1980 SKODA 120 LS Workshop Manual

wi
prl
tht
rer
oul MT
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.a
Fig
Dis S
boll
6-1C
rubl
ovo
exomple
50,000 km ond
more, check the wheel
comber ond prepore
suitoble woshers for its
correction. 2. Jock up the cor ond support the body on
both sides to relieve the front wheels, ond
remove the wheels. 3. Proceeding from
inside the luggoge boot,
remove covers protecting
the threods of the
shock-obsorber piston
rods ond screw off the
nuts. Retoin the piston
rod by holding its flot-
tened end.
b) Operotions inside the cor
4. Remove the steering wheel, the steering
column cowling, ond detoch the steering
shoft
from the body -
see Chopter 7.8.
c) Operotions from under the cor
5. Remove the bolt of the connection of the
steering shoftwith the steering box ond releose
the shoft sleeve from the connection by pull-
ing the steering geor
inside the cor.
6. Slocken the nuts of the bottom wishbone
pins fostening the front oxle to the brocket on
the body until the woshers of the brockets ore
releosed. 7. Detoch the onti-roll bor brockets from
the
body ond disconnect the rubber broke hoses
from the front broke systems.
Before discon-
necting the hose, cleon thoroughly the hose
connector ond its surroundings to prevent
foreign motter from getting
into the broke
system. For the some reoson,
wrop the
hose
ends in o cleon rog. Toke
the some precoutions
with the disconnected broke piping.
8. Ploce o roll-o-cor
iock under the oxle ond
remove the bolts (two
on either side
of the tele-
scopic shock obsorber) fostening the oxle to
the body from obove. 9. Compress the telescopic shock obsorbers,
lower the
iock, ond
move it with the oxle from
under the cor.
6.3 REFITTING FRONT AXLE IN
CAR
1. To reinstoll the oxle in
the cor, reverse the
procedure of its removol, i.
e., begin with the
porogroph 9 ond proceed
to the porogroph
1.
Coot the rubber
cup with greose
ot the point
of its contoct with the steering shoft.
2. While reconnecting the broke hoses, ob-
serve the utmost cleonliness ond bleed the front
wheel brokes if no other ports
of the broke
system hos been dismontled. (lf
such o dis-
montling hos token ploce,
bleed the brokes of
oll wheels ofter hoving fully reclosed
the broke
circuit). 3. Turn the wheels in the stroight oheod di-
rection before connecting the steering shoft
with the steering box. Fit the steering wheel tentotively
ond odiust the direction indicotor
switch -
see Chopter 13.17.
4. Using the steering wheel, tunn the wheels
into full lock positions
to moke sure thot the
lock ongle is correctly limited by the king pin
socket stops -
see Chopter 6.5, porogroph
36.
5. Adiust the toe-in -
see Chopter 6.1.
6.4 DISMANTLING
FRONT AXLE
No speciol instructions ore required for
dis-
montling mony of the subossemblies. Accord-
ingly, only the bosic dismontling procedure
will be
deolth with ond porticulors
will be men-
tioned only os fon
os they ore necessory for the
sequence of operotions ond the use of iigs.
Ports which con be dismontled witlrout re-
moving them from the cor ore the wheel hubs
and beorings, the broke mechonisms, steering
orms, shock obsorbers, ond the
onti-roll bor.
lf ony odditionol ports
hove to be dismontled,
remove the oxle from the cor ond dismontle it
on the stond.
Dismontling Wheel Hubs
ond Beorings
1. Dismontle the broke mechonism os per
Chopter 9.1 ond remove
the wheel hub
cop
using the MP 6-124 drog. When using the MP
6-136 pull-off
cortridge, the hub cop hos to be
prised off with o
tyre lever or o similor tool.
Now remove the costelloted nutwith its wosher
ond pull
out the hub,
ossisting the removol
with
light blows of o mollet, if necessory.
2. Toke out the inner port
of the outer beor-
ing, then the seoling ring, ond, f
inolly, the inner
port of the reor beoring (cone
with topered
rollers). Prise out the seoling ring using o
scrrewdriver. Proceed corefully olong the ring
circumference to ovoid distorting the ring which
Fig. 6.4/1 -
Removing Hub Cop Using
MP 6-124 Drog
106

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Fig.
Hol
over t
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6.5 F
The
which
provid
$H
Remove the csstelloted
nut ond wosher from
the steering orm, screw down the MP 6-105
cotridge on the threod of the orm, ond drive out
the orm.
Removing Steering Knuckles,
Springs,
ond Wishbone
Suspension
1. Remove tlre shock obsorber ond fit the
MP 6-106 spring
instoller in its ploce from obove.
lnstoll o horseshoe wosher on the sphericol end
of the instoller tie-rod possing
tlrrough the
coil
spring ond the bottom wishbone, ond compress
portly the spring (for
fitting the instoller see
Fig. 6.5/4).
2. Screw off the
costellqted nuts of the upper
wishbone pin
ond the bolt of the lower wish-
bone suspension, ond drive out the wishbone
Fig. 6.415 -
Pressing Out Pins of Steering Bcrll
Joints Using MP 6-138
Drog
Fig.6.416 -
Driving Out Steering Arm Using
MP 6-105 Cortridge pin.
lf driving out is impossible, use the MP
6-107 drrog (remover).
Rotote slightly the
flonges of the drog to
breok it up in two ports,
fit it os o yoke
over
the upper wishbone,
clomp it in position
by
rototing its heod, ond screw in the centre bolt
to press
out the wishbone pin.
3. Drive out the bolt of the lower wishbone
suspension ond remove the steering knuckle
from the lower wishbone.
4. Screw off the nut of
the king pin
ond pull
off the king pin
socket using the MP 6'111 drog.
Refer to the following chopters for
further
dismontling of the steering knuckle, the king
pin ond its socket, ond their repoirs.
Hoving removed the spring instoller,lift owoy
the spring ond remove
the wishbones.
5. When removing the upper wishbone, mork
the thickness of the open (horseshoe) woshers
irrserted between the brocket ond oxle body on
tlre individuol brockets. The
woshers ore 3
mm
onct 1 mm thick so thot if there ore, for exomple,
one 3 mm ond two 1
mm woshe'rs, mork the
thickness of 5 mm on the brocket. Also toke
into occount the likely necessity of o correction
of the wosher thickness -
see Chopter 6.2, poro-
groph 1. When reinstolling the upPer wishbone, fit
wo;hers of the morked down thickness to sim'
plify the cdjustnrent of the wheel comber.
Fig.6.4l7 -
Pressing Out Upper Wishbone Pin
Using MP 6-'107 Drog
6. Remove the nuts of the wishbone pin,
clomp the eye of the wishbone ond brocket in
o vice (see
Fig.6.5/3) ond use o screwdriver to
push the circlip out of the groove
to the nor'
rowed down port
of the pin.
Sllp the pin out of
the other eye of the wishbone ond push
out olso
the other circlip.
108

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Pock with
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press it over the nut till it snops home in po-
sition on the lever.
Refitting Upper Wishbones 4. When refitting wishbones
which hove
been olreody used in the cor ond which ore
rother doubtful (for
exomple,
o distortion is
suspected os o result of o crosh), inspect them
corefully ond stroighten
them, if necessory.
5. Press rubber bushes into the eyes from the
outer side. To focilitote their sliding in, dip
them in petrol
or soop
woter (suds).
Put the
bushes into the wishbone eyes with their lorger
diometer first ond push
them so for thot they
protrude from the eye by the some length on
either side. Blow off the soop woter with com-
pressed oir so thot it does no ossist the slipping
of the bush during the next operotion.
6. Slip the spocing tube on the MP 6-122 driIt,
dip the drift in petrol
or soop woter, ond, forcing
it through the rubber
bush, press
the spocing
tube into the bush.
Before pressing
it in, turn the spocing tube so
thot the
ioint of the
pockoged
bush foces the
top side of the wishbone.
7. Threod the wishbone pin
through the eye,
slip on it the cup with its dished port
focing
the bush, two wishbone brockets with the lugs
pointing owoy from the wishbone, ond the other
Fig.6.5/2 -
Pressing Spocing Tube
into
Bush Using MP 6-122 Drift cup with
its dished port
tbword the
other rubber
bush, ond threod the pin
through the other eye.
8. Push the brockets towords the eyes ond
slip two circlips on the norrowest port
of the
pin. To slip them on, hold them with their un-
connected ends on the pin
ond press
down. Use
o screwdriver to move one of the circlips into
the groove
of the pin,
ond push
the pin
with the
circlip in position
into the brocket. Clomp the
other brocket with the wishbone eye
in o vice
to compress the rubber bush, ond slip on the
other circlip. 9. lnsert the rubber deod stop into the wish'
bone.
Fig. 6.5/3- Instolling Circlip into Pin Groove
10. Reinstoll the
two ossenrbled wishbones
on the oxle body. Fit o ploin
wosher under the
spring woshers of the lug bolts. Instoll, from
obove, one 'l
mm or one 3 mm open (horseshoe)
wosher or the previously
removed woshers on
the horizontcrl bolts between the brocket ond
the oxle body lug. First tighten the horizontol ond then the ver-
ticol bolts. Fit the
cups on the wishbone pin
ond screw
down both nuts.
Refitting Lower Wishbones
11. Inspect the wishbones os per porogroph 4.
lnsert rubber bushes in
the eyes of the wish-
bone fnom its inner side. Threod the wishbone
pin through the eye, slip
on it the cup os with
the upper wishbone, then two pin
holders with
the recesses ot the inner hole focing eoch
other, onother cup, ond complete the operotion
by threoding the wishbone pin
through the
other eye. 12. Slip circlips on the wishbone pin
ond
lock with them the wishbone brockets in po-
sition. Proceed in the some monner os with the
upper wishbone (porogroph 8).
110
Rubber

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th
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Fig.6.5/5
-
Pressing-in Beoring Cups Using
MP 6-130 Jig
Fig.6.5/5 -
Instolling Seoling Ring
Using
MP 6-131 Jig 23-
Fit the disk broke bock plote
on the
steering knuckle ond fosten it by bolting down
the broke brocket. Use spring woshers to lock
the bolts. Drive home the wheel hub
on the
steering knuckle with light tops ond use o tube
to top home the beoring cone.
24. Fit the greose-pocked
cone of the outer
beoring on the steering knuckie, locote
the
shim on the beoring, ond tighten the nut with
o torque of 1.5 kpnr (15
Nm) while rototing the
wheel hub.
25. Top
the wheel hub ond the broke disk
with o mollet ond rotote
the wheel hub to bed
in the beorings. Bock off the nut
through obout
-180o
ond retighten it with o torque of obout 5 Nm
(0.5 kpm) while rototing the hub. Then bock off
the nut to the neorest cotter pin
slot (ot
the
most through 30"), ond lock it in this position
by inserting the cotter pin.
26. Check whether the wheel hub rototes
freely br-rt without ony noticeoble
cleoronce in
the beorings, ond secure the nut with the cotter
pin.
Fittirrg Steering Knuckles ond Wheel Hub
into Wishbones
27. Hoving thus ossembled the wheel, instoll
ii into the lower
wishbone, fit
o shim between
tl-re wishbone reor eye ond the resilient bush in
the king pin socket,
threod in the eccentric pin,
cind screw down the nut without tightening it.
28. Press
the wheel ogoinst tlre
upper wish-
borre ond connect it with it
by topping home
the wishbone pin
from the reor side
of the
oxle,
i. e., from the side of the shorter port
of the
king pin
socket. Slip the MP 6-108 pilot
pin
on
the wishbone pin
threod to focilitote threoding
of the pin
through the hole in the wishbone.
Tighten slightly the connection with the costel-
loted nut.
DK ? 2r+
Fig. 6.517 -
MP 6--108 Pilot Pin for
Upper
Wishbone Pin lnstollotion
112

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