192004494 - 4420D24 REAR SUSPENSION AXLE BUSH - REPLACE WITH CROSSMEMBER OR AXLE REMOVED (Station Wagon, 5 doors)

Removing ( Refitting )

If a hydraulic bush is being replaced, the seat of the bush replaced must be marked clearly and permanently (e.g. with indelible paint) because it is ABSOLUTELY PROHIBITED to carry out the operation more than once on the same bush.

1. Undo the fixing bolt (1a) and separate the fixing bracket (1b) from the rear axle (1c).

the bush is hydraulic, therefore it contains an oily substance so CARE should be taken during its removal because some of this oily substance could escape. The area where the operation is carried out has many structural welds that could make the positioning of the tools difficult as a result. DO NOT ALTER OR REPAIR WELDS. The axle is painted to make it resistant to rust and oxides therefore take CARE that the tools do not scratch the layer of paint.

Place the axle in the vice.Place some teflon or rubber between the jaws and the axle.1. With the help of a large, flat screwdriver and using leverage at the rubber buffers, remove the bevel from the spacer. 1. With the help of a large, flat screwdriver and using leverage at the rubber buffers, remove the bevel from the spacer. 1. Cut the outer lip of the bush at the base using a special cutter. 1. Cut the inner lip of the bush at the base using a special cutter. 1. Fit the extractor on the portion of the seal between the end of travel for the fitting of the bush and the welding. 1. Fit the extractor (1a) matching it with the extractor (1b) and use the tool (1c) as a reference between the bush and the extractor.

	Description	Code	Function
1c	Spacer	2.000.005.00	Extract the bush

2. Use the extractor and remove the bush by about 2 mm as illustrated in the diagram.

Take great care during the above operation that no oily substances escape. Whilst cutting take GREAT CARE not to damage the metal seal of the axle.

1. Using a hand saw (1a) or possibly a belt saw or a power saw, completely remove the inner face of the bush. 1. With the assistance of a second operator, secure the axle (1a) safely as illustrated in the diagram using a special safety chain (1b) with a hydraulic lift (1c) to help.

the bush should be removed from the inside towards the outside of the vehicle.

1. Place the axle in the press.2. Use the tool (2a) for counter-torque and the tool (2b) for removing the bush.

	Description	Code	Function
2a	Reaction tool	2.000.002.00	Counter-torque

	Description	Code	Function
2b	Extractor	2.000.003.00	Removing the bush

Refitting ( Removing )

No residues of the bush removed should remain inside the axle seal therefore the inside of the seal should be thoroughly cleaned.

Apply grease (MOLYCOTE PG21) to the outer metal area of the new bush.1. Use the tool as a support for fitting the new bush.

	Description	Code	Function
1	Reaction tool	2.000.002.00	Fitting the bush

2. Before fitting the new bush position the arrow on the bush as illustrated in the diagram in the direction of travel of the vehicle (opposite the bead of structural sealant) aligned with the bead of sealant.

the fitting load SHOULD NEVER BE APPLIED to the thrust washer. The minimum fitting load should not be less than 500 KG.

1. Position the tool so that the three spacers fit perfectly in the three slots on the bush thrust washer, then proceed with fitting the bush on the press.

	Description	Code	Function
1	Fitting tool	2.000.004.00	Fitting bush

This operation is completed when the bush and the seal are in contact.

The protective paint may be damaged where the tools and the axle seal have made contact therefore the damaged areas must be renewed by applying special anti-rust protective paint.

Remove the axle from the press and release it from the hydraulic lift safety chain.1. Place the fixing bracket (1a) in position on the rear axle (1b) and screw in the bolt (1c) without tightening it.2. Rotate the fixing bracket so that the distance between the upper plane and the axle is 30.6 mm as illustrated in the diagram with a tolerance of +/- 0.2 mm making sure that the measurement angle between the measurement plane of the axle and the gauge is 90°.Tighten the fixing bolt (1c) to the recommended torque.

	Value daNm	Fastening	Component	Ø
1c	9.5	Bolt	-	-