Front Damper/Spring Replacement

Special Tools Required
Strut spring compressor,
 (Branick MST-580A or Model 7200,

or equivalent, commercially available)

Removal

1.	Raise the front of the vehicle, and make sure it is securly supported. Remove the front wheels.

2.	Disconnect the stabilizer link and damper bracket.

3.	Release the clip of the wheel sensor harness (A) from the damper. Do not disconnect the wheel sensor connector.

4.	Loosen the flange nuts (B) while holding the damper pinch bolts (C), and remove the bolts and brake hose bracket (D). NOTE: During installation, align the pin (E) of the brake hose bracket to the positioning hole (F) on the damper.

5.	Hold the damper shaft (A) with a hex wrench (B), and loosen the 12 mm nut.

6.	Remove the 12 mm nut and wave washer (A) from the top of the damper.

7.	Lower the knuckle, and remove the damper (B) and damper mounting cushion (C).

8.	Remove the damper mounting base (D) from the body.

9.

Install the damper in the reverse order of removal, and note these items: First install all the suspension components, and lightly tighten the bolts and nuts, then place a floor jack under the lower arm, and raise the suspension to load it with the vehicle's weight before fully tightening the bolts and nuts to the specified torque vales. Before installing the wheel, clean the mating surface of the brake disc and inside of the wheel. Check the wheel alignment, and adjust it if necessary.

Disassembly/Inspection

1.	Compress the damper spring with the commercially available strut compressor (A) according to the manufacture's instructions, then remove the nut (B) while holding the damper shaft (C) with a hex wrench (D). Do not compress the spring more than necessary to remove the nut.

2.	Release the pressure from the strut spring compressor, then disassemble the damper as shown in the Exploded View. NOTE: To remove the bearing (A) from the spring seat, attach a suitable attachment to the resin part (B) of the bearing and push it slowly.

3.	Install the 12 mm nut on the damper shaft end, and set the socket wrench.

4.	Compress the damper assembly by hand, and check for smooth operation through a full stroke, both compression and extension. The damper should extend smoothly and constantly when compression is released. If it does not, the gas is leaking and the damper should be replaced.

5.	Check for oil leaks, abnormal noises, and binding during these tests.

Reassembly

1.	Install the damper bearing (A) on the spring seat (B). Do not tap on the damper bearing to assemble it with the spring seat. Push into the spring seat slowly as shown.

2.

Assemble the spring mounting seat (A), bump stop rubber (B) and the damper bearing (C) with the upper spring seat (D). NOTE: Set the top (E) of the bump stop rubber and the lug (F) of the mounting seat in the upper spring seat securely. Apply silicon grease to the indicator part inside the bump stop rubber.

3.	Align the upper end (G) of the spring (H) and the seat stopper (I), and install the spring on the upper spring seat.

4.	Install the upper spring seat mounted with the spring on a commercially available strut spring compressor (A), and compress the spring lightly.

5.	Insert the damper unit (B) from the underside of the compressed spring.

6.	Align the bottom of the spring (A) and the stepped part (B) of the lower spring seat.

7.	Holding the underside of the damper with your hand, compress the spring to the position (A) where the damper shaft comes in contact with the damper bearing. Do not compress the spring excessively.

8.	Install the 12 mm nut on the damper shaft. Hold the damper shaft (B) with a hex wrench (C), and tighten the 12 mm nut to the specified torque.

9.	Remove the damper assembly from spring compressor.