DAF LF45 Series Manual
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DAF LF45 Series Manual

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9
LF45/55 series
0207
TECHNICAL DATA
SHOCK ABSORBERS
STABILISERS AND TORQUE RODS
LEAF SUSPENSION
CONTENTS
DIAGNOSTICS
CHASSIS
0
1
2
3
4
5

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  • Page 1 CONTENTS LF45/55 series TECHNICAL DATA DIAGNOSTICS CHASSIS SHOCK ABSORBERS STABILISERS AND TORQUE RODS LEAF SUSPENSION 0207...
  • Page 2 fafsfsafa...
  • Page 3 TECHNICAL DATA LF45/55 series Contents CONTENTS Page Date CHASSIS ............. .
  • Page 4 TECHNICAL DATA LF45/55 series Contents 0207...
  • Page 5 TECHNICAL DATA LF45/55 series Chassis 1. CHASSIS 1.1 GENERAL Chassis materials Type Chassis type Material KF 450 Note: KF 450 is a “High Tensile Strength”-steel grade. 0207...
  • Page 6 TECHNICAL DATA LF45/55 series Chassis 0207...
  • Page 7 TECHNICAL DATA LF45/55 series Shock absorbers, stabilisers, torque rods and leaf suspension 2. SHOCK ABSORBERS, STABILISERS, TORQUE RODS AND LEAF SUSPENSION 2.1 GENERAL Fixing the attachment bolts for the leaf spring Ensure that when fixing the attachment bolts (1) for the leaf spring that the leaf spring is at the prescribed height (A).
  • Page 8 TECHNICAL DATA LF45/55 series Shock absorbers, stabilisers, torque rods and leaf suspension Transverse guide torque rod, air sprung rear axle LF45 Fitting angle (A) for mounting rubber on rear 8 - 12 ° axle side C9 00 408 Torque rods stabiliser length (A) A is the centre-to-centre-distance between the attachment points.
  • Page 9 TECHNICAL DATA LF45/55 series Shock absorbers, stabilisers, torque rods and leaf suspension 2.2 TIGHTENING TORQUES The tightening torques stated in this paragraph are different from the standard tightening torques stated in the overview of the standard tightening torques. The other threaded connections which are not stated must therefore be tightened to the tightening torque stated in the overview of standard tightening torques.
  • Page 10 TECHNICAL DATA LF45/55 series Shock absorbers, stabilisers, torque rods and leaf suspension LF45 rear axle, air suspension C9 00 323 M14 shock absorber attachment nut 52 Nm M12 air bellows attachment nut 31 Nm M20 bolt 525 Nm M12 air bellows attachment nut 60 Nm M20 shock absorber attachment bolt 525 Nm...
  • Page 11 TECHNICAL DATA LF45/55 series Shock absorbers, stabilisers, torque rods and leaf suspension Rear axle, air suspension LF55 13- 15 ton C9 00 324 M16 triangular adjustment block 360 Nm attachment bolt M20 triangle attachment bolt 475 Nm Attachment nut for triangle on differential M22 235 Nm M20 shock absorber attachment bolt...
  • Page 12 TECHNICAL DATA LF45/55 series Shock absorbers, stabilisers, torque rods and leaf suspension Rear axle, air suspension LF55 16- 18 ton C9 00 325 M10 air bellows attachment nut 46 Nm Clamping flange bolt M18 460 Nm M14 attachment bolt, property class 10.9 135 Nm M16 air bellows attachment bolt 195 Nm...
  • Page 13 TECHNICAL DATA LF45/55 series Shock absorbers, stabilisers, torque rods and leaf suspension Steered rear axle, air suspension LF55 FAN C9 00 397 Self-locking nut, torque rod ball joint 88 Nm M20 shock absorber attachment bolt 250 Nm M10 air bellows attachment bolt 32 Nm M12 air bellows attachment bolt 34 Nm...
  • Page 14 TECHNICAL DATA LF45/55 series Shock absorbers, stabilisers, torque rods and leaf suspension 0207...
  • Page 15 DIAGNOSTICS LF45/55 series Contents CONTENTS Page Date SHOCK ABSORBERS ...........
  • Page 16 DIAGNOSTICS LF45/55 series Contents 0207...
  • Page 17 DIAGNOSTICS LF45/55 series Shock absorbers 1. SHOCK ABSORBERS 1.1 FAULT-FINDING TABLE COMPLAINT: SHOCK ABSORBER PRODUCES NOISE (CHATTERING, BUMPING ETC.) Possible cause Remedy Shock absorber is loose. Tighten. Attachment rubbers too soft. Fit new rubbers. Shock absorber comes into contact with other Remove components or fasten them.
  • Page 18 DIAGNOSTICS LF45/55 series Shock absorbers COMPLAINT: SHOCK ABSORBER TOO SOFT Possible cause Remedy Incorrect shock absorber type fitted. Fit correct type. Internal wear. Check shock absorber using a test bench and replace, if required. Loss of oil due to leakage. See under Leaky shock absorber.
  • Page 19 DIAGNOSTICS LF45/55 series Leaf suspension 2. LEAF SUSPENSION 2.1 FAULT-FINDING TABLE COMPLAINT: LOOSE U-BOLTS Possible cause Remedy Use of a U-bolt or nut of an incorrect property Use U-bolts and nuts of the correct property class. class. The tightening torque used for the U-bolt nut Tighten the U-bolt to the specified torque.
  • Page 20 DIAGNOSTICS LF45/55 series Leaf suspension COMPLAINT: SPLAYING OF THE SPRING ASSEMBLY (BROKEN SPRING CLAMPS) Possible cause Remedy Incorrect pre-tension of the U-bolts. See under complaint Loose U-bolts. COMPLAINT: SPRING HITS END STOP Possible cause Remedy Overloading. Adjust vehicle loading. Sagged spring assembly. Check height of both spring assemblies.
  • Page 21 CHASSIS LF45/55 series Contents CONTENTS Page Date GENERAL .............
  • Page 22 CHASSIS LF45/55 series Contents 0207...
  • Page 23 Any welding, aligning, drilling and wheelbase alteration activities that are not described in this workshop manual or in any of the latest releases of DAF’s Chassis Guidelines must be authorised by DAF. Following chassis repair, the cause of the chassis damage should be rectified.
  • Page 24 CHASSIS LF45/55 series General Thoroughly grind out the crack on both sides. Take the necessary precautions to prevent damage to electronic components. Place the earth clamp as close as possible to the weld and avoid bridges. W9 01 002 Lay a bead on one side of the ground-out crack.
  • Page 25 “Warm” straightening DAF chassis should not be warm straightened. Heating can cause grains in the material which will adversely affect the material properties. General...
  • Page 26 Note: There are several stress zones in a chassis. Working on the chassis without the appropriate knowledge (and not according to DAF instructions) may cause irreversible damage to the chassis. The repair shop or bodybuilder would be held fully responsible for such work and for any superstructure fitted.
  • Page 27 CHASSIS LF45/55 series General 1.3 REPLACING THE RIVETS BY BOLTS Note: A rivet may either be replaced by a flange bolt M14 x 2, property class 8.8 (DIN 6921), or a flange bolt M16 x 2, property class 10.9. Removing the rivet Remove the rivet head.
  • Page 28 CHASSIS LF45/55 series General Installing M16 flange bolt Drill the rivet hole out to ∅17 mm. Make sure not to damage any lines running behind the rivet hole. Deburr the edges. Repair the chassis lacquer coating. The new paintwork should be no thicker than 50 microns.
  • Page 29 SHOCK ABSORBERS LF45/55 series Contents CONTENTS Page Date GENERAL .............
  • Page 30 SHOCK ABSORBERS LF45/55 series Contents 0207...
  • Page 31 A well-functioning shock absorber with characteristics appropriate to the operating conditions will be the best possible compromise to fulfil the above-mentioned functions. DAF only uses double acting type shock absorbers. On vehicles with air suspension, hydraulic stroke limitation is used.
  • Page 32 SHOCK ABSORBERS LF45/55 series General Double acting shock absorbers The operation of the shock absorber is as follows: the bump stroke moves the cylinder (1) down in relation to the operating cylinder (2). Subsequently, oil flows from the bottom chamber of the piston (1) through the piston holes and valves to the top chamber where the volume increases.
  • Page 33 SHOCK ABSORBERS LF45/55 series Removal and installation 2. REMOVAL AND INSTALLATION 2.1 REMOVAL AND INSTALLATION OF SHOCK ABSORBERS Remving the shock absorber Remove the attachment nuts and/or bolts. Mark the exact positions and location of the mounting rubbers. Remove the shock absorber from under the vehicle.
  • Page 34 SHOCK ABSORBERS LF45/55 series Removal and installation 0207...
  • Page 35 STABILISERS AND TORQUE RODS LF45/55 series Contents CONTENTS Page Date GENERAL .............
  • Page 36 STABILISERS AND TORQUE RODS LF45/55 series Contents 0207...
  • Page 37 STABILISERS AND TORQUE RODS LF45/55 series General 1. GENERAL 1.1 OVERVIEW DRAWING, FRONT-AXLE STABILISER C9 00 400 Stabiliser bar Attachment bolt Silentblock Torque rod Shim Attachment bolt Lock nut Torque rod ball joint Attachment bolt 10. Clamp 11. Stabiliser bracket 12.
  • Page 38 STABILISERS AND TORQUE RODS LF45/55 series General 1.2 OVERVIEW DRAWING, LEAF-SPRUNG REAR AXLE STABILISER C9 00 401 Silentblock Stabiliser bar Attachment bolt Bearing bush cover Bearing bush Bearing-bush cover 0207...
  • Page 39 STABILISERS AND TORQUE RODS LF45/55 series General 1.3 OVERVIEW DRAWING, AIR-SPRUNG REAR AXLE STABILISER LF55 13-15 TON GVW C9 00 319 Stabiliser bar Clamp Bolt Retaining plate Bearing bush Bearing bush cover Stiffener Connecting pin 10. Shackle 11. Spacer ring 12.
  • Page 40 STABILISERS AND TORQUE RODS LF45/55 series General 1.4 OVERVIEW DRAWING, AIR-SPRUNG REAR AXLE STABILISER LF55 16-18 TON GVW C9 00 320 Stabiliser bar Bolt Bracket Silentblock Shackle Bolt Silentblock 10. Nut 11. Bearing bush cover 12. Bearing bush 0207...
  • Page 41 STABILISERS AND TORQUE RODS LF45/55 series General 1.5 OVERVIEW DRAWING, STEERED REAR AXLE STABILISER LF55 FAN C9 00 399 Stabiliser bar Torque rod Torque rod ball joint Lock nut Torque rod ball joint Lock nut Clamp Stabiliser bracket 10. Bearing bush 11.
  • Page 42 STABILISERS AND TORQUE RODS LF45/55 series General 0207...
  • Page 43 STABILISERS AND TORQUE RODS LF45/55 series Removal and installation 2. REMOVAL AND INSTALLATION 2.1 REMOVAL AND INSTALLATION, FRONT-AXLE STABILISER C9 00 400 Removal, front-axle stabiliser Remove the lock nut (9) from the ball joint (8). Press the ball joint (8) out of the stabiliser bar (1).
  • Page 44 STABILISERS AND TORQUE RODS LF45/55 series Removal and installation Remove the stabiliser together with the bearing bushes (12) out of the vehicle supports (11). Remove the attachment bolts (6) and remove the torque rods (4). Installation, front-axle stabiliser Check the condition of the silentblocks (3), the bearing bushes (12) and the ball joints (8).
  • Page 45 STABILISERS AND TORQUE RODS LF45/55 series Removal and installation 2.2 REMOVAL AND INSTALLATION, LEAF-SPRUNG REAR AXLE STABILISER C9 00 401 Removal, leaf-sprung rear axle stabiliser Remove the U-bolt nuts by means of which the mounting rubbers (1) of the stabiliser bar (2) are attached to the rear axle.
  • Page 46 STABILISERS AND TORQUE RODS LF45/55 series Removal and installation Installation, leaf-sprung rear axle stabiliser Check the condition of the silentblocks (1) and the bearing bushes (5). Clean the threaded ends of the U-bolts. Fit the bearing bushes (5) in the bearing bush covers (4).
  • Page 47 STABILISERS AND TORQUE RODS LF45/55 series Removal and installation 2.3 REMOVAL AND INSTALLATION, TRANSVERSE GUIDE TORQUE ROD, AIR SPRUNG REAR AXLE LF45 Removal, transverse guide torque rod Remove the attachment bolts (1) on the side (2) at which the torque rod (5) is attached to the rear axle.
  • Page 48 STABILISERS AND TORQUE RODS LF45/55 series Removal and installation 2.4 REMOVAL AND INSTALLATION, AIR-SPRUNG REAR AXLE STABILISER LF55 13-15 TON GVW C9 00 319 Removal, air-sprung rear axle stabiliser bar LF55 13-15 ton GVW Remove the attachment bolts (3) and nuts (8) from the bearing bush covers (6) and stiffeners (7).
  • Page 49 STABILISERS AND TORQUE RODS LF45/55 series Removal and installation Remove the attachment bolts and nuts from the shackle brackets (12) in the differential. Remove the stabiliser bar. Installation, air-sprung rear axle stabiliser bar LF55 13-15 ton GVW Check the condition of all the rubbers and hinge points.
  • Page 50 STABILISERS AND TORQUE RODS LF45/55 series Removal and installation 2.5 REMOVAL AND INSTALLATION, TRIANGULAR LINK, AIR-SPRUNG REAR AXLE LF55 13-15 TON GVW C9 00 410 Removal, triangular link, air-sprung rear axle LF55 13-15 ton GVW Detach any valves on the inside of the chassis that may hinder removal of the triangular link.
  • Page 51 STABILISERS AND TORQUE RODS LF45/55 series Removal and installation Installation, triangular link, air-sprung rear axle LF55 13-15 ton GVW Check the condition of the mounting rubbers and the silentblock in the triangle. Apply Copaslip to the silentblock attachment pin on the differential. Position the triangle on the attachment pin and check that the mounting rubbers are positioned straight against the support...
  • Page 52 STABILISERS AND TORQUE RODS LF45/55 series Removal and installation 2.6 REMOVAL AND INSTALLATION, AIR-SPRUNG REAR AXLE YOKE LF55 13-15 TON GVW C9 00 410 Support the vehicle securely and work safely. Make sure that the axle cannot tilt if both yokes are removed at the same time.
  • Page 53 STABILISERS AND TORQUE RODS LF45/55 series Removal and installation Installation, air-sprung rear axle yoke LF55 13-15 ton GVW Check the condition of the mounting rubber and the silentblock of the yoke. Position the yoke using a jack underneath the axle. Fit the attachment bolts (9) for the mounting rubber.
  • Page 54 STABILISERS AND TORQUE RODS LF45/55 series Removal and installation 2.7 REMOVAL AND INSTALLATION, TRIANGULAR LINK AND AIR-SPRUNG REAR AXLE TORQUE ROD LF55 13-18 TON GVW C9 00 299 Removal, triangular link, air-sprung rear axle LF55 16-18 ton GVW, axle top Remove the bolts (2).
  • Page 55 STABILISERS AND TORQUE RODS LF45/55 series Removal and installation Installation, triangular link, air-sprung rear axle LF55 16-18 ton GVW, axle top Before installation, check the rubber bushes of the triangular link and the silentblock for hair-line cracks and wear. Check to see if the contact surface of the triangular link flange (1) (see arrow) and the contact surface on the axle housing are free from grease and paint.
  • Page 56 STABILISERS AND TORQUE RODS LF45/55 series Removal and installation 2.8 REMOVAL AND INSTALLATION, AIR-SPRUNG REAR AXLE STABILISER LF55 16-18 TON GVW C9 00 320 Removal, air-sprung rear axle stabiliser bar LF55 16-18 ton GVW Remove the attachment nuts (10) from the bearing bush covers (11).
  • Page 57 STABILISERS AND TORQUE RODS LF45/55 series Removal and installation Installation, air-sprung rear axle stabiliser bar LF55 16-18 ton GVW Position the stabiliser bar (1) together with the bearing bushes (12) in the bearing bush cover halves underneath the differential. Fit the bearing bush covers (11) using the attachment bolts (10), but do not yet tighten the bolts.
  • Page 58 STABILISERS AND TORQUE RODS LF45/55 series Removal and installation 2.9 REMOVAL AND INSTALLATION, STEERED REAR AXLE STABILISER LF55 C9 00 399 Removal, steered rear axle stabiliser bar LF55 FAN Remove the lock nuts (7) from the torque rod balls (5) on the side of the stabiliser bar (1) and press the balls out of the stabiliser bar.
  • Page 59 STABILISERS AND TORQUE RODS LF45/55 series Removal and installation Remove the attachment bolts (12) together with the retaining plates (11) that are mounted to the stabiliser brackets (9) of the stabiliser bar. Remove the stabiliser together with the bearing bushes (10) out of the supports (9). Remove the lock nuts (4) from the torque rods on the chassis side and press the torque rods out of the spring stop brackets.
  • Page 60 STABILISERS AND TORQUE RODS LF45/55 series Removal and installation 0207 2-18...
  • Page 61 The silentblock should be fitted using special tool (DAF no. 1310476). It is not possible to install the silentblock undamaged, without using this puller. The stabiliser bar need not be removed when replacing the silentblocks on the stabiliser bar.
  • Page 62 3.2 DISASSEMBLY AND ASSEMBLY, STABILISER BAR / TORQUE ROD SILENTBLOCK WITH STEEL CASING Notes The silentblocks with steel casing should be fitted using special tool (DAF no. 1310479). It is not possible to install the silentblock undamaged, without using this puller. The stabiliser bar need not be removed when replacing the silentblocks.
  • Page 63 STABILISERS AND TORQUE RODS LF45/55 series Disassembly and assembly Installing silentblock with steel casing Place the thrust piece with the largest diameter (C in the drawing) on the puller (A). Apply for example tyre grease to the thrust piece, and place the puller (A) with the silentblock (1) on the stabiliser bar (2).
  • Page 64 STABILISERS AND TORQUE RODS LF45/55 series Disassembly and assembly Disassembling the transverse guide torque rod mounting rubber, air-sprung rear axle LF45, chassis side Remove the torque rod from the vehicle. Drive the pin and rubber bush unit from the eye of the torque rod. Assembling the transverse guide torque rod mounting rubber, air-sprung rear axle LF45, chassis side...
  • Page 65 STABILISERS AND TORQUE RODS LF45/55 series Disassembly and assembly 3.5 DISASSEMBLY AND ASSEMBLY, TRIANGULAR LINK MOUNTING RUBBER, AIR-SPRUNG REAR AXLE LF55 13-15 TON GVW Disassembly, triangular link mounting rubber Remove the triangular link from the vehicle. Remove the mounting rubber (1) from the triangular link (2) using a puller.
  • Page 66 STABILISERS AND TORQUE RODS LF45/55 series Disassembly and assembly 3.6 DISASSEMBLY AND ASSEMBLY, TRIANGULAR LINK SILENTBLOCK, AIR-SPRUNG REAR AXLE LF55 16-18 TON GVW Disassembly, triangular link silentblock, air-sprung rear axle LF55 16-18 ton GVW Loosen the attachment bolts (7) a few turns. Remove the bolt (1).
  • Page 67 STABILISERS AND TORQUE RODS LF45/55 series Disassembly and assembly Fit the circlip (3) as indicated. Make sure that the entire circlip (3) is positioned correctly in the groove. Install the flange (5), if removed, on the axle housing. Check to see if the contact surface of the flange (5) and the contact surface on the axle housing are free from grease and paint.
  • Page 68 STABILISERS AND TORQUE RODS LF45/55 series Disassembly and assembly 3.7 DISASSEMBLY AND ASSEMBLY, TRIANGULAR LINK/TORQUE ROD MOUNTING RUBBER, AIR-SPRUNG REAR AXLE LF55 16-18 TON GVW Note: Disassembly and assembly of the mounting rubbers are identical for the triangular link and the torque rod.

  • Page 69: Table Of Contents

    LEAF SUSPENSION LF45/55 series Contents CONTENTS Page Date SAFETY INSTRUCTIONS ..........
  • Page 70 LEAF SUSPENSION LF45/55 series Contents 0207...

  • Page 71: Safety Instructions

    LEAF SUSPENSION LF45/55 series Safety instructions 1. SAFETY INSTRUCTIONS Spring leaves Spring leaves should not be subjected to blasting. Blasting will cause indentations in the leaf spring which could initiate pitting corrosion. Corrosion should be prevented as this will considerably shorten the service life of the spring.
  • Page 72 LEAF SUSPENSION LF45/55 series Safety instructions 0207...

  • Page 73: General

    LEAF SUSPENSION LF45/55 series General 2. GENERAL 2.1 DESCRIPTION OF LEAF SUSPENSION Parabolic springs are used on the LF series In a parabolic spring all the leaves are approximately the same length but the thickness of each leaf varies parabolically along its length. Except at the centre clamping and at the spring leaf ends, the spring leaves of a parabolic leaf w9 04 002...

  • Page 74: Overview Drawing, Spring Assembly With Bolt Attachment

    LEAF SUSPENSION LF45/55 series General 2.2 OVERVIEW DRAWING, SPRING ASSEMBLY WITH BOLT ATTACHMENT Note: This drawing gives a general view and may differ from the actual situation on the vehicle. C9 00 305 Attachment bolt Centring sleeve Spring bracket U-bolt Upper spring seat Shock absorber support U-bolt nut...

  • Page 75: Overview Drawing, Spring Assembly With Pin Attachment

    LEAF SUSPENSION LF45/55 series General 2.3 OVERVIEW DRAWING, SPRING ASSEMBLY WITH PIN ATTACHMENT Note: This drawing gives a general view and may differ from the actual situation on the vehicle. C9 00 326 Attachment bolt 10. Spring bracket Mounting bracket 11.
  • Page 76 LEAF SUSPENSION LF45/55 series General 0207...

  • Page 77: Removal And Installation

    LEAF SUSPENSION LF45/55 series Removal and installation 3. REMOVAL AND INSTALLATION 3.1 REMOVAL AND INSTALLATION, SPRING ASSEMBLY WITH BOLT ATTACHMENT C9 00 411 Support the vehicle securely and work safely. Make sure that the axle cannot tilt if both spring assemblies are removed at the same time.
  • Page 78 LEAF SUSPENSION LF45/55 series Removal and installation Installation, spring assembly with bolt attachment Check that all contact faces are free of dirt, grease and paint. If applicable, fit the wedge in the correct position. Install the spring assembly to the spring plate/shock absorber plate.

  • Page 79: Removal And Installation, Spring Assembly With Pin Attachment

    LEAF SUSPENSION LF45/55 series Removal and installation 3.2 REMOVAL AND INSTALLATION, SPRING ASSEMBLY WITH PIN ATTACHMENT C9 00 412 Support the vehicle securely and work safely. Make sure that the axle cannot tilt if both spring assemblies are removed at the same time. Removal, spring assembly with pin attachment Remove all components which are in the...
  • Page 80 LEAF SUSPENSION LF45/55 series Removal and installation Installation, spring assembly with pin attachment Check that all contact faces are free of dirt, grease and paint. If applicable, fit the wedge in the correct position. Install the spring assembly to the spring plate/shock absorber plate.

  • Page 81: Removal And Installation, Steered Rear Axle Spring Assembly Lf55 Fan

    LEAF SUSPENSION LF45/55 series Removal and installation 3.3 REMOVAL AND INSTALLATION, STEERED REAR AXLE SPRING ASSEMBLY LF55 FAN Support the vehicle securely and work safely. Make sure that the axle cannot tilt if both spring assemblies are removed at the same time. Removal, steered rear axle spring assembly LF55 FAN Remove the stabiliser bar together with the...
  • Page 82 LEAF SUSPENSION LF45/55 series Removal and installation Installation, steered rear axle spring assembly LF55 FAN Check that all contact faces are free of dirt, grease and paint. Install the spring assembly to the lower spring seat. This can only be done by two persons working together.

  • Page 83: Removal And Installation, Spring Bracket

    LEAF SUSPENSION LF45/55 series Removal and installation 3.4 REMOVAL AND INSTALLATION, SPRING BRACKET Support the vehicle, axle or spring assembly securely and work safely. Removal, spring bracket Jack up the chassis until the spring or the yoke is free of stress. Remove the spring or yoke bracket.
  • Page 84 LEAF SUSPENSION LF45/55 series Removal and installation 0207...

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