We replace the springs if damage or loss of elasticity of the sheets has occurred
Removing the front spring
We prepare the car and disconnect the front light connector
Using 19 wrenches, unscrew the nuts of the front buffer mounting bolts and remove it
We brake the rear bogie of the car with the parking brake
Raise the front of the car and place a stand under the front of the frame
We raise the front drive axle from the side of the spring to be removed until it is completely unloaded
We unscrew the nuts of the stepladders, remove the spring washers and stepladders, the spring pads and the buffer support
Using 22 wrenches, unscrew the nut of the coupling bolt of the rear spring bracket, remove the spring washer and bushing
We unscrew the nuts of the front bracket coupling bolts, remove the spring washers and knock out the bolts using a bronze extension
Unscrew the oil can from the finger and knock out the finger
Lowering the bridge
Remove the top sheets as an assembly, the bottom sheets (perform with an assistant)
Installing the front spring
Install the lower springs, aligning the centering recesses, install the upper sheets of the spring assembly
Insert the spring eyelet into the front bracket and, aligning the holes of the eyelet and the bracket, insert the eyelet pin (perform with an assistant)
We insert the coupling bolts, put on the spring washers and tighten the M14 nuts with a torque of 78-88 Nm (8-9 kgcm)
Raise the bridge to the stop of the main sheet lining in the rear spring bracket, install the sleeve between the lugs of the rear bracket and, aligning the holes of the sleeve and the bracket
We insert the bolt, put on the spring washer and tighten the nut with a torque of 19.6-39 Nm (2-4 kgcm) (perform with an assistant)
Install the spring pad and buffer support and stepladder pad for the right spring, tighten the M20 nuts with a torque of 245-312 Nm (25-32 kgcm)
We screw the oiler into the spring lug pin and lubricate the pin with Litol-24 grease
Raise the front of the car, remove the stand from under the frame. Lowering the car on wheels
Installing the front buffer and connecting the front light connector
Removing the rear spring
We unscrew the locknuts and M24 nuts of the spring ladders using a 36 mm socket
Installing wheel chocks under the front wheels
We jack up the car balancer bracket until the spring is completely unloaded, put the stand under the frame and lower the frame onto the stand
Remove the upper spring cover and stepladders
We unpin the pins of the spring supports and knock them out
Note. If it is not possible, knock out the fingers, unscrew the nuts of the coupling bolts of the spring clamps and remove the spring
Remove the upper individual sheets of springs and the lower sheets as an assembly (perform with an assistant)
Installing the rear spring
Install the bottom sheets of the spring assembly (or separately) and fasten with clamps, install the top sheets and the spring pad (perform with an assistant)
We install the spring ladders and tighten the M24 nuts and locknuts with a torque of 538.8-607.6 Nm (56-62 kgf.m)
Installing and cottering the pins of the spring supports
Raise the rear of the car, remove the stand from under the frame, lower the car
Remove the wheel chocks from under the front wheels
Repair of the front spring
Disassembly of the front spring. Fix the spring in a vise
Having unscrewed the nuts 5 bolts 3 fastening the ear of the front spring, using two keys for 19, remove the pad 4 ears
Using a 24 wrench, unscrew the nut 6 of the bolt 9, remove the lug 8 of the spring
Using 14 wrenches, unscrew nuts 10, remove bolt 1 and spacers 11 from clamps 2 and 12 of the spring
Smoothly unload the spring sheets in a vice and separate them from each other
We clean the spring from dirt and check its condition
Conditions for defect detection and repair of front spring parts
Not allowed:
- - cracks and breaks on spring sheets and collars;
- - cracks, breaks and chipping of the sleeve ends;
- - the inner diameter of the bushing of the spring ear is more than 40.75 mm;
- - the thickness of the overlay of the root sheet is less than 4.5 mm:
- - weakening of the fit of the rivets of the spring collars, eliminated by replacing the rivets. The rivets fastening the front spring clamps must be riveted flush with the surface of the spring sheets, it is allowed to strip the rivet;
- - deformation of the spring sheets and discrepancy with the dimensions indicated in the table
Front spring assembly
Assemble the sheets, ensuring that the bulges on the convex side of the sheets coincide with the notch on the concave side of the sheet
Before assembling, we lubricate the spring leaves with USSA graphite grease. The displacement of the spring sheets in the transverse direction with respect to the first sheet is allowed no more than 2 mm in the embedding area of 190 mm
Install spacers 11, (see figure) tie bolts 1 into clamps 2 and 12, tighten nuts 10 with a torque of 23.5-35.3 Nm (2.4-3.6 kgcm)
After assembling the spring, rivet the threaded ends of the tie bolts
We install eyelet 8 on the extrusion of the main leaf of the spring, screw in bolt 9 and tighten with nut 6 with a torque of 216-275 Nm (22-28 kgcm)
We install the pad 4 of the ears in the slot in the second, third and fourth sheets, fasten with tie bolts 3 and tighten with nuts 5 with a torque of 98.1-137 Nm (10-14 kgcm)
In the middle part we install a transport clamp (we remove the clamp before installing it on the car)
Technical condition. The gaps in the middle part between the leaves of the spring, pulled together until the sheets touch, should not exceed 1.2 mm, while the gaps along the length of the section less than 75 mm should not be more than 0.3 mm
Repair of the rear spring
Fix the spring in a vise
We unscrew the nuts 3 (rice) of the coupling bolts 5 of the clamps 1 and 6 of the rear spring, remove the bolts 5 and spacers 4
Smoothly unload the spring sheets in a vice and separate from each other
We clean the spring from dirt and check the technical condition
Not allowed:
- - cracks and breaks of leaf springs;
- - wear of spring leaf extensions;
- - weakening of the fit of the rivets fastening the spring clamps, eliminated by replacing the rivets;
- - the thickness of the ends of the first leaf of the spring is less than 9 mm
If the ends of the first leaf of the spring are worn more than 9 mm, it is allowed to replace the first and third leafs of the spring;
- - deformation of the spring sheets and discrepancy with the dimensions indicated in the table
Rear spring assembly
We assemble the spring sheets, ensuring that the notches on the convex side of the sheets coincide with the notch on the concave side of the sheet
Before assembly, we lubricate the spring leaves with USSA graphite grease. The displacement of the spring sheets in the transverse direction with respect to the first sheet is allowed no more than 2 mm in the embedding area of 150 mm
Install the clamps 1 and 6 (see. Fig.) coupling bolts 5, spacers 4 and tighten the nuts 3 with a torque of 23.5-35.3 Nm (2.4-3.6 kgcm)
After assembling the spring, the threaded ends of the tie bolts must be riveted