Dongfeng DFA1101GZ5AD6J-907. Manual - part 50

Suspension

SP-7

Check

1.Measure the outer diameter of the spring pin and lifting

eye pin

2.Inner diameter of the spring bush and lifting eye bush

3.Clearance between spring pin, lifting pin and bush:

                    Spring pin and bush:

                        Repair standard                  0~0.302mm

                        Wear limit                               1.0mm

                    Lifting pin and bush

                         Repair standard                 0.08~0.252mm

                         Wear limit                               1.0mm

4.Check the spring leaf for any cracks or wear condition;

5.Measure the wear condition of the spring leaf, if the wear value is over 15% of the standard thickness, please

replace the spring leaf.

             Standard thickness of the front leaf spring is 9mm, wear limit is 7.65mm;

             Standard thickness of the rear leaf spring is 10mm,  wear limit is 8.5mm;

            Standard thickness of the sub-leaf spring is 8mm,  wear limit is 6.8mm.
Note: If one of the leaf spring is broken, you'd better replace the whole leaf spring assembly. Only replace the

broken one may cause others damaged very soon.

Wear limit

Front suspension

17.5mm

Rear suspension

29.5mm

Wear limit

Front suspension

19mm

Rear suspension

31mm

Suspension

SP-8

Assembly

Assembly of the sub-assembly

Assemble the leaf spring by center bolt accord the sequence of the spring leaf;

Note: Smear some black lead lime grease on the relative friction surface of the spring leaf.

Clamp the leaf spring by a C-shape clip, and tighten the center bolt and nut;

Take down the C-shape clip from the leaf spring;

After tightening the center bolt, rivet the connecting thread of the bolt and nut to lock;

Install sleeve and bolt on the clamp and tighten the nut;

After tightening the clamp bolt, rivet the connecting thread of the bolt and nut to lock.

Assembly of the front suspension

1.Smear a layer of grease on the spring bush and lifting eye bush before assembling;

2.Install the lifting eye to its bracket and insert the pin, then

tighten the locking nut;

3.Install the front leaf spring assembly, cover board, limit

block to the front axle and lift the front axle with a jack;

4.Align the bracket hole of the fixed end to the spring eye,

then insert the spring pin;

Note: Make the spring pin slot align to the set bolt.

5.Install the set bolt;

6.Install the rear end of the spring, align the lifting eye and

spring eye, then insert the lifting eye pin;

Suspension

SP-9

7.Assemble the U-bolt;

8.Lift the front axle by the jack, and then take down the

support of the frame then own the jack;

9.Tighten the U-bolts and nuts;

Tightening torque               200~250N·m

10.Install the damper to the bracket, then the plain washer,

spring washer and nut, then tighten them;

Tightening torque               140~170N·m

11.Add grease to the leaf spring pin and lifting eye pin as

required;

Assembly of the rear suspension

1.Smear a layer of grease on the spring bush and lifting eye

bush, and install the lifting eye to its bracket, then insert
lifting eye pin, then the cotter pin and tighten its lock
nut;

Tightening torque               90~110N·m
Note:When inserting the cotter pin, make the inclined

face contact to the face of lifting eye pin.

2.Set the rear spring to the rear axle, and lift the rear axle

by the jack;

3.Align the fixed end bracket hole to the spring eye, insert

the spring pin, then the cotter pin and tighten the nut;

Tightening torque               32~42N·m
Note:When inserting the cotter pin, make the inclined

face contact to the face of lifting eye pin.

Suspension

SP-10

4.Install the rear end of the spring, align the lifting eye hole

to t spring eye, insert the spring pin, then install the lock
nut;

Tightening torque               32~42N·m
Note:When inserting the cotter pin, make the inclined

face contact to the face of lifting eye pin.

5.Install the underplate, sub-spring and cover board to the

upper of the rear spring, then install the U-bolt;

6.Lift the rear end of the vehicle by a jack, take down the

support under the frame then down the jack;

7.Install the U-bolt underplate and damper lower bracket;

8.Install the U-bolts and nuts and tighten;

Tightening torque:  300~350N·m

9.Add grease to the leaf spring pin and lifting eye pin;

10.Install the rear damper by referring to the assembling method of the front damper.