Technical rear suspension change tips

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Technical rear suspension change tips

Ducato man

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Jan 7, 2009
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west yorkshire
Got the usual clunking and groaning on the rear suspension, looks like rear bushes have split. Plus other bits and bats.

Ive picked up a complete suspension of a 63000 multipla.

Just after tips on changing it. How long and what are the pit falls.

Got access to garage ramps the ones that go under the chassis 4 leg type.

And all tools too.
 
I'm actually going to do the same thing soon, as in 1st try tomorrow!, will add new entry asap, I have bought a better complete subframe from an older multi probably @ 2003 to replace a 2005 one which is much worse and a certain fail next mot, it also has slightly different abs sensor plugs, so will be trying a few different options....fingers very crossed and touching wood.
:)
 
When I replaced my fixed rear axle, I disconnected everything from it, and lowered the axle with the braking system still intact on the car. This might avoid any mismatch between the old and new parts, unless there are differences between the 2003 and 2005 rear axles.
 
Just changed the rear suspension, ie part 1, unfinished.
I was expecting to make some new brake pipes but was lucky with the older subframe brake pipes, they came off without twisting and breaking...
So Tip 1 : Be prepared to make a new brake pipe, e.g using brake pipe flare tool, metric fittings and brake pipe to the ready, or buy new.
I was expecting 1 of the 4 bolts holding the subframe on to be seized, but was lucky, they came off fine, however Tip2 : use 2 hydraulic jacks (with a few bricks..) to hold up either side of the axle, to take up the tension so the bolts are not fighting the weight of the subframe and quietly stripping...
Undo the abs sensors in the usual way, ie withdraw the trim under the passenger door, unclip the fiddly abs connector with screwdriver fiddling, pull from underneath floor hole etc, tidy up.
Tip 3 : There's loads of clips etc holding the brake pipes on, especially above the central axle, plus loads of toe wrap fiddlies, ie dont lower the suspension, using the two jacks with brake pipes attached to the body...
Obvious Tip 4 : Use a rod in wiggly fashion in the 4 bush bolt holes to test the state of the replacement setup before fitting..
Obvious Tip 5 : Do the same for the swing arm bearings...

My abs sensors were the old type, so still testing them before I try to remove the old ones, but I need to find a four leaf clover first.
I'm getting an ABS system error at the moment, which is due to the sensors, I've test connect them using a pins and wires lashup but still no joy, I have left it for my next weekend, need a food, shower, and cup of tea, whilst researching the wonderfull world of abs sensor testing....
 
Part 2...
ABS Sensor issues....
Managed to remove ABS sensors from original hubs without killing them!
Used lots of WD40, night before, spraying a few times, got large mole grips, attached them as tight as I dared to the main sensor body, and twisted, whilst pulling to withdraw, miraculously, they eventually came out, intact, result.
After using these to test against older sensors on the replacement axle, found one of the replacement axle sensors was kaput, confirmed when I tried to remove it, came out very easily, with holding bolt loose. Working sensors fitted, ABS light out.
So a good result overall, hope this helps other conservationists trying to keep these endangered species alive.
 
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