Instructions for installation of EMU and ARB integrated suspension systems including Coil and Leaf Springs.

Below we provide a general guide to assist you with the installation of our Old Man Emu Products

and ARB leaf springs:

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

ARB 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.

Suspension Kits and Components for individual applications:

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