JAC HFC4DA1-2C engine. Service Manual — 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.
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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
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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
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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
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