OVERHAULING OF LEAF SPRING ASSEMBLY

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AIM:

OVERHAULING OF LEAF SPRING ASSEMBLY 

TOOLS REQUIRED

1. BOX SPANNER SET
2. RING SPANNER SET
3. DOUBLE END OPEN SPANNER SET
4. HYDRAULIC JACK
5. LONG SCREW DRIVER (-)
6. TORQUE WRENCH
7. MALLET

MATERIALS REQUIRED

1. KEROSENE OIL
2. COTTON WASTE
3. EMERY PAPER
4. GREASE
5. RUBBER BRUSHES
6. LUBRICANT
7. GRAPHITED OIL

PROCEDURE

1. Chock the wheels.

2. Jack up the frame and lift the vehicle just enough for the wheels to clear the ground.

3. Place a horse to support the frame and take out the jack.

4. Disconnect the shock absorber, if provided.

5. Remove the clamp bolt from the shackle.

6. Remove the spring fixing bolts and nuts all pads.

7. Put the jack to support the axles. And Remove the grease nipples.

8. Remove the shackle pins with the help of special tools.

9. Remove the leaf spring assembly from the axle.

10. Put up the spring in a press, measure the pre - camber.

11. Apply full load and observe the camber. This will be the negative camber.

12. Set the spring eyes at a higher plane on the press.

13. Measure the distance between the spring centre and the base plate.

14. Apply deflection load as per specification.

15. Again measure the distance between the spring centre and the base plate.

16. Calculate the deflection of the spring. ( difference between two readings.)

17. If the deflection is not as per recommendation, hold the spring in a vice firmly and remove the nuts and bolts from the spring, clips and release the vice slowly.

18. Then separate the spring leaves.

19. Inspect the spring leaves for crack or damage.

20. Clean the spring leaves with a thin oil; apply graphited oil and observe the crack.

21. Replace the faulty leaf.

22. Coat each leaf with graphite oil or grease, containing 10% graphite.

23. Assemble the springs.

24. Press new bushes into the front spring eyes and fix in position.

25. Straighten the clips, if distorted.

26. Check the parallelism of the spring. Reject if the first leaf not parallel.

27. Finally fit the clips and tighten up the nuts dead tight.

FITMENT

1. Place the spring perfectly on the spring saddle provided on the axles.

2. Drive in the shackle pin after aligning the spring eye into the hanger bracket using a soft mallet.

💠 Do not use fingers for aligning the spring leaf holes.

3. Fix and tighten the clamp bolts of the spring shackle and spring brackets.

4. Fix all pads and tighten slightly the U clamp bolt/ clamp bolt and nut using the special tool.

5. Release the jack.

6. Finally tighten the nuts of the clamp bolt/U bolt nuts to the recommended torque.

7. Fit back the grease nipple and lubricate.

ADDITIONAL HINTS FOR REAR SPRING OVERHAULING.

▪️ Carry out all the steps for removing the front spring. The following additional steps are also required.

▪️ Remove the axle U bolt with the help of special tools.

▪️ At the time of assembling, use special levers for tightening the U bolt clamps.

RESULT :

 OVERHAULING OF LEAF SPRING ASSEMBLY DONE SUCCESSFULLY.

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