounted at top, with vehicle jacked up and axle halt relieved, make sure that the piston rod is not turning along when loosening upper suspension. Since in this condition the resilience stop in shock absorber rests against operating piston, the attachment of operating piston to piston rod may become loose. The gas pressure would then suddenly extend piston rod and the oil in shock absorber would flow out (risk of an accident).
11 Upper shock absorber suspension
40 Coolant expansion tank
Note: When removing the righthand front shock absorber on model 107, unscrew coolant expansion tank first.
2. Loosen lower shock absorber suspension. For this purpose, unscrew hex. nuts (arrow) on lower control arm,
3. Press-in shock absorber piston rod and remove shock absorber.
4. Remove suspension parts:
Bilstein shock absorber with separating piston starting November 1980 F & S
F & S shock absorber without separating piston Boge shock absorber
a) On shock absorber with separating piston: Pull off protective tube (11f), remove lower rubber ring (11d), lower disk (11e) and supplementary rubber spring (buffer stop) (11h).
b) On shock absorbers without separating piston: Remove lower rubber ring.
Note: The additional rubber rings (buffer stops, 11h) are inside the protective tube on piston rod.
On shock absorbers with separating piston they are located between the housing and the upper suspension, on shock absorbers without separating piston between housing and lower suspension.
Installation
5. Check suspension components, clean lower control arm on supporting surface of fastening bracket of lower shock absorber suspension.
Note: The fastening bracket of the lower shock absorber suspension must be tightly seated in rubber mount, which should not be turnable within the suspension eye.
Bilstein shock absorber with separating piston starting November 1980 F & S
6. Slip suspension members on piston rod (on shock absorbers with separating piston: 11h, 11e, 11d and 11f; on shock absorbers without separating piston 11d).
Attention! On shock absorbers with separating piston do not mix up lower disk (11e) and upper disk (11b), since otherwise the disk may slip over locking ring (11g) while driving.
F & S Boge shock absorber without separating piston
Starting 1975 an additional lower disk is inserted on upper version on shock absorbers without separating piston, while the version installed up to now requires no lower disk.
7. Insert shock absorber into lower control arm and introduce shock absorber into front end.
8. Mount upper and lower suspension.
