Front Damper/Spring Replacement

Exploded View
Special Tools Required
NOTE: When compressing the damper spring, use a commercially available strut spring compressor (Branick MST-580A or Model 7200, or equivalent). According to the manufacturer's instructions.
Removal
  1. Remove the front wheel.
  1. Remove the wheel sensor harness clips (C) and the brake hose bracket (D) from the damper. Do not disconnect the wheel sensor connector.
  1. Remove the damper pinch bolts (A) and self-locking nuts (B) from the damper (C).
  1. Remove the service lid (A) and the cap (B).
  1. Remove the three flange nuts (C) from top of the damper.
    NOTE:
    • Damper springs are different, left and right. Mark the springs L and R before you continue.
    • Be careful not to damage the body.
  1. Remove the damper assembly (A).
Disassembly/Inspection
  1. Compress the damper spring, then remove the self-locking nut (A) using special tool while holding the damper shaft (B) with a hex wrench (C). Do not compress the spring more than necessary to remove the nut.
  1. Release the pressure from the strut spring compressor, then disassemble the damper as shown in the Exploded View.
  1. Reassemble all the parts, except for the upper spring mounting cushion, the dump stop, and the damper spring.
  1. Compress the damper assembly by hand, and check for smooth operation through a full stroke, both compression and extension. The damper should extend smoothly and constantly when compression is released. If it does not, the gas is leaking and the damper should be replaced.
  1. Check for oil leaks, abnormal noises, and binding during these tests.
Reassembly
  1. Install the spring (A) on the damper mounting bearing (B) by align the stopped part (C).
  1. Compress the damper spring.
  1. Install all the parts except the self-locking nut onto the damper unit (A) by referring to the Exploded View.
  1. Align the bottom of the spring and the stepped part of the lower spring seat.
  1. Align the angle of the damper bracket (A) and the damper mounting base (B) so that the ‘‘↔'' stamp (C) points toward the outside.
  1. Install a new self-locking nut (A) using special tool.
  1. Hold the damper shaft (B) using a hex wrench (C), and tighten the new self-locking nut to the specified torque value.
Installation
  1. Install the damper assembly (A) onto the frame.
  1. Loosely install new flange nuts (A).
    NOTE: Install the cap (B) and the service lid (C) after tightening the flange nuts to the specified torque value.
  1. Loosely install new damper pinch bolts (A) and new self-locking nuts (B) to the damper (C).
  1. Loosely install the stabilizer link (A) to the damper.
    NOTE: Use the new flange nut.
  1. Install the wheel sensor harness clip (B) and the brake hose bracket (C) to the damper (D).
  1. Raise the front suspension with a floor jack to load the suspension with the vehicle's weight.
  1. Tighten the damper pinch bolts to the specified torque value.
    NOTE: Tighten it only in the bolt side.
  1. Tighten the flange nuts on top of the damper and the stabilizer link flange nut to the specified torque values.
  1. Install the cap and the service lid.
  1. Install the front wheel.