Lincoln Aviator: Front Suspension - AWD / Disassembly and Assembly - Shock Absorber and Spring Assembly - Vehicles With: Air Suspension

Special Tool(s) / General Equipment

DISASSEMBLY

  WARNING: Vent all air pressure from the air suspension system prior to disconnecting or removing any air suspension components. It is dangerous to remove air suspension components while under pressure. Failure to follow this instruction may result in serious personal injury.

NOTICE: Suspension fasteners are critical parts that affect the performance of vital components and systems. Failure of these fasteners may result in major service expense. Use the same or equivalent parts if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Tighten fasteners as specified.

NOTE: Disassembly steps in this procedure may contain assembly details.

1. Remove the shock absorber and spring assembly.
   Refer to: Shock Absorber and Spring Assembly - Vehicles With: Air Suspension (204-01A Front Suspension - RWD, Removal and Installation).
   

1. NOTICE: Reuse of air spring components may result in leakage of the air spring.

   
   
   • Pry out the retaining ring out of the groove on the top mount.
     Use the General Equipment: Flat Headed Screw Driver
   • Discard the retaining ring.
     

1. NOTICE: Reuse of air spring components may result in leakage of the air spring.

   Remove the sealing cap from the top mount.
   
   1. Twist and pull out the sealing cap from the top mount.
      
   2. Discard the sealing cap and O-ring.
      

1. NOTE: Use the hex-holding feature to prevent the component from turning.

   Remove and discard the shock absorber and spring assembly rod nut.
   

1. NOTICE: Unrolling the air spring bellow will permanently damage the air spring.

   NOTE: Note the position of the components before removal.

   Pull down the damper to remove from the air spring.
   

1. Inspect the air spring bellow for damage, replace if necessary.
   

1. Inspect the damper for damage, replace if necessary.
   

1. NOTE: This step is only necessary if reusing the damper in service.

   NOTE: Note the position of the components before removal.

   Remove and discard the O-ring, support ring and spring support rings.
   

ASSEMBLY

1. NOTE: Make sure that the component is installed to the position noted before removal.

   To assemble, reverse the disassembly procedure.
   

1. • NOTICE: Do not apply grease to the damper rod threads as this will cause damage to the component.

     Clean the damper rod.
     

   • NOTE: Make sure the grease is applied completely around the damper rod.

     Apply the grease from service kit evenly on the damper rod.
     

1. NOTICE: Only use the specified material to lubricate the seals.

   Apply the grease from service kit evenly on the outer and inner diameter of the new O-ring seals.
   

1. Install the O-ring, support ring and spring support rings.
   
   1. Install the spring support ring on damper tube by sliding it down until it is in contact with the damper shoulder stop.
      
   2. Install the support ring on damper tube by sliding it down until it is in contact with the spring support ring.
      
   3. Install the spring support ring on damper tube by sliding it down until it is in contact with the support ring.
      
   4. Install the greased O-ring on damper tube by sliding it down until it is in contact with the spring support ring.
      

1. NOTICE: Make sure that the damper is fully seated inside the air spring. Failure to follow this instruction may result in leakage of the air spring.

   NOTE: This step requires considerable force.

   
   Install the damper inside the air spring assembly until rod protrudes through top mount hole.
   
   1. Align the connector on the cap with the damper solenoid on both sides.
      

1. Clean the top mount and inspect the shock absorber and spring assembly rod seated properly.
   

1. NOTE: Use the hex-holding feature to prevent the component from turning.

   Install the shock absorber and spring assembly rod nut.
   Torque: 41 lb.ft (55 Nm)

1. 1. NOTICE: Only use the specified material to lubricate the seals.

      Apply the grease from service kit evenly on the outer and inner diameter of the new O-ring seals.
      

   2. NOTE: Make sure that a new O-ring seal is installed.

      Install the new O-ring into groove on the sealing cap.
      

1. NOTE: Make sure that the components are correctly seated in the air spring top mount.

   
   
   1. Ensure that the goal posts are perpendicular to the connector.
      
   2. Align and press down the sealing cap into the shock absorber and spring assembly top mount.
      

1. NOTICE: Retaining ring must be fully seated into groove or it will result in the leakage of air spring.

   Insert the new retaining ring into the top mount groove.
   

1. Install the shock absorber and spring assembly.
   Refer to: Shock Absorber and Spring Assembly - Vehicles With: Air Suspension (204-01A Front Suspension - RWD, Removal and Installation).