JAC HFC4DA1-2C engine. Instruction — part 38

FAX

FAX

FAX

FAX Front

Front

Front

Front Suspension

Suspension

Suspension

Suspension

-117

117

117

117 -

Removal

Removal

Removal

Removal and

and

and

and Installation

Installation

Installation

Installation of

of

of

of Subframe

Subframe

Subframe

Subframe (Continued)

(Continued)

(Continued)

(Continued)

Note:

Note:

Note:

Note:

Mounting bolts on the top of the brake caliper
can not be loosened completely until the
complete removal of the brake caliper has been
done.

7.

Remove the brake caliper.

Hang the brake caliper up to avoid brake hose
damage.

8.

Remove cotter pin and castle nuts for fixing the
steering tie rod onto the steering knuckle. (Discard
the removed cotter pin)

Note:

Note:

Note:

Note:

In the separation of the steering tie rod end from

the steering knuckle, sealing protection should be
carried out for the ball joint at any time.

9.

Remove the ball joint of the steering tie rod from
the steering knuckle.

10. Remove the front anti-roll bar link from the lower

swing arm.

11. Support the lower swing arm assembly.

FAX

FAX

FAX

FAX Front

Front

Front

Front Suspension

Suspension

Suspension

Suspension

---- 118

118

118

118 ----

Removal

Removal

Removal

Removal and

and

and

and Installation

Installation

Installation

Installation of

of

of

of Subframe

Subframe

Subframe

Subframe (Continued)

(Continued)

(Continued)

(Continued)

12. Remove mounting nuts of the shock absorber from

the cab.

�

Remove the plastic cap.

�

Remove nuts and washers for fixing the piston
rod with an L-shaped wrench.

�

Remove the disc washer.

Caution:

Caution:

Caution:

Caution:

Pay attention not to damage the lower swing
arm ball joint for connecting the shock absorber
and the front suspension.

13. Lay down the lower swing arm assembly and

remove the helical spring.

14. Support the cross rail.

15. Remove the cross rail assembly.

�

① Remove the two bracket nuts and bolts
from the front suspension.

�

② Remove the four cross rail bolts.

Installation
1.

Reinstall the cross rail assembly.

�

Lift the cross rail, install the two bracket nuts
and bolts of the subframe relaxedly.

�

Reinstall the four cross rail bolts.

�

Tighten bracket nuts and bolts of the front
suspension.

1

2

2

1

FAX

FAX

FAX

FAX Front

Front

Front

Front Suspension

Suspension

Suspension

Suspension

-119

119

119

119 -

Removal

Removal

Removal

Removal and

and

and

and Installation

Installation

Installation

Installation of

of

of

of Subframe

Subframe

Subframe

Subframe (Continued)

(Continued)

(Continued)

(Continued)

2.

Reinstall the helical spring.

Ensure following operations:

�

Correctly prevent the shock insulator from
opening.

�

Correctly

combine

the

shock

insulator

connector.

�

Place the lower end of the helical spring into
the deepest place of the lower swing arm
groove.

3.

Remove the shock absorber.

4.

Lift the lower swing arm assembly and install the
shock absorber.

5.

Fix the shock absorber from the cab.

�

Reinstall the disc washer.

�

Support nuts and washers of the piston rod
with the L-shaped wrench.

�

Install nut caps.

6.

Reinstall the wheel hub assembly.

7.

Reconnect the brake hose onto the shock absorber.

8.

Install each end of the steering tie rod onto the
steering knuckle.
Fix castle nuts with a new cotter pin.

Caution:

Caution:

Caution:

Caution:

The convex side of the washer at the joint of the

front anti-roll bar should face the rubber shaft
sleeve.

9.

At the mounting position of the front anti-roll bar
link, connect it with the lower swing arm.

Caution:

Caution:

Caution:

Caution:

Make

sure

that

the

steering

wheel

is

in

straight-ahead position.

10. Then install tires and lower the vehicle.
11. Align clamped plates of the cross shaft with the

steering column and fix them with a new bolt.

12. Reconnect the negative cable of battery.

FAX

FAX

FAX

FAX Front

Front

Front

Front Suspension

Suspension

Suspension

Suspension

---- 120

120

120

120 ----

Disassembly

Disassembly

Disassembly

Disassembly and

and

and

and Assembly

Assembly

Assembly

Assembly of

of

of

of Subframe

Subframe

Subframe

Subframe

Disassembly
1.

Remove the two mounting bolts at the mounting
position of the front anti-roll bar.

2.

Remove the steering gear box.

3.

Remove the lower swing arm assembly.

�

Remove connecting bolts between the lower
swing arm and the subframe.

�

Remove feedthrough bolts and nuts between
the lower swing arm and the subframe.

4.

Remove the compression travel stop block.

FAX

FAX

FAX

FAX Front

Front

Front

Front Suspension

Suspension

Suspension

Suspension

-121

121

121

121 -

Removal

Removal

Removal

Removal and

and

and

and Installation

Installation

Installation

Installation of

of

of

of Subframe

Subframe

Subframe

Subframe (Continued)

(Continued)

(Continued)

(Continued)

Assembly
1.

Install the compression travel stop block.

2.

Reinstall the lower swing arm assembly.
Install feedthrough bolts and nuts between the
lower swing arm and the cross rail from the rear
side.

3.

Align and reinstall the lower swing arm assembly.

�

Tighten bolts between the front suspension
and the subframe.

�

Insert feedthrough bolts into the cross rail,
install and then tighten them.

FAX

FAX

FAX

FAX Front

Front

Front

Front Suspension

Suspension

Suspension

Suspension

---- 122

122

122

122 ----

Removal

Removal

Removal

Removal and

and

and

and Installation

Installation

Installation

Installation (Continued)

(Continued)

(Continued)

(Continued)

4.

Reinstall the steering gear box.
Make sure to install mounting bolts in the direction

of underside of the cross rail.

Caution:

Caution:

Caution:

Caution:

Make sure that the positioning shaft sleeves of the

front anti-roll bar are in the inner side of the rubber
space ring, with their opening marks backward.

5.

Install the two mounting bolts of the front anti-roll
bar.

FAX

FAX

FAX

FAX Front

Front

Front

Front Suspension

Suspension

Suspension

Suspension

-123

123

123

123 -

Removal

Removal

Removal

Removal and

and

and

and Installation

Installation

Installation

Installation of

of

of

of Lower

Lower

Lower

Lower Swing

Swing

Swing

Swing Arm

Arm

Arm

Arm

Removal
1.

Loosen wheel nuts, lift the vehicle and remove
wheels.

2.

Loosen mounting nuts of the front lower swing
arm.

Note:

Note:

Note:

Note:

In the process of steering tie rod removal from the

steering knuckle, wrap up ball seals with cloth as
protection for them.

3.

Remove the steering tie rod end ball joint from the
steering knuckle.

4.

Support the lower swing arm.

5.

At the mounting position, disconnect the front
anti-roll bar link from the lower swing arm.

FAX

FAX

FAX

FAX Front

Front

Front

Front Suspension

Suspension

Suspension

Suspension

---- 124

124

124

124 ----

Removal

Removal

Removal

Removal and

and

and

and Installation

Installation

Installation

Installation of

of

of

of Lower

Lower

Lower

Lower Swing

Swing

Swing

Swing Arm

Arm

Arm

Arm (Continued)

(Continued)

(Continued)

(Continued)

6.

Remove the ball joint from the lower swing arm.

7.

Lower the lower swing arm and remove the helical
spring.

8.

Remove the lower swing arm.

�

Remove nuts and bolts between the lower
swing arm and the cross rail.

�

Remove nuts and bolts between the lower
swing arm and the front suspension.

�

Remove the disc washer.

Installation
1.

Reinstall the lower swing arm.

�

Install the disc washer.

�

Install nuts and bolts between the lower swing
arm and the front suspension.

�

Install nuts and bolts between the lower swing
arm and the cross rail.

2.

Reinstall the helical spring.
Ensure following operations:

�

Correctly place the positioning opening of the
gasket.

�

Correctly combine the gasket positioning lug.

�

The lower end of the spring is located at the
groove of the lower swing arm

3.

Lift the lower swing arm.

FAX

FAX

FAX

FAX Front

Front

Front

Front Suspension

Suspension

Suspension

Suspension

-125

125

125

125 -

Removal

Removal

Removal

Removal and

and

and

and Installation

Installation

Installation

Installation of

of

of

of Lower

Lower

Lower

Lower Swing

Swing

Swing

Swing Arm

Arm

Arm

Arm (Continued)

(Continued)

(Continued)

(Continued)

Caution:

Caution:

Caution:

Caution:

When install the ball joint into the lower swing
arm, the mounting of the front axle is not allowed
to exceed the specified value to avoid damage of
the lower swing arm ball joint dust cover.

4.

Reinstall the ball joint into the lower swing arm.

5.

Reinstall the steering tie rod end onto the steering
knuckle.

6.

Reconnect the front anti-roll bar link with the lower
swing arm.

7.

Install wheels and lower the vehicle.

8.

Tighten mounting nuts of the lower swing arm.

�

Tighten nuts and bolts between the lower
swing arm and the cross rail.

�

Tighten nuts and bolts between the lower
swing arm and the front suspension

FAX

FAX

FAX

FAX Front

Front

Front

Front Suspension

Suspension

Suspension

Suspension

---- 126

126

126

126 ----

Removal

Removal

Removal

Removal and

and

and

and Installation

Installation

Installation

Installation of

of

of

of Helical

Helical

Helical

Helical Spring

Spring

Spring

Spring

Removal
1.

Loosen wheel nuts, lift the vehicle and remove
wheels.

2.

Remove the fixed cotter pin and castle nuts
between the steering tie rod end and the steering
knuckle.

Note:

Note:

Note:

Note:

In the process of steering tie rod removal from the
steering knuckle, wrap up ball seals with cloth as
protection for them.

3.

Remove the steering tie rod ball joint from the
steering knuckle.

4.

Support the lower swing arm.

5.

At the mounting position, remove the front anti-roll
bar link from the lower swing arm.

FAX

FAX

FAX

FAX Front

Front

Front

Front Suspension

Suspension

Suspension

Suspension

-127

127

127

127 -

Removal

Removal

Removal

Removal and

and

and

and Installation

Installation

Installation

Installation of

of

of

of Helical

Helical

Helical

Helical Spring

Spring

Spring

Spring

Caution:

Caution:

Caution:

Caution:

To avoid lower swing arm ball joint damage, tie the
top of the lower swing arm together with the cross
swing arm.

6.

Remove the shock absorber form the steering
knuckle.

7.

Lower the lower swing arm assembly and remove
the helical spring

8.

Remove the gasket from the top of the spring.

Installation
1.

Reinstall the helical spring.
Ensure flowing operations:

�

Correctly place the positioning opening of the
gasket.

�

Correctly combine the gasket positioning lug.

�

The lower end of the spring is located at the
groove of the lower swing arm.

2.

Reinstall the shock absorber onto the steering
knuckle.

Loosen the steering knuckle, lift the lower swing

arm and align it with the shock absorber.

3.

Retighten the steering tie rod with the steering
knuckle.
Fix castle nuts with new cotter pins.

FAX

FAX

FAX

FAX Front

Front

Front

Front Suspension

Suspension

Suspension

Suspension

---- 128

128

128

128 ----

Removal

Removal

Removal

Removal and

and

and

and Installation

Installation

Installation

Installation of

of

of

of Helical

Helical

Helical

Helical Spring

Spring

Spring

Spring

4.

Connect the steering tie rod link with the lower
swing arm.

5.

Install wheels and lower the vehicle.

FAX

FAX

FAX

FAX Front

Front

Front

Front Suspension

Suspension

Suspension

Suspension

-129

129

129

129 -

Removal

Removal

Removal

Removal and

and

and

and Installation

Installation

Installation

Installation of

of

of

of Front

Front

Front

Front Shock

Shock

Shock

Shock Absorber

Absorber

Absorber

Absorber

Removal
1.

Loosen wheel nuts, lift the vehicle and remove
wheels.

2.

Remove the brake hose from the shock absorber.

3.

Support the lower swing arm.

4.

Support the wheel hub assembly.

5.

Remove the shock absorber from the cab.

�

Remove the cap.

�

Remove nuts and washers for fastening the
central shaft with an L-shaped allen wrench.

�

Remove the disc washer.

6.

Remove the shock absorber form the steering
knuckle.

Installation
7.

Install the shock absorber onto the steering
knuckle.

8.

Apply some soap solution onto the inner side of the
shock insulator and top of the shock absorber.

9.

Install the shock absorber in place.

FAX

FAX

FAX

FAX Front

Front

Front

Front Suspension

Suspension

Suspension

Suspension

---- 130

130

130

130 ----

Removal

Removal

Removal

Removal and

and

and

and Installation

Installation

Installation

Installation of

of

of

of Front

Front

Front

Front Shock

Shock

Shock

Shock Absorber

Absorber

Absorber

Absorber

10. Fix the shock absorber firmly from the cab.

�

Reinstall the disc washer.

�

Install nuts and washers for fastening the
central shaft with an L-shaped allen wrench.

�

Install the cap.

11. Reinstall the brake hose onto the shock absorber.

12. Install wheels and lower the vehicle.

FAX

FAX

FAX

FAX Front

Front

Front

Front Suspension

Suspension

Suspension

Suspension

-131

131

131

131 -

Specification

Specification

Specification

Specification

1.

List of Main Tightening Torques

Name of Bolt（Nut）

Tightening Torque (N.m)

Tightening torque for ball pin nut

220～250

Connecting rod nut

20～30

Ball pin mounting bolt

35～75

Front anti-roll bar clamping bolt

16～26

Front nut of the lower swing arm

180～245

Rear nut of the lower swing arm

180～245

2.

List of Front Suspension Wearing Parts

Name

Quantity

Lower swing arm bushing assembly

2

Front cross rail bushing assembly

2

Front wheel hub inner and outer bearings

2 sets for each

Left and right friction linings

2 pieces for each

3.

Maintenance Parameter Table of Front Suspension

Item

Major Parameter

Remarks

Axle load

1.54t

Wheel base

1760mm

Center distance of helical spring

1170mm

Brake type

Disc brake

Brake specification

R135mm,cylinder boreΦ45

Camber angle of front wheel

0.75±1°

Max.tolerance between the left
and right 1.25°

Caster angle of kingpin

1.5±1.5°

Max.tolerance between the left
and right 1°

Inclination angle of kingpin

12.75°±1°

Max.tolerance between the left
and right 1.25°

Toe-in

2～4mm

Wheel bolt

6-M16X1.5

Standard pitch diameter of hub and wheel bolt

Φ180mm

RAX

RAX

RAX

RAX Rear

Rear

Rear

Rear Axle

Axle

Axle

Axle

-133-

Rear

Rear

Rear

Rear Axle

Axle

Axle

Axle

Applied models: SUNRAY products manufactured by JAC

Subject

Page

Instruction

Instruction

Instruction

Instruction and

and

and

and Operation

Operation

Operation

Operation

Rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 134

Explosive View of Rear Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..134
Introduction of Rear Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 135

Diagnosis

Diagnosis

Diagnosis

Diagnosis and

and

and

and Testing

Testing

Testing

Testing

Rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 136

Operating principle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Inspection and Confirmation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 137
Fault symptom Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 140

Removal/Installation

Removal/Installation

Removal/Installation

Removal/Installation

Rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 141

Differential. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..141

Specification

Specification

Specification

Specification

Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148

Tightening torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148