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REAR SUSPENSION
Leaf Springs
Page 9-2
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
9
LEAF SPRINGS
See General Warning on page 1-1.
LEAF SPRING REMOVAL – 800 AND 810
1. Loosen, but do not remove, lug nuts on tire and wheel assembly on the side from which the spring is to
be removed. Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack.
Position jack stands under the frame crossmember between the spring mount and the side stringer, just
forward of each rear wheel. Lower the vehicle to let the jack stands support the vehicle
(Figure 9-1,
Page 9-2)
.
See following WARNING
.
ý
WARNING
• Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic
floor jack) with 1000 lb. (454 kg) minimum lifting capacity. Do not use lifting device to hold
vehicle in raised position. Use approved jack stands of proper weight capacity to support the
vehicle and chock the wheels that remain on the floor. When not performing a test or service
procedure that requires movement of the wheels, lock the brakes.
2. Place a floor jack under the transaxle differential casing to support (but not lift) the drivetrain. Raise it just
enough to relieve tension on the shock absorbers without compressing them.
3. Remove the tire and wheel assembly on the side from which the spring is to be removed.
4. Remove the bow-tie pin (1) and the clevis pin (2) at the brake lever and brake cable connection and pull
the clevis (3) away from the lever
(Figure 9-2, Page 9-2)
. Detach the brake cable from the shock mount
bracket (16)
(Figure 9-3, Page 9-3
and
Figure 9-4, Page 9-5)
.
5. Remove the nut (5), cup washers (9), and rubber bushings (10) from the lower mounting stem of the
shock absorber.
6. Remove the nuts (14) and the U-bolt (11) securing the spring to the jounce bumper bracket (20) and
spacer (17) to the transaxle. Remove the shock mount bracket (16), angle bracket (13) and the U-bolt.
Figure 9-1 Support Vehicle on Jack Stands
Figure 9-2 Disconnect Brake Cable
1
2
3
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