DAF LF45, LF55 Service manual

9

LF45/55 series

CONTENTS

TECHNICAL DATA

0

DIAGNOSTICS

1

CHASSIS

2

SHOCK ABSORBERS

3

STABILISERS AND TORQUE RODS

4

LEAF SUSPENSION

5

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fafsfsafa

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LF45/55 series Contents

TECHNICAL DATA

CONTENTS

Page Date

1. CHASSIS 1-1 0207............................................................. ......

1.1 General 1-1 0207......................................................... ......

2. SHOCK ABSORBERS, STABILISERS, TORQUE RODS AND

LEAF SUSPENSION 2-1 0207................................................... ......

2.1 General 2-1 0207......................................................... ......

2.2 Tightening torques 2-3 0207................................................ ......

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TECHNICAL DATA

Contents LF45/55 series

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LF45/55 series Chassis

TECHNICAL DATA

1. CHASSIS

1.1 GENERAL

Chassis materials

Type

LF All KF 450

Note:

KF 450 is a “High Tensile Strength”-steel grade.

Chassis type Material

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TECHNICAL DATA

Chassis LF45/55 series

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TECHNICAL DATA

LF45/55 series Shock absorbers, stabilisers, torque rods and leaf suspension

2. SHOCK ABSORBERS, STABILISERS, TORQUE RODS AND LEAF
SUSPENSION

2.1 GENERAL

Fixing the attachment bolts for the leaf
spring

Ensure that when fixing the attachment bolts (1)
for the leaf spring that the leaf spring is at the
prescribed height (A). The height (A) is to be
measured above the axle, between the top edge
of the chassis cross member and the underside
of the leaf spring.

A

0

1

1

Front axle

MODEL

LF45 All models 404 mm 459 mm

LF45 All models 502 mm 566 mm

Rear axle

MODEL

LF45 7.5T GVW 295 mm

LF45 7.5T GVW A-symmetric 295 mm

LF45 10-12T GVW 327 mm

LF45 10-12T GVW A-symmetric 295 mm

LF55 13-15T GVW 391 mm

LF55 13-15T GVW A-symmetric 362 mm

LF55 16-18T GVW 414 mm

LF55 16-18T GVW type Kipper 391 mm

LF55 16-18T GVW A-symmetric 362 mm

HEIGHT (A)

frontmost attachment point (1) rearmost attachment point (2)

HEIGHT (A)

2

C9 00 409

Note:

With the rear axle height (A) applies to both
the frontmost (1) and the rearmost attachment
point (2) of the leaf spring.

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Shock absorbers, stabilisers, torque rods and leaf suspension LF45/55 series

Transverse guide torque rod, air sprung
rear axle LF45

Fitting angle (A) for mounting rubber on rear
axle side

8-12°

A

C9 00 408

Torque rods stabiliser length (A)

A is the centre-to-centre-distance between the
attachment points.

Front axle

LF45 all models 342 - 344 mm
LF55 all models 348 - 352 mm

Rear axle

LF55 FAN steered rear axle 598 - 602 mm

2-2

A

C9 00 413

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TECHNICAL DATA

LF45/55 series Shock absorbers, stabilisers, torque rods and leaf suspension

2.2 TIGHTENING TORQUES

The tightening torques stated in this paragraph
are different from the standard tightening
torques stated in the overview of the standard
tightening torques. The other threaded
connections which are not stated must therefore
be tightened to the tightening torque stated in
the overview of standard tightening torques.

When attachment bolts and nuts are to be
replaced, it is important - unless stated
otherwise - that these bolts and nuts are of
exactly the same length and property class as
the removed ones.

U-bolt nuts

MODEL

LF45 all models 215 Nm* 468 Nm*

LF55 13 - 15 ton GVW 468 Nm* 468 Nm*

LF55 16-18 ton GVW Leaf suspension 537 Nm* 537 Nm*

LF55 16-18 ton GVW Air suspension 537 Nm* 880 Nm*

LF55 FAN steered rear axle 468 Nm*

* Tighten the U-bolt nuts evenly and

alternately.

FRONT AXLE REAR AXLE

0

Shock absorbers

If using self-locking nut M14x2 52 Nm

Front axle torque rod locking nut

LF45 135 Nm
LF55 80 Nm

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Shock absorbers, stabilisers, torque rods and leaf suspension LF45/55 series

LF45 rear axle, air suspension

9

0

A B

C

DE

C9 00 323

A M14 shock absorber attachment nut 52 Nm
B M12 air bellows attachment nut 31 Nm
C M20 bolt 525 Nm
D M12 air bellows attachment nut 60 Nm
E M20 shock absorber attachment bolt 525 Nm

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LF45/55 series Shock absorbers, stabilisers, torque rods and leaf suspension

Rear axle, air suspension LF55 13- 15 ton
GVW

TECHNICAL DATA

A B

C D E

IJ

H

0

F

G

C9 00 324

A M16 triangular adjustment block

attachment bolt
B M20 triangle attachment bolt 475 Nm
C Attachment nut for triangle on

differential M22
D M20 shock absorber attachment bolt 525 Nm
E M20 air bellows support attachment bolt 465 Nm
F M12 air bellows attachment bolt 31 Nm
G M16 attachment bolt 285 Nm
H M20 shock absorber attachment bolt 525 Nm
I Attachment bolt 385 Nm
J M22 bolt with break nut, breakpoint nut +/-- 750 Nm

360 Nm

235 Nm

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Shock absorbers, stabilisers, torque rods and leaf suspension LF45/55 series

Rear axle, air suspension LF55 16- 18 ton
GVW

9

0

A

ED D

A M10 air bellows attachment nut 46 Nm
B Clamping flange bolt M18 460 Nm
C M14 attachment bolt, property class 10.9 135 Nm
D M16 air bellows attachment bolt 195 Nm
E M20 attachment bolt, property class 10.9,

shock absorber

520 Nm

ABB C

C9 00 325

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LF45/55 series Shock absorbers, stabilisers, torque rods and leaf suspension

Steered rear axle, air suspension LF55 FAN

B C

A

TECHNICAL DATA

0

F D

A Self-locking nut, torque rod ball joint 88 Nm
B M20 shock absorber attachment bolt 250 Nm
C M10 air bellows attachment bolt 32 Nm
D M12 air bellows attachment bolt 34 Nm
E M12 attachment bolt, stabiliser bar

retaining plate

F Automatic lubricating nipple 5 Nm

E

25 Nm

C9 00 397

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TECHNICAL DATA

Shock absorbers, stabilisers, torque rods and leaf suspension LF45/55 series

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LF45/55 series Contents

DIAGNOSTICS

CONTENTS

Page Date

1. SHOCK ABSORBERS 1-1 0207.................................................. ......

1.1 Fault-finding table 1-1 0207................................................. ......

2. LEAF SUSPENSION 2-1 0207................................................... ......

2.1 Fault-finding table 2-1 0207................................................. ......

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LF45/55 series Shock absorbers

1. SHOCK ABSORBERS

1.1 FAULT-FINDING TABLE

COMPLAINT: SHOCK ABSORBER PRODUCES NOISE (CHATTERING, BUMPING ETC.)

Possible cause Remedy

Shock absorber is loose. Tighten.

Attachment rubbers too soft. Fit new rubbers.

Shock absorber comes into contact with other
components.

Shock absorber cover is loose. Tighten cover or replace shock absorber.

COMPLAINT: SHOCK ABSORBER DOES NOT FUNCTION

Possible cause Remedy

Internal defect. Replace shock absorber.

Loss of oil. Replace shock absorber.

COMPLAINT: LEAKY SHOCK ABSORBER

Possible cause Remedy

Defective piston rod sealing.
Caution: a thin, greasy layer is normal.

COMPLAINT: SHOCK ABSORBER TOO HARD

Remove components or fasten them.

Replace shock absorber.

1

Possible cause Remedy

Incorrect shock absorber type fitted. Fit correct type.

Internal shock absorber defect. Check shock absorber using a test bench and

replace, if required.

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DIAGNOSTICS

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Shock absorbers LF45/55 series

COMPLAINT: SHOCK ABSORBER TOO SOFT

Possible cause Remedy

Incorrect shock absorber type fitted. Fit correct type.

Internal wear. Check shock absorber using a test bench and

replace, if required.

Loss of oil due to leakage. See under Leaky shock absorber.

Vehicle overloaded. Adjust vehicle loading.

COMPLAINT: POOR DRIVING CHARACTERISTICS/FLAT WEAR SPOTS ON THE TYRES

Possible cause Remedy

Incorrect damping. Check shock absorbers using a test bench and

replace, if required.

Vehicle overloaded. Adjust vehicle loading.

COMPLAINT: SHOCK ABSORBER HITS END STOP

Possible cause Remedy

Defective stop rubber. Replace rubber.

Insufficient damping. See under Shock absorber too soft.

Vehicle overloaded. Adjust vehicle loading.

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DIAGNOSTICS

LF45/55 series Leaf suspension

2. LEAF SUSPENSION

2.1 FAULT-FINDING TABLE

COMPLAINT: LOOSE U-BOLTS

Possible cause Remedy

Use of a U-bolt or nut of an incorrect property
class.

The tightening torque used for the U-bolt nut
was too low.

Reuse of a U-bolt with corroded or damaged
thread.

No or inadequate cleaning of the thread (which
includes removal of paint) before reuse of the
U-bolt.

No oil or faulty application of oil on the thread
and the bearing surface of the nut.

Coating (i.e. paint) on the contact faces of the
connection.

Inadequate retorquing of the U-bolt nut or no
retorquing.

COMPLAINT: BROKEN SPRING

Possible cause Remedy

Regular overloading. Adjust vehicle loading.

Use U-bolts and nuts of the correct property
class.

Tighten the U-bolt to the specified torque.

Fit new U-bolt.

Clean the thread thoroughly before re-use.

Apply the oil as prescribed.

Clean the contact faces before assembly.

Tighten the U-bolt nut as specified.

1

Driving too fast over bad roads. Adjust speed when the road is bad.

Notching effect due to welding or grinding
activities.

Spring damaged due to impact of a steel
hammer.

Incorrect repair of a spring leaf which has broken
before.

Spring has been heated. Replace spring assembly. Springs should never

Cover spring assembly when welding or
grinding.

Never hit the springs using a steel hammer or
some other hard tool.

When replacing a broken spring leaf, always
replace the leaf on top and under the broken
leaf; better yet, replace the entire spring
assembly.

be heated.

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Leaf suspension LF45/55 series

COMPLAINT: SPLAYING OF THE SPRING ASSEMBLY (BROKEN SPRING CLAMPS)

Possible cause Remedy

Incorrect pre-tension of the U-bolts. See under complaint Loose U-bolts.

1

COMPLAINT: SPRING HITS END STOP

Possible cause Remedy

Overloading. Adjust vehicle loading.

Sagged spring assembly. Check height of both spring assemblies.

Replace spring assemblies.

Broken spring. Repair spring assembly or replace.

COMPLAINT: SHIFTING OR BREAKING OF CENTRE BOLT

Possible cause Remedy

Incorrect pre-tension of the U-bolts. See under complaint Loose U-bolts.

COMPLAINT: BUMPING OR CHATTERING OF THE SPRING

Possible cause Remedy

Loose U-bolts. See under complaint Loose U-bolts.

Spring bracket is loose. Secure the spring bracket.

Spring comes into contact with other
components during spring action.

Check freedom of movement of spring.

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LF45/55 series Contents

CHASSIS

CONTENTS

Page Date

1. GENERAL 1-1 0207............................................................ ......

1.1 Repairs to the chassis 1-1 0207............................................. ......

1.2 Drilling in the chassis 1-4 0207.............................................. ......

1.3 Replacing the rivets by bolts 1-5 0207........................................ ......

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CHASSIS

LF45/55 series General

1. GENERAL

1.1 REPAIRS TO THE CHASSIS

- Any welding, aligning, drilling and
wheelbase alteration activities that are not
described in this workshop manual or in any
of the latest releases of DAF’s Chassis
Guidelines must be authorised by DAF.

- Following chassis repair, the cause of the
chassis damage should be rectified.

Welding

- Chassis welding may only be carried out by
welders holding a valid EN 287-1 certificate.

- Slag inclusions and other contamination in
the welds are totally unacceptable.

Note:

Welding a chassis made from High Tensile
Strength steel KF 450 is strongly advised
against. If, however, you do wish to weld a High
Tensile Strength steel chassis, contact DAF
always first.
The welding electrode must meet the standard:
EN 757: EY 4666 MNB.

2

To repair cracks in the chassis, proceed as
follows, taking account of the guidelines given
above:

1. Remove all parts restricting a clear working
area.

2. Thoroughly clean the crack so that the
course of the crack is clearly visible.

3. Drill a small hole at the end of the crack.
This will prevent the crack from continuing.

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CHASSIS

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General LF45/55 series

4. Thoroughly grind out the crack on both
sides.

5. Take the necessary precautions to prevent
damage to electronic components. Place
the earth clamp as close as possible to the
weld and avoid bridges.

6. Lay a bead on one side of the ground-out
crack.

7. Gouge or grind off the material at the back
of the bead (see the arrow) so that the new
weld material is clearly visible.

8. Finish-weld the X-seam in the usual
manner.

9. Fill in the drilled hole.

10. Grind down the new weld so that it is flush.
Take care not to grind the chassis flange in
the process.

W9 01 002

W9 01 003

11. The beginning and end of a weld should not
curve inwards (see the arrow).

12. Round off the weld at the edge of the
chassis member.

R=1

R=1

W9 01 004

100mm

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CHASSIS

LF45/55 series General

Straightening

Do not forget your own safety
during straightening operations.
When working with presses, take
care that parts cannot fly out.

The straightening of a chassis demands a high
degree of craftsmanship as in every case of
damage, an individual assessment must be
made to establish whether or not straightening
would be a sensible measure.
Deformations found after accidents will mainly
be of the following 6 types:

- chassis is bent sideways

- chassis has a double bend sideways
(“S-bend”)

- chassis sags

- chassis bulges upwards

- chassis is twisted

- chassis is out of square.

In many cases, the damage will be a
combination of two or more of these basic
deformations. In general, the deformations
should be dealt with in the sequence shown
above, although some combinations can be
dealt with in one straightening operation. When
deciding whether or not to straighten a chassis,
you must consider not only the degree of
chassis bending but also the angle of a bend.
If there is a sharp angular bend or fold in the
chassis, the material in that area is likely to be
severely deformed. If such a chassis were to be
realigned to its original form, there would be a
high risk of overstretching the already weakened
material and causing a crack to develop.

2

“Warm” straightening

DAF chassis should not be warm straightened.
Heating can cause grains in the material which
will adversely affect the material properties.

General

For every straightening operation, all stresses in
the stiffer parts of the chassis, for example in the
tandem axle attachment cross member, should
be relieved. If this is not done, these stresses
will later cause new distortions or cracks in the
chassis.

It is obvious from the above points that
straightening is a highly specialised job for which
the specialist involved bears full responsibility.
Always contact DAF when in doubt about
complicated “straightening operations”.

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General LF45/55 series

1.2 DRILLING IN THE CHASSIS

Note:

There are several stress zones in a chassis.
Working on the chassis without the appropriate
knowledge (and not according to DAF
instructions) may cause irreversible damage to
the chassis. The repair shop or bodybuilder
would be held fully responsible for such work
and for any superstructure fitted.

If holes must be drilled in the chassis frame,
note the following points:

Drilling holes within a distance of 70 mm
(distance A) from a bend in the chassis is not
permitted.

- It is on no account permitted to drill holes in
the tapered ends at the rear of a tractor
chassis.

- Drilling holes in the flanges of the chassis
side members is not permitted.

- The maximum diameter for drilled holes is
17 mm (dimension D in the drawing).

- The distance between the holes, and
between the holes and the side member
flange, must be at least 3xD - with a
minimum of 30 mm (dimension B in the
drawing).

- The distance between the lower stud hole
and the chassis underside should at least
be equal to distance C.
Distance C is > 70 mm for a tractor
chassis.
Distance C is > 50 mm for all other
chassis.

- Deburr (at an angle of 45_) and lacquer
coat the drilled hole.

Wheelbase alteration

Any alteration to the wheelbase or changes to
the rear overhang should be done in accordance
with the latest DAF Trucks Bodybuilders’
Guidelines.

B
B

C

A

A

A

A

A

A

A

A

C9 00 304

B

D

B

C9 00 291

Note:

When using the Bodybuilders’ Guidelines, you
are advised to first read the “General” section.

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CHASSIS

LF45/55 series General

1.3 REPLACING THE RIVETS BY BOLTS

Note:

A rivet may either be replaced by a flange bolt
M14 x 2, property class 8.8 (DIN 6921), or a
flange bolt M16 x 2, property class 10.9.

Removing the rivet

1. Remove the rivet head. Make sure not to
damage the chassis during this procedure.

2. Usea10mmdrilltodrillaholeintherivet.
Remove the rivet from the chassis.

Installing flange bolt M14

1. Ream the rivet hole to fit 14 H7 (14 + .000 ­14 + .018 mm). Make sure not to damage
any lines running behind the rivet hole.
Deburr the edges.

2. Repair the chassis lacquer coating. The
new paintwork should be no thicker than
50 microns.

3. It is important that part of the bolt shank is
not threaded. Determine the length (L) of
the non-threaded shank part using the
formula below.

L=T1+T3,inwhichT3mustbe>

L = shank length without thread
T1 = part to be clamped
T2 = part to be clamped

4. Tighten the flange bolt to the standard
tightening torque for bolts, property class

8.8.

1

/2T2.

2

L

T3

T1

T2

C9 00 295

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General LF45/55 series

Installing M16 flange bolt

1. Drill the rivet hole out to ∅17 mm. Make
sure not to damage any lines running
behind the rivet hole. Deburr the edges.

2. Repair the chassis lacquer coating. The
new paintwork should be no thicker than
50 microns.

2

3. Install a flange bolt M16 x 2, property class

10.9, with a non-threaded shank (A) of
6 mm.

4. Tighten the flange bolt to the standard
tightening torque for bolts, property class

10.9.

A

C9 00 296

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LF45/55 series Contents

SHOCK ABSORBERS

CONTENTS

Page Date

1. GENERAL 1-1 0207............................................................ ......

1.1 Operation of shock absorber 1-1 0207....................................... ......

2. REMOVAL AND INSTALLATION 2-1 0207......................................... ......

2.1 Removal and installation of shock absorbers 2-1 0207.......................... ......

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SHOCK ABSORBERS

LF45/55 series General

1. GENERAL

1.1 OPERATION OF SHOCK ABSORBER

The function of the shock absorber is twofold:

- to control the movements of chassis and
superstructure in relation to the axle.
Optimum comfort is achieved when the
chassis and superstructure remain truly
horizontal and are not subjected to any
vertical accelerations when moving;

- to control the movements of the wheels on
the road. Optimum handling is achieved
when all wheels remain in constant contact
with the road surface.

The rate of the above-mentioned movements
depends on the available spring travel. The
available spring travel is the difference in height
between an unloaded spring and a fully loaded
spring.
A well-functioning shock absorber with
characteristics appropriate to the operating
conditions will be the best possible compromise
to fulfil the above-mentioned functions.

3

DAF only uses double acting type shock
absorbers.
On vehicles with air suspension, hydraulic stroke
limitation is used.

The shock absorber consists of:

- an operating cylinder, in which the actual
damping is done by a piston with piston rod
of which the valve unit damps the rebound
stroke;

- a bottom valve which, in combination with
the piston valve unit, damps the bump
stroke.

- a reservoir tube which draws in oil surplus
(result of the volume taken up by the piston
rod) via the bottom valve;

- a dust cover, attached to the piston rod.

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SHOCK ABSORBERS

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General LF45/55 series

Double acting shock absorbers

The operation of the shock absorber is as
follows:
the bump stroke moves the cylinder (1) down in
relation to the operating cylinder (2).
Subsequently, oil flows from the bottom chamber
of the piston (1) through the piston holes and
valves to the top chamber where the volume
increases. The oil pressure is equal on either
side of the piston (1).

To compensate for the volume taken up by
piston rod (3), oil flows from under the piston (1),
via the bottom valve (4), to the reservoir
tube (5).
The resistance met by the oil during this
movement dampens the bump stroke of the
shock absorber.
The rebound stroke moves the piston (1) up in
relation to the operating cylinder (2).
Subsequently, pressure is exerted on the oil in
the upper chamber of the piston (1) causing the
oil to flow to the bottom chamber under the
piston (1), via the piston holes and valves.
The resistance met by the oil during this
movement dampens the bump stroke of the
shock absorber.
To compensate for the volume taken up by the
piston rod (3) in the upper chamber, oil flows via
bottom valve (4) from the reservoir tube (5) to
the bottom chamber under the piston (1).

3

1

5
2

4

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SHOCK ABSORBERS

LF45/55 series Removal and installation

2. REMOVAL AND INSTALLATION

2.1 REMOVAL AND INSTALLATION OF SHOCK ABSORBERS

Remving the shock absorber

1. Remove the attachment nuts and/or bolts.

2. Mark the exact positions and location of the
mounting rubbers.

3. Remove the shock absorber from under the
vehicle.

Installing the shock-absorber

1. Check the shock absorber mountings for
hair-line cracks.

2. If the old rubbers are to be reused, check
them for hair-line cracks and ageing. Install
the rubbers in the original locations and
positions.

3. When replacing the rubbers, use only the
specified types.

3

4. Replace any self-locking nuts. Tighten the
attachment bolts to the specified tightening
torque, see “Technical data”.

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SHOCK ABSORBERS

Removal and installation LF45/55 series

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STABILISERS AND TORQUE RODS

LF45/55 series Contents

CONTENTS

Page Date

1. GENERAL 1-1 0207............................................................ ......

1.1 Overview drawing, front-axle stabiliser 1-1 0207............................... ......

1.2 Overview drawing, leaf-sprung rear axle stabiliser 1-2 0207..................... ......

1.3 Overview drawing, air-sprung rear axle stabiliser LF55

13-15 ton GVW 1-3 0207................................................... ......

1.4 Overview drawing, air-sprung rear axle stabiliser LF55

16-18 ton GVW 1-4 0207................................................... ......

1.5 Overview drawing, steered rear axle stabiliser LF55 FAN 1-5 0207............... ......

2. REMOVAL AND INSTALLATION 2-1 0207......................................... ......

2.1 Removal and installation, front-axle stabiliser 2-1 0207......................... ......

2.2 Removal and installation, leaf-sprung rear axle stabiliser 2-3 0207............... ......

2.3 Removal and installation, transverse guide torque rod,

air sprung rear axle LF45 2-5 0207.......................................... ......

2.4 Removal and installation, air-sprung rear axle stabiliser LF55

13-15 ton GVW 2-6 0207................................................... ......

2.5 Removal and installation, triangular link, air-sprung rear axle LF55

13-15 ton GVW 2-8 0207................................................... ......

2.6 Removal and installation, air-sprung rear axle yoke LF55

13-15 ton GVW 2-10 0207................................................... .....

2.7 Removal and installation, triangular link and air-sprung rear axle torque rod

LF55 13-18 ton GVW 2-12 0207.............................................. .....

2.8 Removal and installation, air-sprung rear axle stabiliser LF55

16-18 ton GVW 2-14 0207................................................... .....

2.9 Removal and installation, steered rear axle stabiliser LF55 FAN 2-16 0207......... .....

4

3. DISASSEMBLY AND ASSEMBLY 3-1 0207........................................ ......

3.1 Disassembly and assembly, stabiliser bar / torque rod silentblock

with rubber casing 3-1 0207................................................ ......

3.2 Disassembly and assembly, stabiliser bar / torque rod silentblock

with steel casing 3-2 0207.................................................. ......

3.3 Disassembly and assembly, transverse guide torque rod mounting rubber,

air-sprung rear axle LF45 3-3 0207.......................................... ......

3.4 Disassembly and assembly, triangular link silentblock, air-sprung rear axle

LF55 13-15 ton GVW 3-4 0207.............................................. ......

3.5 Disassembly and assembly, triangular link mounting rubber,

air-sprung rear axle LF55 13-15 ton GVW 3-5 0207............................ ......

3.6 Disassembly and assembly, triangular link silentblock, air-sprung rear axle

LF55 16-18 ton GVW 3-6 0207.............................................. ......

3.7 Disassembly and assembly, triangular link/torque rod mounting rubber,

air-sprung rear axle LF55 16-18 ton GVW 3-8 0207............................ ......

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STABILISERS AND TORQUE RODS

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STABILISERS AND TORQUE RODS

LF45/55 series General

1. GENERAL

1.1 OVERVIEW DRAWING, FRONT-AXLE STABILISER

2

3

4

5

6

14

13

1

4

7

1

8

12

11

9

10

C9 00 400

1. Stabiliser bar

2. Attachment bolt

3. Silentblock

4. Torque rod

5. Shim

6. Attachment bolt

7. Lock nut

8. Torque rod ball joint

9. Attachment bolt

10. Clamp

11. Stabiliser bracket

12. Bearing bush

13. Retaining plate

14. Attachment bolt

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1-1

STABILISERS AND TORQUE RODS

General LF45/55 series

1.2 OVERVIEW DRAWING, LEAF-SPRUNG REAR AXLE STABILISER

7

5

4

6

9

4

2

1

1. Silentblock

2. Stabiliser bar

3. Attachment bolt

4. Bearing bush cover

5. Bearing bush

6. Bearing-bush cover

3

C9 00 401

1-2

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9

STABILISERS AND TORQUE RODS

LF45/55 series General

1.3 OVERVIEW DRAWING, AIR-SPRUNG REAR AXLE STABILISER LF55

13-15 TON GVW

3

4
5

2

1

14

13

6

7
8

11

4

9

10

12

C9 00 319

1. Stabiliser bar

2. Clamp

3. Bolt

4. Retaining plate

5. Bearing bush

6. Bearing bush cover

7. Stiffener

8. Nut

9. Connecting pin

10. Shackle

11. Spacer ring

12. Shackle bracket

13. Bush

14. Circlip

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1-3

4

STABILISERS AND TORQUE RODS

9

General LF45/55 series

1.4 OVERVIEW DRAWING, AIR-SPRUNG REAR AXLE STABILISER LF55

16-18 TON GVW

3

4

2

5

1

12

11

10

1. Stabiliser bar

2. Bolt

3. Bracket

4. Nut

5. Silentblock

6. Shackle

7. Bolt

8. Nut

9. Silentblock

10. Nut

11. Bearing bush cover

12. Bearing bush

6

7

8

9

C9 00 320

1-4

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9

STABILISERS AND TORQUE RODS

LF45/55 series General

1.5 OVERVIEW DRAWING, STEERED REAR AXLE STABILISER LF55 FAN

4

3

6

1

2

4

12

11

1. Stabiliser bar

2. Torque rod

3. Torque rod ball joint

4. Lock nut

5. Torque rod ball joint

6. Nut

7. Lock nut

8. Clamp

9. Stabiliser bracket

10. Bearing bush

11. Retaining plate

12. Attachment bolt

10

6

1

5

9

8

7

C9 00 399

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1-5

4

STABILISERS AND TORQUE RODS

General LF45/55 series

9

1-6

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9

STABILISERS AND TORQUE RODS

LF45/55 series Removal and installation

2. REMOVAL AND INSTALLATION

2.1 REMOVAL AND INSTALLATION, FRONT-AXLE STABILISER

2

3

4

5

6

1

4

14

13

Removal, front-axle stabiliser

1. Remove the lock nut (9) from the ball
joint (8).

2. Press the ball joint (8) out of the stabiliser
bar (1).

3. Remove the attachment bolts (14) together
with the retaining plates (13) that are
mounted to the stabiliser brackets (11) of
the stabiliser bar.

12

11

7

1

8

9

10

C9 00 400

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2-1

STABILISERS AND TORQUE RODS

9

Removal and installation LF45/55 series

4. Remove the stabiliser together with the
bearing bushes (12) out of the vehicle
supports (11).

5. Remove the attachment bolts (6) and
remove the torque rods (4).

Installation, front-axle stabiliser

1. Check the condition of the silentblocks (3),
the bearing bushes (12) and the ball
joints (8).

2. Fit the torque rod (4) with the attachment
bolt (6) to the chassis.

3. Turn the bearing bushes (12) on the
stabiliser bar (1), so that the bearing bushes
(12) can be positioned in the brackets (11).

4

4. Fit the stabiliser bar (1).

5. Check whether the stabiliser bar is situated
in the centre of the vehicle. Move the
positioning clamps (10), if necessary.

6. Fit the retaining plates (13), using the
attachment bolts (14). Tighten the
attachment bolts evenly to the specified
torque.

7. Fit the ball joint (8) to the stabiliser bar (1).
Tighten the lock nuts (9) to the specified
tightening torque, see “Technical data”.

2-2

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9

STABILISERS AND TORQUE RODS

LF45/55 series Removal and installation

2.2 REMOVAL AND INSTALLATION, LEAF-SPRUNG REAR AXLE STABILISER

7

5

4

6

2

1

Removal, leaf-sprung rear axle stabiliser

1. Remove the U-bolt nuts by means of which
the mounting rubbers (1) of the stabiliser
bar (2) are attached to the rear axle.

2. Remove the attachment bolts (3) from the
bearing bush covers (4).

3. Remove the stabiliser (2) from under the
vehicle.

4. Remove the bearing bushes (5) from the
stabiliser bar (2).

3

4

C9 00 401

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2-3

4

STABILISERS AND TORQUE RODS

9

Removal and installation LF45/55 series

Installation, leaf-sprung rear axle stabiliser

1. Check the condition of the silentblocks (1)
and the bearing bushes (5).

2. Clean the threaded ends of the U-bolts.

3. Fit the bearing bushes (5) in the bearing
bush covers (4).

4. Fit the bearing caps (4) and the stabiliser
bar (2) simultaneously to the stabiliser
bracket (5).

5. Fit the attachment bolts (12) with the heads
facing towards the front of the vehicle and
hand-tighten them.

6. Fit the mounting rubber to the U-bolts.
Tighten the U-bolts to the specified
tightening torque, see “Technical data”.

7. Apply grease to the threaded ends of the
U-bolts.

8. Tighten the attachment bolts (12).

2-4

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9

STABILISERS AND TORQUE RODS

LF45/55 series Removal and installation

2.3 REMOVAL AND INSTALLATION, TRANSVERSE GUIDE TORQUE ROD, AIR

SPRUNG REAR AXLE LF45

Removal, transverse guide torque rod

1. Remove the attachment bolts (1) on the
side (2) at which the torque rod (5) is
attached to the rear axle.

1

5

2. Remove the attachment bolts (3) on the
side (4) at which the torque rod (5) and the
attachment bracket (6) are attached to the
chassis.

3. Remove the torque rod (5) together with the
attachment bracket (6).

Installation, transverse guide torque rod

Caution: on one side of the torque rod, the

mounting rubber is fitted into the eye of the
torque rod at an angle. This side must be fitted
to the rear axle.

1. Fit the torque rod (5) with the attachment
bolt (6) to the chassis. Hand-tighten the
attachment bolts (3).

2. Position the other side (2) of the torque rod
(5) on the attachment point of the rear axle
and fit the attachment bolts (1).

3. Tighten all attachment bolts (1 and 3).

2

3

4

C9 00 403

6

4

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2-5

STABILISERS AND TORQUE RODS

Removal and installation LF45/55 series

2.4 REMOVAL AND INSTALLATION, AIR-SPRUNG REAR AXLE STABILISER

LF55 13-15 TON GVW

3

4
5

2

9

4

1

14

13

6

7
8

9

10

11

12

C9 00 319

Removal, air-sprung rear axle stabiliser bar
LF55 13-15 ton GVW

1. Remove the attachment bolts (3) and nuts
(8) from the bearing bush covers (6) and
stiffeners (7).

2. Remove the bearing bush covers (6) from
the stiffeners (7).

2-6

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9

STABILISERS AND TORQUE RODS

LF45/55 series Removal and installation

3. Remove the attachment bolts and nuts from
the shackle brackets (12) in the differential.

4. Remove the stabiliser bar.

Installation, air-sprung rear axle stabiliser
bar LF55 13-15 ton GVW

1. Check the condition of all the rubbers and
hinge points.

2. Fit the stabiliser bar (1) under the chassis.

3. Fit the shackle brackets (12) of the stabiliser
bar in the hinge points on the differential.

4. Fit the attachment nuts and bolts of the
shackle brackets (12) and tighten them.

5. Fit the bearing bush cover (6) together with
the stiffeners (7) over the silentblocks (5)
and the retaining plates (4). Tighten the
attachment bolts (3) and nuts (8).

4

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2-7

4

STABILISERS AND TORQUE RODS

9

Removal and installation LF45/55 series

2.5 REMOVAL AND INSTALLATION, TRIANGULAR LINK, AIR-SPRUNG REAR

AXLE LF55 13-15 TON GVW

12 3 4 5

6

Removal, triangular link, air-sprung rear axle
LF55 13-15 ton GVW

1. Detach any valves on the inside of the
chassis that may hinder removal of the
triangular link.

2. Remove the attachment nut (3) of the
silentblock on the differential.

3. Remove the attachment bolts (2) and nuts
(1) of the mounting rubbers on the triangle
legs.

4. Jack up the chassis until the triangle is free
of stress.

5. Remove the triangle from the differential.
Use a pulley puller of the silentblock does
not come off the attachment pin on the
differential.

7

8910

C9 00 410

2-8

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9

STABILISERS AND TORQUE RODS

LF45/55 series Removal and installation

Installation, triangular link, air-sprung rear
axle LF55 13-15 ton GVW

1. Check the condition of the mounting
rubbers and the silentblock in the triangle.

2. Apply Copaslip to the silentblock
attachment pin on the differential.

3. Position the triangle on the attachment pin
and check that the mounting rubbers are
positioned straight against the support
points on the chassis. Hand-tighten the
attachment nut.

4. Lower the chassis and fit the attachment
bolts (2) and nuts (1) for the mounting
rubbers. Tighten the bolts to the specified
tightening torque, see “Technical data”.

5. Tighten the attachment nut (3) to the
specified tightening torque, see “Technical
data“.

6. Fix any detached valves on the inside of the
chassis.

4

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4

STABILISERS AND TORQUE RODS

9

Removal and installation LF45/55 series

2.6 REMOVAL AND INSTALLATION, AIR-SPRUNG REAR AXLE YOKE LF55

13-15 TON GVW

12 3 4 5

6

Support the vehicle securely and
work safely.
Make sure that the axle cannot tilt if
both yokes are removed at the same
time.

Removal, air-sprung rear axle yoke LF55
13-15 ton GVW

1. Support the chassis with a jack.

2. Remove the lower attachment bolt (8) of the
shock absorber.

3. Support the yoke at the centre.

4. Support the fixing bar for the air bellows
using a jack. Remove the attachment bolts
(7) by means of which the fixing bar for the
air bellows is attached to the yoke.

7

8910

C9 00 410

5. Remove attachment bolt (10) from the
silentblock.

6. Remove the attachment bolts (9) from the
mounting rubber.

7. Remove the yoke.

2-10

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9

STABILISERS AND TORQUE RODS

LF45/55 series Removal and installation

Installation, air-sprung rear axle yoke LF55
13-15 ton GVW

1. Check the condition of the mounting rubber
and the silentblock of the yoke.

2. Position the yoke using a jack underneath
the axle.

3. Fit the attachment bolts (9) for the mounting
rubber. Tighten the attachment bolts to the
specified tightening torque, see “Technical
data”.

4. Fit the attachment bolt (10) together with
the lock washer, centring ring, jack support
and plastic rings in the torque rod support
and the silentblock. Caution: Fit a new
break nut. For the breaking torque of the
break nut, see “Technical data”.

5. Position the attachment bolts of the fixing
bar for the air bellows in the yoke.

6. Fit the attachment nuts (7). Tighten the nuts
to the specified tightening torque, see
“Technical data”.

4

7. Fit the shock absorber on the yoke. Tighten
the attachment bolt (8) to the specified
tightening torque, see “Technical data“.

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4

STABILISERS AND TORQUE RODS

9

Removal and installation LF45/55 series

2.7 REMOVAL AND INSTALLATION, TRIANGULAR LINK AND AIR-SPRUNG

REAR AXLE TORQUE ROD LF55 13-18 TON GVW

1

2

3

7

4

5

Removal, triangular link, air-sprung rear axle
LF55 16-18 ton GVW, axle top

1. Remove the bolts (2).

2. Remove the bolts (3) and remove the
torque rod (1). This can only be done by two
persons working together.

10

9

6

8

C9 00 299

2-12

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9

STABILISERS AND TORQUE RODS

LF45/55 series Removal and installation

Installation, triangular link, air-sprung rear
axle LF55 16-18 ton GVW, axle top

1. Before installation, check the rubber bushes
of the triangular link and the silentblock for
hair-line cracks and wear.
Check to see if the contact surface of the
triangular link flange (1) (see arrow) and the
contact surface on the axle housing are free
from grease and paint.

2. Install the triangular link (1) to the vehicle.
This can only be done by two persons
working together. Fit the bolts (2 and 3).
Tighten the bolts (2) evenly to the specified
torque. See “Technical data”.

Removal, air-sprung rear axle torque rod
LF55 16-18 ton GVW, axle bottom

1. Remove the bolts (5 and 8) and remove the
torque rod (7).

Installation, air-sprung rear axle torque rod
LF55 16-18 ton GVW, axle bottom

1. Before installation, check the rubber bushes
of the torque rod (7) for hair-line cracks and
wear.

4

2. Clean the contact surfaces if necessary.
These should be free from dirt and grease.

3. Fit the torque rod (7) between the torque
rod support (4) and the yoke (10).

4. Fit the bolts (5 and 8) with the heads facing
towards the front of the vehicle. Tighten the
bolts (5 and 8).

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4

STABILISERS AND TORQUE RODS

9

Removal and installation LF45/55 series

2.8 REMOVAL AND INSTALLATION, AIR-SPRUNG REAR AXLE STABILISER

LF55 16-18 TON GVW

3

4

2

5

1

12

11

10

Removal, air-sprung rear axle stabiliser bar
LF55 16-18 ton GVW

1. Remove the attachment nuts (10) from the
bearing bush covers (11).

6

7

8

9

C9 00 320

2. Remove the attachment bolts (7) and the
attachment nuts (8) from the silentblocks
(8).

3. Remove the stabiliser bar (1).

2-14

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9

STABILISERS AND TORQUE RODS

LF45/55 series Removal and installation

Installation, air-sprung rear axle stabiliser
bar LF55 16-18 ton GVW

1. Position the stabiliser bar (1) together with
the bearing bushes (12) in the bearing bush
cover halves underneath the differential.

2. Fit the bearing bush covers (11) using the
attachment bolts (10), but do not yet tighten
the bolts.

3. Install the stabiliser bar (1) together with the
silentblocks (9) in the shackles (6).

4. Fit the attachment bolts (7) and nuts (8) and
tighten the bolts and nuts to the specified
tightening torque, see “Technical data”.

5. Tighten the attachment bolts (10) of the
bearing bush covers (11) to the specified
tightening torque, see “Technical data”.

4

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STABILISERS AND TORQUE RODS

Removal and installation LF45/55 series

2.9 REMOVAL AND INSTALLATION, STEERED REAR AXLE STABILISER LF55

FAN

4

3

6

9

4

12

11

1

2

6

1

5

10

9

8

7

Removal, steered rear axle stabiliser bar
LF55 FAN

1. Remove the lock nuts (7) from the torque
rod balls (5) on the side of the stabiliser bar
(1) and press the balls out of the stabiliser
bar.

2-16

C9 00 399

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9

STABILISERS AND TORQUE RODS

LF45/55 series Removal and installation

2. Remove the attachment bolts (12) together
with the retaining plates (11) that are
mounted to the stabiliser brackets (9) of the
stabiliser bar.

3. Remove the stabiliser together with the
bearing bushes (10) out of the supports (9).

4. Remove the lock nuts (4) from the torque
rods on the chassis side and press the
torque rods out of the spring stop brackets.

Installation, steered rear axle stabiliser bar
LF55 FAN

1. Check the condition of the bearing
bushes (10) and the torque rod ball joints
(3 and 5).

2. Install the torque rods to the spring stop
brackets. Tighten the lock nuts (4) to the
specified tightening torque, see “Technical
data”.

3. Turn the bearing bushes (10) on the
stabiliser bar (1), so that the bearing bushes
(10) can be positioned in the brackets (9).

4

4. Fit the stabiliser bar (1).

5. Check whether the stabiliser bar is situated
in the centre of the vehicle. Move the
positioning clamps, if necessary.

6. Fit the retaining plates (11), using the
attachment bolts (12). Screw in the
attachment bolts evenly and tighten them to
the specified torque. See “Technical data”.

7. Fit the torque rod balls (5) to the stabiliser
bar (1). Tighten the lock nuts (7) to the
specified tightening torque, see “Technical
data”.

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2-17

4

STABILISERS AND TORQUE RODS

Removal and installation LF45/55 series

9

2-18

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9

STABILISERS AND TORQUE RODS

LF45/55 series Disassembly and assembly

3. DISASSEMBLY AND ASSEMBLY

3.1 DISASSEMBLY AND ASSEMBLY, STABILISER BAR / TORQUE ROD

SILENTBLOCK WITH RUBBER CASING

Notes

- The silentblocks for the stabiliser bar and
the stabiliser bar shackle are identical to
one another.

- The silentblock should be fitted using
special tool (DAF no. 1310476). It is not
possible to install the silentblock
undamaged, without using this puller.

- The stabiliser bar need not be removed
when replacing the silentblocks on the
stabiliser bar.

Removing silentblock with rubber casing

1. Force the silentblock (1), using the puller
(A), special tool (DAF no. 1310476) from
the stabiliser bar (2) or the stabiliser bar
shackle (2).
Before fitting the puller, apply a lubricant to
the contact surface of the puller or the
silentblock, for example tyre grease or a
soap solution.

A12A

4

Installing silentblock with rubber casing

1. Before fitting the puller, apply plenty of
lubricant to the outer circumference of the
new silentblock (1) and the contact surface
of the puller/silentblock, for example tyre
grease. Never apply any grease or oil
product to the new silentblock.

2. Place the guide sleeve (B), which forms part
of the puller, on the stabiliser bar or the
shackle.

3. Place the new silentblock (1) on guide
sleeve (B) and, using puller (A), special tool
(DAF no. 1310476), pull the silentblock (1)
into the stabiliser bar (2) or the shackle (2).

A

C9 00 308

1

BA2

C9 00 135

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3-1

4

STABILISERS AND TORQUE RODS

9

Disassembly and assembly LF45/55 series

4. Pull the silentblock into the eye until the
collar of the silentblock has been pulled fully
through the eye.
Remove the guide sleeve (B) and, if
necessary, slightly force the silentblock
backwards so that the collars of the
silentblock protrude from both sides of the
stabiliser bar or the shackle. See arrows in
drawing.

C9 00 307

3.2 DISASSEMBLY AND ASSEMBLY, STABILISER BAR / TORQUE ROD

SILENTBLOCK WITH STEEL CASING

Notes

- The silentblocks with steel casing should be
fitted using special tool (DAF no. 1310479).
It is not possible to install the silentblock
undamaged, without using this puller.

- The stabiliser bar need not be removed
when replacing the silentblocks.

Removing silentblock with steel casing

1. Fit the thrust piece with the smallest
diameter (B in the drawing) on the puller
(A), special tool (DAF no. 1310479).

2. Apply a lubricant to the thrust piece, for
example tyre grease, and fit the puller.

3. Using the puller, force the silentblock from
the stabiliser bar.

12ABA

C9 00 149

3-2

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9

STABILISERS AND TORQUE RODS

LF45/55 series Disassembly and assembly

Installing silentblock with steel casing

1. Place the thrust piece with the largest
diameter (C in the drawing) on the
puller (A).

2. Apply for example tyre grease to the thrust
piece, and place the puller (A) with the
silentblock (1) on the stabiliser bar (2).

3. Force the silentblock into the stabiliser bar
using the puller. The thrust piece (C) must
just touch the stabiliser bar.

4. Check whether the two sides of the
silentblock protrude equally out of the
stabiliser bar.

2ACA 1

3.3 DISASSEMBLY AND ASSEMBLY, TRANSVERSE GUIDE TORQUE ROD

MOUNTING RUBBER, AIR-SPRUNG REAR AXLE LF45

Diassembling the transverse guide torque
rod mounting rubber, air-sprung rear axle
LF45, rear axle side

Note:

The mounting rubber is fitted at an angle (A) in
the eye of the torque rod, on the side of the rear
axle.

C9 00 150

4

1. Remove the torque rod from the vehicle.

2. Drive the pin and rubber bush unit from the
eye of the torque rod.

Assembling the transverse guide torque rod
mounting rubber, air-sprung rear axle LF45,
rear axle side

1. Apply a thin film of acid-free petroleum jelly
or tyre grease to the rubber.

2. Force the mounting rubber at the right
mounting angle (A) in the eye of the torque
rod. See “Technical data” for the correct
mounting angle (A).

3. Force the mounting rubber so far until the
rubber collars protrude an equal distance on
both sides of the eye.

4. Fit the torque rod to the vehicle.

A

C9 00 408

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3-3

4

STABILISERS AND TORQUE RODS

9

Disassembly and assembly LF45/55 series

Disassembling the transverse guide torque
rod mounting rubber, air-sprung rear axle
LF45, chassis side

1. Remove the torque rod from the vehicle.

2. Drive the pin and rubber bush unit from the
eye of the torque rod.

Assembling the transverse guide torque rod
mounting rubber, air-sprung rear axle LF45,
chassis side

1. Apply a thin film of acid-free petroleum jelly
or tyre grease to the rubber.

2. Force the pin in the eye of the torque rod.
Make sure that the bolt holes are parallel
with the torque rod.

3. Force the mounting rubber so far until the
rubber collars protrude an equal distance on
both sides of the eye.

4. Fit the torque rod to the vehicle.

3.4 DISASSEMBLY AND ASSEMBLY, TRIANGULAR LINK SILENTBLOCK,

AIR-SPRUNG REAR AXLE LF55 13-15 TON GVW

Disassembly, triangular link silentblock,
air-sprung rear axle LF55 13-15 ton GVW

1. Remove the triangular link from the vehicle.

2. Remove the silentblock (1) from the
triangular link (2) using a puller. Make sure
that the puller rests on the outer rim (A) of
the silentblock (1).

Assembly, triangular link silentblock,
air-sprung rear axle LF55 13-15 ton GVW

1. Clean the chamber in the triangular link.

2. Apply a thin layer of acid-free petroleum
jelly to the outer shell of the new silentblock.

3. Force the silentblock into the triangular link.
Make sure that the puller rests on the outer
rim (A) of the silentblock.

4. Force the silentblock into the triangular link
so that both sides of the silentblock are
equally far into the triangle chamber.

5. Fit the triangular link to the vehicle.

A

2

1

C9 00 407

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STABILISERS AND TORQUE RODS

LF45/55 series Disassembly and assembly

3.5 DISASSEMBLY AND ASSEMBLY, TRIANGULAR LINK MOUNTING RUBBER,

AIR-SPRUNG REAR AXLE LF55 13-15 TON GVW

Disassembly, triangular link mounting rubber

1. Remove the triangular link from the vehicle.

2. Remove the mounting rubber (1) from the
triangular link (2) using a puller. Make sure
that the puller rests on the outer rim (A) of
the mounting rubber (1).

Assembly, triangular link mounting rubber,
air-sprung rear axle LF55 13-15 ton GVW

1. Apply a thin film of acid-free petroleum jelly
or tyre grease to the rubber.

2. Force the mounting rubber into the
triangular link. Make sure that the puller
rests on the outer rim (A) of the mounting
rubber. Make sure that the bolt holes are
parallel with the triangle rod.

3. Force the mounting rubber into the
triangular link so that both sides of the
mounting rubber are equally far into the
triangle chamber.

4. Fit the triangular link to the vehicle.

A

2

1

4

C9 00 406

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3-5

STABILISERS AND TORQUE RODS

9

Disassembly and assembly LF45/55 series

3.6 DISASSEMBLY AND ASSEMBLY, TRIANGULAR LINK SILENTBLOCK,

AIR-SPRUNG REAR AXLE LF55 16-18 TON GVW

4

Disassembly, triangular link silentblock,
air-sprung rear axle LF55 16-18 ton GVW

1. Loosen the attachment bolts (7) a few turns.

2. Remove the bolt (1).

3. Screw an M24 x 1.5 bolt into the
silentblock ((4). This will remove the
triangular link (2) from the tapered
attachment pin. If the triangular link (2)
cannot be removed, the flange (5) must be
removed from the axle housing and be
forced from the triangular link (2) using a
puller.

4. Remove the attachment bolts (7). Remove
the triangular link from under the vehicle.
This can only be done by two persons
working together.

5. Remove the circlip (3).

6. Remove the silentblock (4) from the
triangular link (2) using a puller. Make sure
that the puller rests on the outer rim of the
silentblock (4).

Assembly, triangular link silentblock,
air-sprung rear axle LF55 16-18 ton GVW

1. Clean the chamber in the triangular link (2).

123

4

56

7

7

C9 00 300

2. Remove all rust and grease from the
tapered part of the flange (5).

3. Apply a thin layer of acid-free petroleum
jelly to the outer shell of the new
silentblocks (4).

4. Position the new silentblock (4) such that
the marking (see arrow) is positioned in
between the torque rods as indicated.

5. Force the silentblock (4) into the triangular
link (2). Make sure that the puller rests on
the outer rim of the silentblock (4).

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9

STABILISERS AND TORQUE RODS

LF45/55 series Disassembly and assembly

6. Fit the circlip (3) as indicated. Make sure
that the entire circlip (3) is positioned
correctly in the groove.

7. Install the flange (5), if removed, on the axle
housing. Check to see if the contact surface
of the flange (5) and the contact surface on
the axle housing are free from grease and
paint. Tighten the attachment bolts (6) to
the specified tightening torque, see
“Technical data”.

8. Install the triangular link (2) under the
vehicle. This will take two persons working
together. Tighten the attachment bolts (7)
by hand.

9. Fit the bolt (1). Tighten the bolt (1) to the
specified tightening torque, see “Technical
data”.

10. Tighten the attachment bolts (7).

123

56

4

7

7

C9 00 300

4

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STABILISERS AND TORQUE RODS

9

Disassembly and assembly LF45/55 series

3.7 DISASSEMBLY AND ASSEMBLY, TRIANGULAR LINK/TORQUE ROD

MOUNTING RUBBER, AIR-SPRUNG REAR AXLE LF55 16-18 TON GVW

Note:

Disassembly and assembly of the mounting
rubbers are identical for the triangular link and
the torque rod.

Disassembly, triangular link/torque rod
mounting rubber, air-sprung rear axle LF55
16-18 ton GVW

1. Remove the triangular link or torque rod
from the vehicle.

2. Remove the circlip (1) and the shim (2).

4

3. Drive the pin and rubber bush unit (3) from
the torque rod housing (4).

Assembly, triangular link/torque rod
mounting rubber, air-sprung rear axle LF55
16-18 ton GVW

1. Apply a thin film of acid-free petroleum jelly
or tyre grease to the rubber.

2. Push the pin (3) into the housing (4). Make
sure that the bolt holes are parallel with the
torque rod.

3. Fit the shim (2).

4. Fit the circlip (1) as indicated. Ensure that
thecirclip(1)iscorrectlyfittedintothe
groove of the housing.

5. Fit the triangular link or torque rod to the
vehicle.

4
2
1

3

W9 03 009

3-8

C9 00 133

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9

LF45/55 series Contents

LEAF SUSPENSION

CONTENTS

Page Date

1. SAFETY INSTRUCTIONS 1-1 0207............................................... ......

2. GENERAL 2-1 0207............................................................ ......

2.1 Description of leaf suspension 2-1 0207...................................... ......

2.2 Overview drawing, spring assembly with bolt attachment 2-2 0207............... ......

2.3 Overview drawing, spring assembly with pin attachment 2-3 0207................ ......

3. REMOVAL AND INSTALLATION 3-1 0207......................................... ......

3.1 Removal and installation, spring assembly with bolt attachment 3-1 0207.......... ......

3.2 Removal and installation, spring assembly with pin attachment 3-3 0207.......... ......

3.3 Removal and installation, steered rear axle spring assembly LF55 fan 3-5 0207.... ......

3.4 Removal and installation, spring bracket 3-7 0207............................. ......

5

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1

LEAF SUSPENSION

Contents LF45/55 series

9

5

2

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9

LEAF SUSPENSION

LF45/55 series Safety instructions

1. SAFETY INSTRUCTIONS

Spring leaves

- Spring leaves should not be subjected to
blasting. Blasting will cause indentations in
the leaf spring which could initiate pitting
corrosion.

- Corrosion should be prevented as this will
considerably shorten the service life of the
spring.

- Any type of damage should be prevented.
Damage will considerably shorten the
service life.

- Spring leaves should not be heated.

- Bear this in mind when welding on the
vehicle. Take precautionary measures
against weld and fire damage (notching
effect).

- Never hit a parabolic spring leaf with a
hammer. This could cause the leaf to break.

- Never replace a single broken leaf within a
spring assembly, because this will
substantially shorten the service life of the
other spring leaves.

5

Spring brackets

Spring brackets should be removed, if:

- there is doubt about the dimensional
accuracy after having been subjected to a
heavy load (e.g. a collision). The spring
bracket should be magnaflux tested.
If cracks are detected, the spring bracket
should be replaced. If it is not possible to
magnaflux test the spring bracket, the
spring bracket should always be replaced.

- such a degree of wear has occurred that it
must be replaced.

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1-1

LEAF SUSPENSION

Safety instructions LF45/55 series

9

5

1-2

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9

LEAF SUSPENSION

LF45/55 series General

2. GENERAL

2.1 DESCRIPTION OF LEAF SUSPENSION

Parabolic springs are used on the LF series

In a parabolic spring all the leaves are
approximately the same length but the thickness
of each leaf varies parabolically along its length.
Except at the centre clamping and at the spring
leaf ends, the spring leaves of a parabolic leaf
spring assembly should not come into contact
with each other. To that end spacer plates have
been fitted between the spring leaves. Because
the leaves of a parabolic spring do not move
over each other, the vehicle is more
comfortable.

Apart from the spring function, the leaf spring
assemblies also have the task of guiding the
axle. This means that braking, driving and lateral
forces are passed on to the chassis via the
spring assembly and the front spring bracket.

During fierce braking on a rough road surface,
the leaf spring and the spring bracket have to
deal with the forces of the weight of the vehicle
(which is increased by driving over holes) and
with the braking forces at the same time. This
results in a considerable total force exerted on
the leaf spring and the spring bracket.

w9 04 002

w9 04 004

5

Spring opening

The spring opening (P in the drawing) indicates
the deflection of the spring.
The spring assembly is tailored to the optimum
spring opening for a laden vehicle. If possible,
check the spring opening on both sides of an
evenly laden vehicle.
As a result of tolerances in the manufacturing
process, the spring openings may differ from
each other when the springs are unloaded, but
are equal when the springs are loaded.
When spring assemblies are new, the difference
in spring opening is small. As a result of settling
of the spring assembly, the difference in spring
opening may increase.
When the springs are loaded they become
longer and the axle will move backwards. If the
left and right spring openings of one axle differ
too much, the result will be misalignment of both
the vehicle and the axle.

P

W9 04 005

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LEAF SUSPENSION

9

General LF45/55 series

2.2 OVERVIEW DRAWING, SPRING ASSEMBLY WITH BOLT ATTACHMENT

Note:

This drawing gives a general view and may
differ from the actual situation on the vehicle.

9

10

11

10

4

12

13

5

1

2

1. Attachment bolt

2. Centring sleeve

3. Spring bracket

4. U-bolt

5. Upper spring seat

6. Shock absorber support

7. U-bolt nut

8. Spring assembly

9. Attachment nut

10. Shackle seat

11. Spring bracket

12. Ring

13. Attachment bolt

3

8

5

6

7

C9 00 305

2-2

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LEAF SUSPENSION

LF45/55 series General

2.3 OVERVIEW DRAWING, SPRING ASSEMBLY WITH PIN ATTACHMENT

Note:

This drawing gives a general view and may
differ from the actual situation on the vehicle.

6

4

3

5

10

2

7
8

1

9

5

11

18
17

12

16

13

15

14

C9 00 326

1. Attachment bolt

2. Mounting bracket

3. Centring pin

4. Silentblock

5. Spring assembly

6. U-bolt

7. Upper spring seat

8. Insert nut for centre bolt

9. Silentblock

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10. Spring bracket

11. Shackle seat

12. Attachment bolt

13. Attachment nut

14. Centre bolt

15. U-bolt nut

16. Shock absorber support

17. Lower block

18. Spacer

2-3

LEAF SUSPENSION

General LF45/55 series

9

5

2-4

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LEAF SUSPENSION

LF45/55 series Removal and installation

3. REMOVAL AND INSTALLATION

3.1 REMOVAL AND INSTALLATION, SPRING ASSEMBLY WITH BOLT

ATTACHMENT

A

1

Support the vehicle securely and
work safely.
Make sure that the axle cannot tilt if
both spring assemblies are
removed at the same time.

Removal, spring assembly with bolt
attachment

1. Remove all components which are in the
way when removing the attachment bolts.

2. Remove the U-bolt nuts (2).

3. Loosen the attachment bolts (1, 3 and 4) of
thespringassembly.

4
3

2

C9 00 411

5

4. Jack up the chassis until the spring
assembly is free of stress.

5. Mark the position of the bolt heads (3).
Remove the attachment bolts (1 and 3).

6. Jack up the chassis until the spring
assembly is released from the spring
bracket.

7. Make sure that the spring assembly cannot
tilt after the U-bolts have been removed.

8. Remove the U-bolts.

9. Mark the position of any wedge (if present).

10. Remove the spring assembly safely. This
can only be done by two persons working
together.

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5

LEAF SUSPENSION

9

Removal and installation LF45/55 series

Installation, spring assembly with bolt
attachment

1. Check that all contact faces are free of dirt,
grease and paint.

2. If applicable, fit the wedge in the correct
position.

3. Install the spring assembly to the spring
plate/shock absorber plate. This can only be
done by two persons working together.
Make sure that the centre bolt, if present,
fits into the centring hole.

4. When reusing the U-bolts, check for
corrosion and damage. Replace them if
necessary. If they are to be re-used,
thoroughly clean the thread and remove any
paint.
If hexagonal U-bolt nuts are used, fit a
hardened steel ring under the U-bolt nut.

5. Fit the U-bolts and hand-tighten the U-bolt
nuts (2).

6. Lower the chassis or raise the axle such
that the attachment bolts can be installed.
Press the centring sleeve partly back, if
necessary. Fit the attachment bolts (1 and

3) and hand-tighten them.

7. Lower the chassis. Tighten the U-bolt nuts
(2) evenly to the specified tightening torque,
see “Technical data“.

8. Apply grease to the threaded ends of the
U-bolts.

9. Adjust the chassis to the prescribed height
(A), see “Technical data”. Note, when
tightening the frontmost and rearmost blade
spring bracket of the front axle, that height
(A) differs.

10. Tighten the attachment bolts (1, 3 and 4).

11. Fit all removed parts, if applicable.

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LEAF SUSPENSION

LF45/55 series Removal and installation

3.2 REMOVAL AND INSTALLATION, SPRING ASSEMBLY WITH PIN

ATTACHMENT

A

4

1

3

Support the vehicle securely and
work safely.
Make sure that the axle cannot tilt if
both spring assemblies are
removed at the same time.

Removal, spring assembly with pin
attachment

1. Remove all components which are in the
way when removing the attachment bolts.

2. Remove the U-bolt nuts (2).

3. Loosen the attachment bolts (1, 3 and 4) of
thespringassembly.

4. Jack up the chassis until the spring
assembly is free of stress.

5. Mark the position of the bolt heads (3).
Remove the attachment bolts (1 and 3).

6. Jack up the chassis until the mounting
brackets at the front of the spring assembly
are clear of the support. If necessary, use a
rim tool to detach the mounting brackets.

2

C9 00 412

5

7. Make sure that the spring assembly cannot
tilt after the U-bolts have been removed.

8. Remove the U-bolts and the upper spring
seat.

9. Mark the position of any wedge (if present).

10. Remove the spring assembly safely. This
can only be done by two persons working
together.

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3-3

5

LEAF SUSPENSION

9

Removal and installation LF45/55 series

Installation, spring assembly with pin
attachment

1. Check that all contact faces are free of dirt,
grease and paint.

2. If applicable, fit the wedge in the correct
position.

3. Install the spring assembly to the spring
plate/shock absorber plate. This can only be
done by two persons working together.
Make sure that the centre bolt, if present,
fits into the centring hole.

4. When reusing the U-bolts, check for
corrosion and damage. Replace them if
necessary. If they are to be re-used,
thoroughly clean the thread and remove any
paint.
If hexagonal U-bolt nuts are used, fit a
hardened steel ring under the U-bolt nut.

5. Fit the upper spring seat and the U-bolts
and hand-tighten the U-bolt nuts (3).

6. Lower the chassis or raise the axle such
that the mounting brackets and attachment
bolts (1 and 3) can be installed. Ensure that
the centring pins at the front are located
exactly in front of the centring holes in the
mounting brackets.

7. Lower the chassis. Tighten the U-bolt nuts
(2) evenly to the specified tightening torque,
see “Technical data“.

8. Apply grease to the threaded ends of the
U-bolts.

9. Adjust the chassis to the prescribed height
(A), see “Technical data”. Note, when
tightening the frontmost and rearmost blade
spring bracket of the front axle, that height
(A) differs.

10. Tighten the attachment bolts (1, 3 and 4).

11. Fit all removed parts, if applicable.

3-4

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LEAF SUSPENSION

LF45/55 series Removal and installation

3.3 REMOVAL AND INSTALLATION, STEERED REAR AXLE SPRING

ASSEMBLY LF55 FAN

Support the vehicle securely and
work safely.
Make sure that the axle cannot tilt if
both spring assemblies are
removed at the same time.

Removal, steered rear axle spring assembly
LF55 FAN

1. Remove the stabiliser bar together with the
torque rods.

2. Jack up the chassis, until the spring
package is clear of the spring stop.

3. Remove the spring stop.

4. Remove the U-bolt nuts.

5. Remove the attachment bolts by means of
which both spring packages are attached to
the fixing bar for the air bellows.

5

6. Jack up the fixing bar for the air bellows.

7. Remove the U-bolts and the upper spring
seat.

8. Remove the two clamp bolts from the lower
spring seat.

9. Check that the spring package is not under
stress.

10. Remove the automatic lubricating nipple (5)
from the shackle pin (3).

11. Remove the clamp bolts from the shackle
pin (3) and press the shackle pin (3) out of
the spring bracket (1) and the leaf spring
(2). Prevent the spring assembly from tilting
after removal of the shackle pin.

12. Remove the spring assembly safely. This
can only be done by two persons working
together.

1
2

3

5

4

C9 00 398

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3-5

LEAF SUSPENSION

9

Removal and installation LF45/55 series

Installation, steered rear axle spring
assembly LF55 FAN

1. Check that all contact faces are free of dirt,
grease and paint.

2. Install the spring assembly to the lower
spring seat. This can only be done by two
persons working together. Make sure that
the centre bolt fits properly into the centring
hole.

3. Fit the two clamp bolts in the lower spring
seat and hand-tighten them.

4. Put the U-bolts in place, preferably use new
ones. When reusing the U-bolts, check for
corrosion and damage. Thoroughly clean
the threads and remove any paint from
them.

5. Fit the upper spring seat and the U-bolts.
Hand-tighten the U-bolts.

5

6. Apply a thin layer of grease to the shackle
pin.

7. Fit the shackle pin (3) in the spring bracket
(1) and the leaf spring (2) so that the
connection for the automatic lubricating
nipple (5) is on the inside of the chassis and
the notches (4) for the clamp bolts are on
the underside.

8. Fix the clamp bolts of the shackle pin.

9. Fit the automatic lubricating nipple (5) in the
shackle pin (3).

10. Lower the fixing bar for the air bellows onto
the leaf springs. Install the attachment bolts
and tighten them.

11. Fit the spring stop.

12. Lower the chassis. First tighten the U-bolt
nuts (1) evenly to the specified tightening
torque, see “Technical data”. Then tighten
the two clamp bolts (2) in the lower spring
seat of the spring assembly.

13. Apply grease to the threaded ends of the
U-bolts.

1
2

3

5

4

C9 00 398

2

14. Fit the stabiliser bar with the torque rods.

3-6

1

C9 00 402

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9

LEAF SUSPENSION

LF45/55 series Removal and installation

3.4 REMOVAL AND INSTALLATION, SPRING BRACKET

Support the vehicle, axle or spring
assembly securely and work safely.

Removal, spring bracket

1. Jack up the chassis until the spring or the
yoke is free of stress.

2. Removethespringoryokebracket.

3. Jack up the chassis further until the spring
assembly or the yoke has been released
from the spring bracket.

4. Watch the position of the attachment bolts
(in view of the difference in length). Remove
the attachment bolts. Remove the spring
bracket from the chassis.

Installation, spring bracket

1. Install the spring bracket in the same
position as before removing it. Place the
spring bracket on the spring-bracket outline
on the chassis.

5

2. Check the contact surfaces of spring
bracket, chassis and stiffening plates.
These should be absolutely free from dirt
and grease.

3. Fit the attachment bolts in the correct
position and the correct location.

4. Tighten the attachment bolts of the spring
bracket.

5. Fit the spring or yoke bracket. Caution: use
a new break nut to attach the yoke. For the
breaking torque of the break nut, see
“Technical data”.

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3-7

LEAF SUSPENSION

Removal and installation LF45/55 series

9

5

3-8

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