Workshop manual

5018 PDS 2000

Product
Exploded View
Disassembly & Assembling

Shock absorber 5018 PDS 2000

02/2002

Shock absorber

5018 PDS OEM 2000

Introduction
Exploded view
Disassembly shock absorber
Disassembly piston-rod
Disassembly adaptor DU-bush
Assembling adaptor DU-bush
Assembling piston-rod
Disassembly tube-side
Assembling tube-side
Bleeding
On pressure with nitrogen
Mounting spring
Adjusting

2
3
4
11
15
17
21
27
34
48
56
57
60

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Introduction
General notice
Pay attention to the following notes, when you are working
with WP suspension products as described in this
workshop manual:
Always use clean and professional tools.
Regular you need next to the general equipment, the
special tools of WP Suspension.
These tools with a unique T number (available at
WP Suspension) protect you from damaging the parts.

Always use aluminium protector-plates, when clamping

our products or parts in the vice.
Always replace damaged or worn parts.

Shock absorber 5018 PDS 2000

02/2002

Clean all parts before assembling.

Caution:
Many times it is necesarry to assemble parts with T131,
T132 and T163.
These parts must dry for at least four hours!!

We r k p l a a t s h a n d b o e k

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Shock absorber 5018 PDS 2000

02/2002

Exploded view

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Disassembly
shock absorber
Measure the length (preload) of the
spring.

175

Take note of the rebound (REB) position.

1 is closed.
(+ mark)

Shock absorber 5018 PDS 2000

02/2002

176

Take note of the compression (COM)

position.
1 is open.
( mark).
177

We r k p l a a t s h a n d b o e k

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Unscrew the spring retainer.

(Allenkey 5)

178

Loosen the spring retainer with T106.

Shock absorber 5018 PDS 2000

02/2002

179

Screw the spring retainer to the

bottom.

180

We r k p l a a t s h a n d b o e k

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Pull the spring downwards and take off

the open spring retainer.

181

Remove the spring washer.

Shock absorber 5018 PDS 2000

02/2002

182

Remove the spring.

183

We r k p l a a t s h a n d b o e k

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Remove the second washer.

184

Remove rubber cap of the nitrogen

reservoir.

Shock absorber 5018 PDS 2000

02/2002

185

Slowly release the nitrogen pressure.

186

We r k p l a a t s h a n d b o e k

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Tap off the cap on one side with a drift...

187

...and on the other side.

Shock absorber 5018 PDS 2000

02/2002

188

Tap the adaptor DU-bush loose with

T1216.

191

We r k p l a a t s h a n d b o e k

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Push the adaptor downwards.

192

Remove the springring.

Shock absorber 5018 PDS 2000

02/2002

194

Pull firmly but carefully the piston-rod

complete out of the tube.

195

We r k p l a a t s h a n d b o e k

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Drain the oil out of the tube.

Shock absorber 5018 PDS 2000

02/2002

594

We r k p l a a t s h a n d b o e k

10

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Disassembly piston-rod
Unscrew the piston-rod nut. (size 22)

196

Place a screwdriver on top of the

piston-rod and lift the entire assembly,
consisting of rings, pistons and shims.

Shock absorber 5018 PDS 2000

02/2002

197

- rebound bush plane

- compression shims piston 1
- piston 1
- rebound shims piston 1
- intermediate bush
198
We r k p l a a t s h a n d b o e k
- compression shims piston 2
onderdelen
- piston 2
rijtje
- rebound shims piston 2
- piston-rod nut

11

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Remove the adaptor DU-bush.

199

Remove springring and cap.

Shock absorber 5018 PDS 2000

02/2002

200

Remove bump rubber.

12_001

We r k p l a a t s h a n d b o e k

12

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Disassemble the screw-cap rebound

adjustment holder with T1218.

12_003

Disassemble the adaptor out of the

mounting fork with a screwdriver.

Shock absorber 5018 PDS 2000

02/2002

12_004

Unscrew the adjustment needle out of

the adaptor.

We r k p l a a t s h a n d b o e k
12_005

13

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Pay attention to the spring and the steel

balls!!!

Shock absorber 5018 PDS 2000

02/2002

12_006

We r k p l a a t s h a n d b o e k

14

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Disassembly adaptor
DU-bush
Pull the rebound rubber out of the
adaptor.

209

Prise the dirt scraper out of the adaptor.

Shock absorber 5018 PDS 2000

02/2002

211

Disassemble the DU-bush with T1208

and T1209.

215

We r k p l a a t s h a n d b o e k

15

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Press the DU-bush out of its adaptor.

216

- rebound rubber
- disc steel
- quad ring
- back-up ring
- DU-bush
- adaptor
- O-ring
- dirt scraper

Shock absorber 5018 PDS 2000

02/2002

217

We r k p l a a t s h a n d b o e k

16

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Assembling adaptor
DU-bush
Assemble a new DU-bush with T1208
and T1209.
Wet the DU-bush with oil.

220

Press the DU-bush into the adaptor.

Shock absorber 5018 PDS 2000

02/2002

221

Calibrate the DU-bush with T1205 and

T1209.
Wet the mandrel with oil.
222

We r k p l a a t s h a n d b o e k

17

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Drive the calibration mandrel through the

DU-bush.

224

Press a new dirt scraper into the

adaptor with T1204.

Shock absorber 5018 PDS 2000

02/2002

227

Replace the O-ring.

228

We r k p l a a t s h a n d b o e k

18

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Assemble the back-up ring.

229

Assemble the quad ring.

Shock absorber 5018 PDS 2000

02/2002

230

Replace the steel disc.

231

We r k p l a a t s h a n d b o e k

19

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

After assembling the rebound rubber

ensure if the rubber can be rotated in the
adaptor.

Shock absorber 5018 PDS 2000

02/2002

232

We r k p l a a t s h a n d b o e k

20

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Assembling piston- rod

Grease the O-rings and steel ballls with
T158.

12_006

Assemble the needle.

Shock absorber 5018 PDS 2000

02/2002

12_007

Screw the needle into the adaptor.

12_008

We r k p l a a t s h a n d b o e k

21

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Grease the O-ring of the screw-cap with

T158.

12_011

Assemble the rebound adjustment

holder cpl.

Shock absorber 5018 PDS 2000

02/2002

12_013

Tighten the screw-cap with T1218.

12_014

We r k p l a a t s h a n d b o e k

22

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Place T1215 on top of the piston- rod.

238

Assemble bump rubber.

Shock absorber 5018 PDS 2000

02/2002

12_002

Place cap.

240

We r k p l a a t s h a n d b o e k

23

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Grease the dirt scraper with T625 and...

241

...assemble the DU-bush adaptor.

Shock absorber 5018 PDS 2000

02/2002

242

Replace the entire damping packet.

243

We r k p l a a t s h a n d b o e k

24

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Grease the O-ring of the adaptor with

T158.

244

Drip T163 on the thread of the pistonrod nut.

Shock absorber 5018 PDS 2000

02/2002

245

Slide T1214 over both pistons and the

adaptor.

246

We r k p l a a t s h a n d b o e k

25

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Place T107S through T1214, intermediate

bush and piston-rod.

247

Tighten the nut to a torque of 40Nm.

Shock absorber 5018 PDS 2000

02/2002

248

We r k p l a a t s h a n d b o e k

26

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Disassembly tube-side
Heat the nitrogen reservoir near the
bottom.

250

Unscrew reservoir with T146 and T147.

Shock absorber 5018 PDS 2000

02/2002

251

Clamp nitrogen reservoir into T146 and

T147 and unscrew the screw-cap with
T125S and T145S.
252

We r k p l a a t s h a n d b o e k

27

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Push the separation piston out of the

reservoir with T107S.

253

Remove the springring out of the

groove and and place it below the
groove.

Shock absorber 5018 PDS 2000

02/2002

254

Slide spring guide downwards and....

256

We r k p l a a t s h a n d b o e k

28

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

....remove the upper springring.

257

Remove the spring guide.

Pay attention to the assembling
direction!!!

Shock absorber 5018 PDS 2000

02/2002

258

Disassemble the springring.

259

We r k p l a a t s h a n d b o e k

29

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Screw the spring retainer from the tube.

260

Unscrew (size 2.5) compression

adjusting knob and remove it.
Pay attention to the spring in the knob!!!

Shock absorber 5018 PDS 2000

02/2002

261

Remove steel ball.

262

We r k p l a a t s h a n d b o e k

30

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Disassemble the lock washer.

264

Pull out the compression control

mechanism.

Shock absorber 5018 PDS 2000

02/2002

265

The compression control mechanism.

275

We r k p l a a t s h a n d b o e k

31

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Remove the adaptor bushes with T120.

310

Tap adaptor bushes out of the heim-joint

KGW and remove the seals.

Shock absorber 5018 PDS 2000

02/2002

277

Remove the springring on both sides.

283

We r k p l a a t s h a n d b o e k

32

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Disassemble heim-joint KGW with

T1207S.

279

Press the heim-joint KGW out of the

bottom with the vice.

Shock absorber 5018 PDS 2000

02/2002

280

288

- adaptor bush
- seal
- springring
- heim-joint KGW
- springring
We r k p l a a t s h a n d b o e k
- seal
- adaptor bush

33

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Assembling tube-side
Drip on the innerside of the bottom eye
T163 and mount the heim-joint KGW with
T1206.
(with the bevelled edge direction bottom)

311

Press heim-joint into the bottom with the

vice.

Shock absorber 5018 PDS 2000

02/2002

290

Assemble both the springrings.

312

We r k p l a a t s h a n d b o e k

34

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Assemble the seals.

313

Press one adaptor bush in the heim-joint

with T1206.
And the other without the tool.

Shock absorber 5018 PDS 2000

02/2002

293

Building up the nitrogen reservoir:

Grease the O-ring of the piston with
T158.
294

We r k p l a a t s h a n d b o e k

35

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Assemble the separation piston with the

spherical surface into the direction of the
groove.

295

Groove.

Shock absorber 5018 PDS 2000

02/2002

297

Wet the thread of the reservoir on both

sides with T132.

298

We r k p l a a t s h a n d b o e k

36

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Drip T132 on thread screw-cap.

299

And T132 on thread bottom.

Shock absorber 5018 PDS 2000

02/2002

301

Assemble the screw-cap and the

reservoir.

302

We r k p l a a t s h a n d b o e k

37

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Tighten the screw-cap and the reservoir

on the bottom with T125S and T145S.

303

Assemble the spring retainer.

Shock absorber 5018 PDS 2000

02/2002

314

Screw the retainer against the bottom.

315

We r k p l a a t s h a n d b o e k

38

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Assemble the springring on the tube past

the second groove.

316

Slide the spring guide on the tube with

the chamber of the spring guide in the
direction of the upper springring groove.

Shock absorber 5018 PDS 2000

02/2002

317

Place the upper springring into the

groove.

320

We r k p l a a t s h a n d b o e k

39

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Slide the guide over the springring.

321

Assemble the springring.

Shock absorber 5018 PDS 2000

02/2002

324

Assembling compression control

mechanism:
Grease the O-rings with T158.
326

We r k p l a a t s h a n d b o e k

40

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Assemble mechanism so that its hole is

facing to the hole of the tube.

327

Push mechanism with T160 past lock

washer groove.

Shock absorber 5018 PDS 2000

02/2002

328

Assemble lock washer with the flat side

above.

329

We r k p l a a t s h a n d b o e k

41

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Grease the upper side of mechanism

with T159 and place steel ball next (left
side) to the pin.

331

Place the adjusting knob with the spring,

the spring directly on the steel ball.

Shock absorber 5018 PDS 2000

02/2002

332

Push the knob and tighten it.

Turn the adjusting knob to position 1.
( mark).
333

We r k p l a a t s h a n d b o e k

42

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Fill the tube with oil about 10mm under

the springring groove.

330

Place T1210S into the tube and T107S

into the reservoir, slide the O-ring as far
as the screw-cap.

Shock absorber 5018 PDS 2000

02/2002

336

Push the plunger all the way

downwards.

337

We r k p l a a t s h a n d b o e k

43

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Push T107S downwards, (separation

piston) repeat those two handlings
several times.

337 / 338

Adjust the separation piston with

T1210S about 10mm from bottom, also
the O-ring on the shaft of T107S will be
10mm from the screw-cap.

Shock absorber 5018 PDS 2000

02/2002

339

Adjust compression mechanism to

position 13.
(+ mark).
340

We r k p l a a t s h a n d b o e k

44

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Fill up oil about 10mm under the

springring groove.

346

Assembling piston-rod cpl..

Grease the O-ring of the DU-bush
adaptor with T158.

Shock absorber 5018 PDS 2000

02/2002

348

Assemble piston-rod complete into the

tube.

351

We r k p l a a t s h a n d b o e k

45

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Push the adaptor into the tube....

352

...past springring groove.

Shock absorber 5018 PDS 2000

02/2002

353

Assemble the springring also past the

groove.

354

We r k p l a a t s h a n d b o e k

46

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Pull up the piston-rod, and the springring

will spring in the groove.

355

Tap the cap into the tube.

Shock absorber 5018 PDS 2000

02/2002

356

We r k p l a a t s h a n d b o e k

47

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Bleeding
(not the correct pictures)
Disassemble the knob.

261

Remove the steel ball.

Shock absorber 5018 PDS 2000

02/2002

262

Remove the lock washer.

We r k p l a a t s h a n d b o e k
264

48

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Remove the compression control

mechanism.

265

Shock absorber 5018 PDS 2000

02/2002

275

We r k p l a a t s h a n d b o e k
362

49

Clamp the shock absorber (not too tight)

on the spring guide in the vice at an
angle of approximately 45 degrees with
the housing of the compression
mechanism at the highest level.

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Connect the adaptor of T144S into the

housing.

363

Shock absorber 5018 PDS 2000

02/2002

Ensure that there is sufficient oil in the

bottle and that the hose is also full with
oil.
You will see air bubbles rising up
through the hose.

364

Push the piston-rod slowly in.

We r k p l a a t s h a n d b o e k
365

50

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Pull the piston-rod out.

366

Shock absorber 5018 PDS 2000

02/2002

Remove the shock absorber out from

the vice and turn it 45 degrees several
times.
Repeat all the bleeding procedures until
all air is bled out.
367

Pull the piston-rod completely out.

Check position (10mm) of the
separation piston with T107S.
We r k p l a a t s h a n d b o e k
368

51

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Unscrew adjusting needle clockwise out

of the mechanism.

370

Shock absorber 5018 PDS 2000

02/2002

Assemble the mechanism.

Hole of the mechanism facing hole
direction tube!!!

371

Assembled compression control

mechanism.

We r k p l a a t s h a n d b o e k
372

52

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Screw the adjusting needle hand tight

into the mechanism.

Shock absorber 5018 PDS 2000

02/2002

373

We r k p l a a t s h a n d b o e k

53

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Push the mechanism with T160 past the

lock washer groove.

328

Assemble the lock washer with the flat

side above in the groove.

Shock absorber 5018 PDS 2000

02/2002

329

Place steel ball left next to pin.

We r k p l a a t s h a n d b o e k
331

54

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Assemble the adjusting knob with spring

on the steel ball.

332

Push the knob against the housing and

tighten it.

Shock absorber 5018 PDS 2000

02/2002

333

We r k p l a a t s h a n d b o e k

55

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

On pressure with
nitrogen
Screw the nitrogen plug with O-ring
several turns into the nitrogen reservoir
screw-cap.

374

Place the shock absorber in T170S and

fill the reservoir with nitrogen
(20 sec.) and tighten the plug under
pressure.

Shock absorber 5018 PDS 2000

02/2002

379

Assemble the rubber cap.

We r k p l a a t s h a n d b o e k
380

56

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Mounting spring
Turn mounting fork parallel with bottom
eye.
Rebound and compression mechanism
in the same direction

381

Replace spring washer.

Shock absorber 5018 PDS 2000

02/2002

382

Replace the spring with the progressive

coils in direction of the bottom.

383

We r k p l a a t s h a n d b o e k

57

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Replace the second washer.

384

Assemble open spring retainer with the

closed side on the end of the coil.

Shock absorber 5018 PDS 2000

02/2002

385

Turn the spring and retainer in this

position.

387

We r k p l a a t s h a n d b o e k

58

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Adjust the preload of the spring.

388

Tighten the bolt of the spring retainer

to...

Shock absorber 5018 PDS 2000

02/2002

389

...a torque of 5Nm.

390

We r k p l a a t s h a n d b o e k

59

Workshop manual
5018 PDS 2000
Product
Exploded View
Disassembly & Assembling

Adjusting
Rebound position!

391

Compression position!

Shock absorber 5018 PDS 2000

02/2002

392

We r k p l a a t s h a n d b o e k

60