IFS-SCORPIO

INDEPENDENT FRONT SUSPENTION

GENERAL CONSTRUCTION
 IFS- RIGHT SIDE VIEW

UBJ

COIL
SPRING

BUMP STOPPER LOWER ARM

 IFS- FRONT VIEW

UPPER
ARM

KNUCKLE

STABILIZER STABILIZER
LINK BAR
OLD STABILIZER BAR MOUNTING
NEW STABILIZER BAR MOUNTING
 UPPER CONTROL ARM BUSHES

OLD BUSHES NEW BUSHES

 SPECIFICATION
SUSPENTION TYPE : INDEPENDENT DOUBLE
WISHBONE TYPE SUSPENTION
WITH COIL SPRING.
COIL SPRING
WIRE DIAMETRE : 16.6 mm
INNER DIAMETER : 82.6 mm TO 94.6 mm
APPRO.FREE LENGTH : 309 mm

SHOCKABSORBERS : HYDRAULIC , CYLINDRICAL ,

DOUBLE ACTING TYPE
MAXIMUM LENGTH : 335 +/- 3 mm
MINIMUM LENGTH : 218 +/- 3 mm
STROKE : 117 mm
 STEERING GEOMETRY

CAMBER : 00 14 ’ +/- 30’

DIFFERENCE BETWEEN LH & RH : 30’ ( MAX )

CASTOR : 20 45 ’ +/- 10
DIFFERENCE BETWEEN LH & RH : 45’ ( MAX )
TOE IN
AT THE RIM OF THE WHEEL DISC : 1-3 mm
PARTIAL TOE IN : 00 ’ TO 20 ’
TOTAL TOE IN : 09 ’ TO 27 ’
KING PIN INCLINATION : 100 45 ’+/- 10

TURNING ANGLE : 360 00

 CARE OF THE SYSTEM

THE FIRST WHEEL ALIGNMENT SHOULD BE CARRIED OUT

AT 5000 KMS THEN SUBSEQUENTLY EVERY 10,000 KMS.

CHECK THE SHOCK ABSORBER FOR LEAKS EVERY 10,000 KMS.

CHECK THE RUBBER BUSHES FOR THE MOUNTING OF THE

SHOCK ABSORBER, STABILIZER BAR AND LINKS EVERY
20,000 KILOMETER'S OR ONCE IN A YEAR

CAUTION: DO NOT LUBRICATE THE SUSPENSION BUSHES,

JOINTS
 IMP STEPS DURING DISASSEMBLY
JACK THE VEHICLE- LOCATE THE JACK BEHIND THE LOWER
ARM JUST BELOW THE FIRST OUTRIGGER.
REMOVE THE TYRE
REMOVE THE CALLIPER ASSEMBLY WITHOUT DISCONNECTING
THE BRAKE TUBE.
CAUTION: ENSURE THAT THE BRAKE TUBES ARE NOT
STRETCHED/ DAMAGED. PUT THE CALLIPER WITHOUT
STRAINING THE BRAKE TUBE.
DISCONNECT STABILIZER LINK OF BOTH SIDE.
REMOVE THE SHOCK ABSORBER.
REMOVE THE TIE ROD END BY USING MST 549.

MST 549
LOOSE SLIGHTLY UPPER ARM & LOWER ARM PIVOT NUT .
FIT THE SPRING COMPRESSOR & TIGHT IT SO THAT THE
SPRING IS SLOWLY COMPRESSED.

AT THIS STEP IT MAY REQUIRED TO COMPRESS THE SPRING

INITIALLY BY USING JACK & THEN FIT THE COMPRESSOR
REMOVE THE UPPER ARM FULCRUM LEVER BOLT.
CAREFULLY TAKE OUT THE UPPER ARM FROM CHASSIS
BRACKET.

LOOSE THE SPRING COMPRESSOR

SO THAT THE SPRING IS SLOWLY
DECOMPRESSED.
AT THIS STEP IT MAY REQUIRED
TO USE JACK WHILE
DECOMPRESSING THE SPRING
AT THE END, TO AVOID THE
DAMAGED TO THE THREAD OF
SPRING COMPRESSOR
TAKE OUT THE COIL SPRING.
REMOVE LOWER ARM BOLTS &
TAKE OUT THE ASSEMBLY OF
KNUCKLE, UPPER ARM & LOWER
ARM.
FOR REMOVING THE UPPER AND LOWER ARM BUSHES USE
THE SPECIAL FIXTURE

MST 564

WHILE FITTING NEW BUSHES USE SOAP

SOLUTION SO THAT THE BUSH CAN
PRESSED EASILY. USE OF ANY
LUBRICANT WILL RESULT IN
DEGRADATION OF THE RUBBER BUSH
AND LOWER LIFE.PRESSING WITHOUT
SOAP SOLUTION WILL DAMAGE THE
BUSH
FOR REMOVING THE CHASSIS BUSH USE THE SPECIAL TOOL
MST 566

MST 566
WHILE FITTING NEW CHASSIS BUSHE USE SOAP SOLUTION
SO THAT THE BUSH CAN PRESSED EASILY.

GUIDE

MST 566

USE OF ANY LUBRICANT WILL RESULT IN DEGRADATION OF

THE RUBBER BUSH AND LOWER LIFE. PRESSING WITHOUT
GUIDE & SOAP SOLUTION WILL DAMAGE THE BUSH
 FOR CHANGING ONLY UPPER BALL JOINT.

COMPRESS THE COIL SPRING & REMOVE THE UBJ NUT BY

USING MST 561.

MST561
REMOVE BALL JOINT BOLT,TAKE OUT OLD BALL JOINT.

FIT NEW BALL JOINT & TORQUE IT. ASSEMBLE THE

SUSPENTION
 COIL SPRING
THE SMALLER DIA OF THE COIL SPRING IS ON TOP i.e. THE
TAPER OF THE SPRING IS UPWARDS.
 BOTH THE SPRING SHOULD HAVE
SAME SPRING RATING
( 1 DOT OR 2 DOT)

THE RUBBER PAD AT THE TOP HAS TO BE REPLACED IF

FOUND CRACKED OR RUPTURED.
 STAND OUT DIMENSION FOR SHOCK-ABSORBER: 7 mm

7mm

STAND-OUT DIMENSION CAN BE CHECKED FROM PIN END TO

UPPER LOCK NUT.
 STEERING WHEEL CENTRALIZATION

TO CHECK FOR THE CENTRALIZATION OF THE STEERING

WHEEL.DRIVE THE VEHICLE ON A LEVEL ROAD SURFACE.
NOTE THE ANGULAR POSITION (MISALIGNMENT OF THE
STEERING WHEEL SPOKES. RAISE THE VEHICLE. KEEP
THE WHEELS IN STRAIGHT AHEAD POSITION. MARK THE
POSITION OF THE TRACK RODS AND THE TRACK ROD ENDS
SLACKEN THE TRACK ROD END LOCK NUTS AND ALSO
REMOVE THE GAITER OUTER RETAINING CLIPS.ROTATE
BOTH TRACK RODS IN THE SAME DIRECTION APPROXIMATELY
30 DEGREES FOR EVERY 1-DEGREE OF STEERING
MISALIGNMENT ERROR.
IF THE STEERING WHEEL HAS AN ANTI CLOCKWISE ANGULAR
ERROR THEN BOTH TRACK RODS MUST BE ROTATED
CLOCKWISE WHEN VIEWED FROM THE LEFT – HAND SIDE OF
THE VEHICLE. IF THE STEERING WHEEL HAS AN CLOCKWISE
ANGULAR ERROR THEN BOTH TRACK RODS MUST BE
ROTATED ANTICLOCKWISE WHEN VIEWED FROM THE LEFT
HAND SIDE OF THE VEHICLE

CLOCKWISE ANTI CLOCKWISE

ERROR ERROR
WHEEL ALIGNMENT
BEFORE CHECKING THE WHEEL ALIGNMENT ENSURE
FOLLOWINGS :
RUN THE VEHICLE ATLEAST FOR 1 Km. ON ROUGH ROAD
AFTER SUSPENSION OVERHAUL FOR SETTELING OF
SUSPENSION COMPONENTS.

VEHICLE SHOULD BE EMPTY AND ON A PLANE SURFACE.

BOTH FRONT AND REAR TYRES SHOULD BE OF SAME MAKE

AND HAVE UNIFORM WEAR.

TYRE PRESSURE SHOULD BE MAINTAINED TO 2.0 bar [29psi]

FOR FRONT AND 2.2 bar [31psi] REAR TYRES.

ALL RUBBER BUSHINGS, BALL JOINTS AND TIE ROD ENDS

SHOULD BE CHECKED AND REPLACED IF FOUND DEFECTIVE.
IF ALIGNMENT IS DONE WITH COMPUTERIZED ALIGNER
PLEASE FOLLOW THE INSTRUCTIONS OF EQUIPMENT
MANUFACTURER.

WHEEL ALIGNMENT SHOULD BE CHECKED AT EVERY

10, 000 Kms
 CAMBER

CAMBER ANGLE FOR SCORPIO IS : 14’ +/- 30’

TO INCREASE THE CAMBER REMOVE SHIM FROM UPPER ARM

FULCRUM LEVER & CHASSIS BRACKET.
TO DECREASE THE CAMBER ADD SHIM INBETWEEN UPPER
ARM FULCRUM LEVER & CHASSIS BRACKET.
SHIMS ARE AVAILABLE IN THREE DIFFERENT SIZES
0.80mm
1.60mm
3.20mm
VARIATION OF 0.80mm WILL VARY THE CAMBER
APPROXIMATELY BY 9’.
EX : SAY IF THE WHEEL ALIGNMENT IS DONE & CAMBER OF
RIGHT SIDE IS FOUND 59’

OBSERVED CAMBER : 59’

REQUIRED CAMBER : 14’
DIFFERENCE : 59’-14’=45
SINCE VARIATION OF 0.80mm WILL VARY THE CAMBER BY 9 ’
TOTAL SHIMS REQUIRED TO ADD TO GET SET CAMBER
: 45/9
APPROXIMATELY : 5 SHIMS OF 0.8 mm.
CASTOR SHIM

CAMBER SHIM
 CASTOR
CASTOR ANGLE FOR SCORPIO IS : 20 45 ’ +/- 10
TO INCREASE THE CASTOR, ADD SHIM INBETWEEN UPPER
ARM FULCRUM LEVER REAR BOLT & CHASSIS BRACKET.
TO DECREASE THE CASTOR, ADD SHIM INBETWEEN UPPER
ARM FULCRUM LEVER FRONT BOLT & CHASSIS BRACKET.

ADD SHIM ADD SHIM F

HERE TO HERE TO R
INCREASE DECREASE O
THE THE N
CASTOR CASTOR T
S
I
D
E
SHIMS ARE AVAILABLE IN TWO DIFFERENT SIZES
0.40mm & 1.60mm
ADDITION OF 0.40mm SHIM WILL VARY THE CASTOR
APPROXIMATELY BY 9’.
EX : SAY IF THE WHEEL ALIGNMENT IS DONE & CASTOR OF
RIGHT SIDE IS FOUND 30 48 ’

OBSERVED CASTOR : 30 48’

REQUIRED CASTOR : 20 45 ’
DIFFERENCE : 30 48’ - 20 45 ’ = 10 03 ’=63 ’

SINCE VARIATION OF 0.40mm WILL VARY THE CASTOR BY 9 ’

TOTAL SHIMS REQUIRED TO ADD INBETWEEN FRONT
FULCRUM BOLT & CHASSIS BRACKET TO GET SET CASTOR
: 63/9
APPROXIMATELY : 7 SHIMS OF 0.4 mm.
IMPORTANT NOTES : ADDITION OF CASTOR SHIM EITHER
IN FRONT OR REAR WILL REDUCE THE CAMBER ANGLE.
IT IS IMPORTANT THAT WHILE SETTING THE BOTH ANGLE OR
SETTING ONLY THE CASTOR ANGLE, THE SET CAMBER
SHOULD BE CONSIDER ON POSITIVE SIDE i.e 14’ + 30 ’.
ENSURED THAT THE DIFFERENCE BETWEEN LHS CAMBER &
RHS CAMBER SHOULD NOT BE MORE THAN 30 ’.
ENSURED THAT THE DIFFERENCE BETWEEN LHS CASTOR &
RHS CASTOR SHOULD NOT BE MORE THAN 45 ’.
TOE
TOTAL TOE FOR SCORPIO IS : 9’ TO 27’ [ 1 mm TO 3 mm ]
TOE CAN BE ADJUSTED BY USING TIE ROD LENGTH.
 WHEEL TURNING ANGLE ( WITH MANUAL GAUGE)

BRING THE WHEELS IN STRAIGHT AHEAD POSITION (SAP).

AT THIS POSITION CONFIRM THAT THE TURNTABLES SHOWS
ZERO.TURN THE STEERING WHEEL TO RIGHT HAND SIDE SO
THAT THE WHEEL TURNS THROUGH 36 ± 0.5°. CHECK THE
CONDITION OF THE STOPPER BOLT OF LH SIDE IT SHOULD
TOUCH THE BRACKET ON THE LOWER ARM ASSY.

IF IT IS NOT TOUCHING OR THE WHEEL IS NOT ABLE TO TURN

THROUGH 36 ± 0.5° THEN LOOSEN THE LOCK NUT ADJUST THE
BOLT AND THEN LOCK THE BOLT WITH LOCKNUT.TURN THE
STEERING NOW TOWARDS THE LEFT-HAND SIDE AND THEN
ADJUST THE STOPPER ON THE RIGHT HAND SIDE.
 TYRE ROTATION & PRESSURE

FRONT SIDE TYRE PRESSURE [TUBE TYPE]

[ LADEN & UNLADEN ]
FRONT2.0 bar [29 PSI]
REAR 2.2 bar [31 PSI]

TYRE PRESSURE [TUBELESS]

[ LADEN & UNLADEN ]
FRONT2.2 bar [32 PSI]
REAR 2.2 bar [32 PSI]

TYRE SIZE
235 / 75 R15 105 S
235 / 70 R16 105 S
TROUBLE SHOOTING
ONE EDGE WEAR

CAUSE :
-CAMBER TO BE CHECKED
AND ADJUSTED
-CHECK AND ADJUST HUB
END PLAY
FEATHERED EDGE WEAR

CHECK & CORRECT TOE IN.

CHECK THE CHASSIS BEND
IF TYRE ROTATION NOT
CARRIED OUT AS PER
SCHEDULE.DO THE TYRE
ROTATION.

INCORRECT TOE IN
EXCESSIVE VEHICLE ROLLING
•BODY MOUNTS LOOSE.
•SUSPENSION MOUNTING LOOSE.
•BROKEN OR DETERIORATED STABILIZER
•WORN STABILIZER BUSH
•MALFUNCTIONING SHOCK ABSORBER
VEHICLE INCLINED

•BROKEN OR DETERIORATED COIL SPRING

NOISE

•PARTS WORN OR LOOSE

•BROKEN COIL SPRING
•MALFUNCTIONING SHOCK ABSORBER
 SQUEAK NOISE

A SQUEAK NOISE FROM THE SHOCK ABSORBER CAN BE

PRODUCED IF MOVEMENT BETWEEN THE RUBBER BUSHING
AND METAL OCCURS. TIGHTENING THE ATTACHING PARTS
CAN USUALLY STOP THIS NOISE. IF THE SQUEAK NOISE
PERSIST THEN INSPECT FOR WORN OR DAMAGED BUSHINGS
AND ATTACHING COMPONENTS. REPAIR AS NECESSARY IF
ANY THING FOUND AMISS.

THE SHOCK ABSORBER BUSHINGS DO NOT REQUIRE ANY

KIND OF LUBRICATION. DO NOT LUBRICATE THE BUSHINGS
TO REDUCE BUSHING NOISE. GREASE OR MINERAL OIL BASE
LUBRICANTS WILL DETERIORATE THE BUSHING.
THE SHOCK ABSORBERS ARE NOT REFILLABLE OR
ADJUSTABLE. IF A MALFUNCTION OCCURS, THE
SHOCK ABSORBER MUST BE REPLACED. TO TEST A SHOCK
ABSORBER HOLD IT UPRIGHT IN FULLY EXTENDED POSITION
FOR 10 MINUTES. THEN FORCE THE PISTON IN AND OUT OF
THE CYLINDER FOUR OR FIVE TIMES. THE ACTION
THROUGHOUT EACH STROKE SHOULD BE SMOOTH AND EVEN
 TIGHTENING TORQUE
UPPER ARM SIDE BUSHES 2 EACH SIDE 110-130 NM
(81-96 LBFT)
UPPER ARM BALL JOINT
MOUNTING NUT 4 EACH SIDE 23-29 NM
(17- 21 LBFT)
UPPER ARM PIN FULCRUM
MOUNTING NUT 2 EACH SIDE 120-140 NM
(88.5 –103 LBFT)
LOWER CONTROL ARM
FRONT MOUNTING 1 EACH SIDE 150-180 NM
(111-133 LBFT)
LOWER CONTROL ARM
REAR MOUNTING 1 EACH SIDE 110-130 NM
(81-96 LBFT)
ARM M12X1.25 WITH SPRING
WASHER & WELD NUT 1 EACH SIDE 60-80 NM
(44-59 LBFT)
TORQUE ARM M10X1.25 2 EACH SIDE
(1 IS WITH FLANGED NUT & WASHER THE OTHER IS WITH
WELD NUT.) 40-60 NM
( 29.5-44 LBFT)
LCA BALL JOINT MOUNTING 4 60-80 NM
NUT (44-59 LBFT)
LCA BUMP STOP MOUNTING 1 40-60 NM
( 29.5-44 LBFT)
STABILIZER BAR ON FRAME 2 EACH SIDE 30-45 NM
(22- 33 LBFT)
STABILIZER BAR +LINK 1 60-80 NM
(44-59 LBFT)
LINK ON LOWER ARM 1 16-22 NM
( 12- 16 LBFT)
SHOCK ABSORBER TOP-ON 1+1 EACH SIDE ( 2WD)
FRAME 16- 22 NM
( 12- 16 LBFT)
SHOCK ABSORBER BOTTOM ON LCA 2 16-22 NM
(12- 16 LBFT)
STEERING STOPPER ON KNUCKLE 1 50-75 NM
(37-55 LBFT)
CASTLE NUT UCA 1 120-160 NM
(88.5-118 LBFT)
CASTLE NUT LCA 1 120-160 NM
(88.5-118 LBFT)
FRAME- REBOUND STOPPER 1 40-60 NM
( 29.5-44 LBFT)
THANK YOU