Instructions for installation of EMU integrated suspension systems
When your off road and only the best will do, Emu!
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Instructions for installation of EMU integrated suspension systems |
When your off road and only the best will do, Emu! |
Below we provide a general guide to assist you with the
installation of our Old Man Emu Products:
Part 1: Suspension Component Pre-Fitment Checklist
Prior to removing standard suspension the vehicle must be driven to detect any inherent
problems, i.e. drive line vibration, steering wheel wobble, driveline or wheel bearing
noises, etc. At the same time a compulsory brake performance test must be carried
out using an approved brake test unit in current calibration. Should the vehicle
fail the braking test investigate and identify the cause.
Complete vehicle inspection by checking for any repairs or damage to suspension mounting
points, study standard suspension measurement for signs that vehicle chassis may
be twisted. Consult with customer before proceeding to clarify any additional cost
for parts and or labor.
Remove standard suspension and carry out the following procedures.
U Bolts:
Check if standard U bolts will fit new springs by checking OME application catalog
under individual vehicle suspension selection (NB: Toyota Pickup & 4 Runner front
— OME U52 mandatory fitment requirement). If placement U bolt is not shown ensure
the standard U bolts have:
(a) No damage to the Ubolt, nut and thread,
(b) Minimum of 2 threads protruding from nut when torqued to manufacturer’s specifications.
Should any of the above be in doubt replace with correct new OME U bolts.
Shackles:
Spring Bushings:
Only genuine OME polyurethane bushings are recommended fitment with OME long
travel springs. Rubber bushings can be used, however, due to the increased torsional
twist placed on bushings (because of increased suspension travel) experience has
shown that rubber bushings may twist the head away from the bushing body. Customers
should be advised of this problem.
Shock Absorber Bushing Inspection
If any signs of wear, splitting or bushing distortion are evident, replace with
new OME polyurethane bushings.
Suspension Mounting Points:
All suspension mounting points (eg. Shock absorber towers, panhard rod bushings,
chassis mounting points, coil spring mounting seats, etc.) must be carefully checked
and inspected for any signs of excessive wear, rust, damage or fatigue cracking,
and if found be repaired or replaced.
Bump Stops:
Bump stops are an important component in the suspension design, controlling suspension
compression limits. Therefore, if bump stops have been removed, modified or damaged
they must be replaced or restore to manufacturer’s specifications.
Important Note:
Failure to do this can void the OME Warranty.
Part 2: Installation of OME Suspension
Leaf Springs:
Spring Bushings:
OME Splined Polyurethane Bushings: Install bushing into spring eye and chassis mount
ensuring shackle pin slides freely. Remove shackle pin, liberally grease the bushing
bore and outer flange with Molybdenum based grease
IMPORTANT: Do not grease between bushing and spring
eye.
Install shackle insuring free movement between shackle and spring bushing — this
is to ensure the shackle will not seize to the spring bushing under heavy usage which
can result in spring failure due to bushing ‘bonding’ to shackle pin.
Polyurethane Bushing Maintenance:
The polyurethane bushing principle requires the shackle pin to rotate in the bushing
which therefore requires regular lubrication. Greasing intervals depend on vehicle
operational conditions. Heavy usage (eg. Sand, water, constant corrugations and heavy
loads) require more servicing. An obvious sign greasing is urgently required is when
the bushing squeaks.
Rubber Bushings:
Once the bushings have been placed into the spring, install the shackles and
fixed pins finger tight only. When suspension installation has been completed, lower
vehicle onto the ground and bounce the vehicle 3-4 times. This is done to ensure
the bushings don’t bind up on the shackle pins at an incorrect position. Only then
should all shackle and fixed end pins be fully tightened.
Coil Springs:
Coils may vary in free height due to uneven vehicle weight distribution. Although
these coils are marked D/S for Driver’s Side and P/S for Passenger’s Side, these
designations apply to Right Hand Drive Vehicles and may require opposite fitment
to left hand drive vehicles. As a general rule, the taller OME coil should be installed
on the same side of the vehicle as the taller OE coil.
Fitment:
Polyurethane Trim Spacers:
Do not use OME trim spacers as a replacement for OE spring isolators. In all
cases, OME trim spacers must be installed on top of the coil between coil isolator
and top coil mounting seat.
Shock Absorbers:
Pin Type Shock Absorber Mount:
10mm diameter Pin: tighten nut until- bushing crush is achieved, be careful not to
over crush bushing. 14mm Diameter pin: Tighten nut until bottom of nut contacts pin
shoulder. In all cases ensure the concave bushing retaining washers are installed
with both concave surfaces facing each other.
Eye Top Shock Absorber Mount:
Bush retaining washers must be fitted with concave surfaces facing AWAY from each
other. Ensure bushings are located correctly in shock absorber eye and on mounting
pin. Tighten nut until bottom of nut contacts pin shoulder.
Important Note:
Correct fitment of shock absorber bushing retaining washers must happen to prevent
premature bushing failure due to poor bushing containment. In a number of vehicles
the shock absorber is the limiting factor for suspension droop. These vehicles require
shock absorber fitment to be carried out with the vehicle on the ground.
Part 3 Final Suspension Check
(remember you are responsible for vehicle safety)
Prior to road testing visually check vehicle for any obvious problems (eg. Inverted
shackles, etc) and correct problems before road testing. A front end alignment check
must be carried out and any required adjustments made to ensure vehicle is within
the manufacturer’s specifications.
Road test vehicle at least 1 mile, paying particular attention to:
Return vehicle to level ground, carry out following checks:
Part 4: Technical
Interleaf Liners — Greasing:
Raise vehicle to take load off spring pack to allow grease to flow between leaves.
Check that the leaves are still moving relatively freely. They can be regreased,
and the interleaf liners (where fitted) can be drilled and greased if necessary.
1. Ensure hole in center of liner is clear. Most have a thin membrane covering the
hole. Clear hole if necessary.
2. Insert a straight grease nipple into grease gun nozzle.
3. Press gun with nipple into liner hole. Pump until grease is squeezing out at sides
of liner.
Extra Leaf - Adding A Leaf:
1. Unfold all clips and/or remove nut, bolt and spacer from bolt type clips.
When unfolding clips be careful not to score the surface of the main leaf. Note:
If spring is already fitted with a trim spacer and a new center bolt is not available,
a few end thread of the existing center bolt will have to cleaned so damage to nut
is minimal when it is removed. This will allow the use of the same center bolt.
2. Hold the center bolt head in a vice and clamp spring leaves together with a suitable
C clamp as close as possible to the center bolt. Remove center bolt nut.
3. Release the C clamp and dismantle the spring.
4. Clean all leaves to remove road dirt and grease. Particular attention should be
given to both leaf faces where leaves contact each other and on liners at the leaf
ends.
5. Grease all liners and contacting surfaces with Molybdenum based grease or graphite
impregnated grease.
6. If spring was originally supplied with a spacer, do not use this spacer when assembling
the spring with the extra leaf.
7. With head of center bolt in a vice, assemble spring together with added leaf.
Ensure that leaves are oriented correctly as most springs are not symmetrical and
have a long end and a short end. Tighten center bolt and lightly peen the end threads
to prevent loss of nut should it loosen.
8. If clips are fold type clips, clamp spring in vice across clips and bend legs
over. Ensure the ends do not touch surface of main leaf.
9. If clips are bolt type, assemble clips with spacers and tighten nuts. Do not over
tighten. If spacer buckles, nut is too tight.
Extra Leaf — Removing A Leaf:
1. Unfold all clips and/or remove nut, bolt and spacer from bolt type clips.
When unfolding clips be careful not to score the surface of the main leaf. Note:
If spring is already fitted with a trim spacer and a new center bolt is not available,
a few end threads of the existing center bolt will have to be cleansed so damage
to nut is minimal when removed. This will allow the use of the same center bolt.
2. Hold the center bolt head in a vice and clamp spring leaves together with a suitable
C clamp as close as possible to the center bolt. Remove center bolt nut.
3. Release the C clamp- and dismantle the spring.
4. Put aside the leaf to be removed and clean all remaining leaves to remove road
dirt and grease. Particular attention should be given to both leaf faces where leaves
contact each other and on the liners at the leaf ends.
5. Grease all liners and contacting surfaces with Molybdenum based grease or graphite
impregnated grease.
6. Clamp head of center bolt in a vice.
7. To ensure the same spring pack height, a trim spacer of the same thickness as
the leaf removed is to be used. The packer is to be fitted adjacent to the shortest
spring leaf.
8. Assemble spring ensuring that leave are oriented correctly as most springs are
not symmetrical and have a long end and a short end.
9. Tighten center bolt and slightly peen the end threads to prevent loss of nut should
it loosen.
10. If clips are folding type clips, refold clips, ensuring that ends of clip do
not touch surface of main leaf.
11. If clips are bolt type, assemble clips with spacers and tighten nuts. Do not
over tighten. If spacer buckles, nut is too tight.
In addition to the performance the suspension accessories listed here, we also provide an impressive list of automotive after market products for car, pickup truck, SUV and 4wd repair parts and accessories that includes rear end covers, ring and pinion gears, OE clutches and heavy duty performance clutches, diesel gauge kits, exhaust brakes, re manufactured manual and automatic transmissions and both manual and automatic overhaul kits. Other products we offer for the RV recreational vehicle market include REMCO driveline disconnects, tow bar and baseplates and auxiliary overdrive units to improve vehicle performance and save fuel. We have a complete 4 wheeling drivetrain product line including complete differential assemblies, limited slip and other solid locking positractions. We offer transmission conversion kits including the NV4500 and NV5600 as well as replacement kits for light duty GM and Jeep transmissions. You may be interested in visiting our Ford and Powerstroke Diesel page, Dodge Ram and other Jeep pages for detailed information.
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