ServiceManual

suspenslon,

Repairs 240/260,DL
GL. GT, G LT,
GLE,COUPE
and maintenance DTESEL 1975-
,

Contents
Opor.tions Pa96
Specificntions. 2

Special tools 2

Group 65
Replacing the reaction rod and,/or bushings A 1 - A 5 . . . . . . . . . .3
Replacing the track rod and/or bushings.. ........... .. . 8r 86... ...... 5
Replacing the trailing arm and/or bushings ...... cr cr 3 7

Noio: Torque speciticationsin this manual cover I975 8t

models. Refer to appropriatenew modeLliteraturetor sub-
sequentspecification changes.

Oid€rNo.TP 30125/2.

We rese.vethe right to make aherations

 Specifications
Nm

W h e e l n J t s. .. - 1 15::l:15 85a11
c - a ' ; o 1 ' o d ( b o d ya r a c h m e . r ) 85 65
( a r l ed t L ar, m " 4 t . 85 65
T l d , l , F o o l b o o ya r r a L l a e rr , 85 65
( a r l ea l l a L h r e l L ) 60
T a , l , r 9d - s ( b o d yd r r a c h m e l r ) 115 85
( a r l ea r ' a c h - e . r ) 115 85
F e a r5 0 , a g r u r u p p p r. 45:!1O 357.7
20 t5
S h o c l a b s o r b " r u p p e ra r d l o ^ . r 1 u t s 85 65

Special tools
999

2706 Diilt- n g a n d n s l a l l i n gl r a c kr o d b u s h i n g
2731 Drift- n g a n d n s l a l l i n gl r a c kr o d b u s h r n g
2733 Countorhold- rep n g t r a c kr o d b u s h i n g
5078 PrBs tool- rep n g l r a l l i n ga r m b u s h i n g
5079 Spacersleove- rep n g t r a l l i n ga m b u s h i n g
5046 Drift- rep ng reactionrod bushing
5047 Slesve- rep ng reactionrod bush ng
5048 Dritl- rep ng reactionrod bush ng

;ilr
2731,2733 5078,5079

5086,50a7 5047,5044

Group 65
Rear wheel suspension
 Replactngthe rcactrcnrcd and/ot bushings

Group65
A. Replacingthe reaction rod and/or bushings
Special tools: 5O86 Drift
5087 Sleeve

A1

o Jack up the real end

P acesuppoftsln Jroniofthereafjackattachments

A2

Remove reaction rod

A3

Replacing bushings
P r e s sb u s h i n g so u t ( o r i n ) w t h s p e c i a lt o o 5 0 8 6
c o u n l e r h o l d5 0 8 7 .
Note! Pos r on the bushings in the react'on rod so
t h e f l a t s d e sa r e p a r a l l e l t ot h e r o d

Gtoup 65
Rear wheel suspension 3
 -T-
Repladng the teact'on rcd dnd ot bushtngs

T h r e ed i l e r e n lr o d e . g t h s a v a l l a b l e
1 4O2 mm (1s 839") standard
2 3 9 7 m m ( 1 s 6 4 1 " ) 5 m m s h o r t e r ( 01 9 7 " )
')
3 3 9 2 m m 1 1 5 4 4 s " ) - 1 0 m m s h o n e .( O . 4 0
R o d s2 a n d 3 a r e u s e d1 0l e s s e nv b r a t i o no n t a k eo f f

A5

In$alling the reaction lod

Insiall the reaclion rod bu do not tighten Lower the

Not€: Do not lightenthe nuls u.til the car has b€en

o w e r e da n d s e t t l € sT h i sa v o d s s v a i n i n gt h e b u s hn g s
T i g h t e nn g t o r q u e r 8 5 N m ( 6 5 1 t l b s ) b o t h f r o n t a n d

Replacing stabili2el

R e m o v et w o r e a r r e t . i n i n gb o h s ( h e x l 9 m m ) o n e a c h

R e m o v et w o f r o n i r e t an i n g b o t s ( h e x 1 7 m m ) o n e a c h

o
T l g h t e n i n gt o r q u e s l:r o n l a f t a c h m e . t8 5 N m ( 6 5 i t L b s )
rear allachment45 Nm (3O fr lbs)

Group64
4 Reatwheelsuspensian

IL
 ReplacingtQck rod and/or bushings

B. Replacingtrack rod and/or bushings

Specialtools2706 Drift
2731 Drift
2 733

B1

Jack up the rear end

Placesupporrsin front of rearlack attachmenis

B2

Remove fack rod

B3

Replacing bushings
P r e s so u t r e a r a x e e n d o { b u s h n g w i r h s p e o a l t o o l
2 7 3 1 a n d s l e e v e2 7 3 3 u s e da s c o u n l e r h o l da n d t u r n e d
a s s h o w ni n i l l u s t r a l i o n
Pressin new bushlng w th the same lools but w th coun

Gtoup 64
Rear wheelsuspension 5
Replacingtrack rod and /or bushings

B4

Pressout body side of bushing with spec al tool 2705

a n d s e e v e 2 7 3 3 u s e d a s c o u n t e r h o l da n d t u r n e d . s
show. n uslralion
P r e s sI n n e w b u s h i n gw h h r h e s a m eb o L sb u t w i l h c o u n -

(lJsea soapysolutlon as a lubr cant to assrst n this oper

B5

Note:
T h e b o d y s L d eo l b u s h i n g h a s b e e n r e p l a @ d
type lt can be litted without the necessity to

4 0 m m : 1 5 7 4 " ( 19 / I 6 " )
o
3 4m m: 1 3 3 8 ' ( 1 5 / 1 6 " )

B6

Replace track lod

Feplaceirackrod but do not tighten.Lowerthe car
Note: Do not lighten the nuts until the car has been
loweredandsettles.Th s avods slraningthe bushi.gs

axleatlachment 60 Nm (45i1lbs)
bodyattachmenl 85 Nm (65 ft bs)

Gtoup 64
6 Rear wheel suspension
 ReplacingtBiling arm and/ot bushtngs

G. Replacingtrailing arm and/or bushings

Specialtaols5078
5079 Spacer sleeve
5087 Sleeve
sOBB Drift

C1

Jack up the iear end

Placesuppo.ts in lront ol rear lack a n a c h m e n l sJ a c k u p
r e a ra x e s l i g h t l y t oo f f o a d s p r n g and shock absorber

c2

Remove lowel shock absorber attachment

bolt (1) and spring bottom nut (2)

,o Lowertackandremove spring

C3

Removetrailing arm
Replacement
ot t.ailingarmo n l y ,s e eo p e r a to n C 1 1

'].
.rii

Group64
Rearwheelsuspenston 7
Replacingttailing atm and/or bushings

C4

Replacing bushings
Replacelsading bushing(fronr).
ljse speciatool 5O8aandcounterhold
5087

c5

L€adingbushing (tront)
lJ ear y iype bushlngs are ffacked or worn and need re-
placement bolh sldes must be replaced wilh the later

C6

Replacetrailing bushing (rear)

Note: The tools are stamped with dentfrcation marks
A , B ,c o r D
U s es p e ca l l o o 5 0 7 8 a n d s p a c e 5
r 079
P l a c es p a c e 5
r 0 7 9 ( 1 ) r o u n db u s h i n g .
I n s e r t h r e a d e db o l t ( 2 ) t h r o u g hb u s h l n gf r o m i n s i d e
l r s r a l la d " p L . ' ' c ( 3 ) a n d r u r ( 4 ) o 1 r l . eo u r s , d e
'C (3)
Cenve adapter belore t ghtening t secur€lywilh
boh (2)

c7

Removingbushing
P l a c e s l e e v e ' 8 " ( 1 )a g a n s t b . a c k e t .
P l a c ea d a p t e r" A ( 2 ) a n d n u t ( 3 ) o n t h . e a d e db o l t
C e n l r ea d a p t e r" A " ( 2 ) a s a i n s ts L € e v e B " ( 1 ) b e f o r e

W i l h d r a wb u s h i n gu s i n ga n i m p a d w r e n c h

Gtoup 65
8 Rear wheelsuspension
 ReplacingtQiling arm and/or bushings

CA

Installing bushing
P l a c ea d a p t e r" D " ( 1 ) a g a i n s tf l a t e n d
centre adapteragainstbushing hole.
I n s e r t h r e a d e db o k ( 3 ) t h r o u s hb u s h i n s(2)
'D'
F i l n u t o n b o l t a n d t g h t e nu p a d a p t e r (1)withbolt.

o
C9

Install bushing in blacket from insid€

o l \ l o t e : T h e b u s h i n gh a s r e c e s s e(sl ) w h i c h s h o u L db e r n
a honzontal ({or€ and aft) Dositionwhen installed- a so
note that the recessesare ollset towards the top; larger
rubber area (2) should be at bottom lbelow centre ne)

cl0

A i g n a d a p t e .' A ' ( 2 ) a n d t i g h t e nnut 11)1opull bushins

R e m o v el o o l a n d s p a c e r .

cl l

Installing tlailing arm

F t t r a i l i n ga r m , t o l r o n l a n d t h e n t o r e a ra t t a c h m e ntto ,
gether w th stabl zer attachmenl
Noie: Do noi tghten the nuts unti the car has been
r o w e r e da n d s e t r l e sT. h i sa v o i d ss t r a i n i n gt h e b u s h i n g s .

Group 65
Rearwheelsuspension 9
Feplacing trailing am and/o. bushings

cl2
Placespringon trailingarmandinstallbottorn
nut (2).
n a s e i a c ka n d g u i d ei h e s p r i n gi n t o p o s i t i o n .
Reconnectshock absorber boitom attachment
stabili?erattachm6nticenain mode sl.
Nois: Spacersleeveshould lie on inside. Do not tighten
before lhe car has been lowered and bounced a tew

Shock absorber upper and lower nuts 8 5 N m ( 6 5 f t l b s )

S p r i n gn u t 45 Nm (3O ft lbs)
20 Nm (15 ft lbs)
Trailing arrn body attachment I 1 5 N m ( 8 5f t l b s )
axteattachment 1 1 5 N m ( 8 5 1 tl b s )

cl3

Install wheel and low€r car

Tighlenins torque {wheel nuts):
1I5 Nm (85 ft lbs)

Group65
10 Rearwheelsuspension