In the process of reassembling the rear suspension. Checked the JTIS for instructions about the installation of the rear wishbones but cannot find anything in this topic! Lots of other procedures for the sub frame and the differential but nothing for the arms.From SNG Barratt I found the overview of all items involved, see below. What puzzles me here is the lower (in the picture) fulcrum washer no 5 that seems to go in the middle of the fulcrum bolt. This seems strange to me. The fulcrum washers are the ones with some kind of white plastic material on one side? In that case, they should be at each side of the wishbone itself where the wishbone meets the bushings? Also, should the side of the fulcrum washers with the white plastic material be faced toward the wishbone or the bushing next to it?

 

Higgins, Agree the JTIS is very poor regarding rear Wishbone re-assembly. When I took mine apart, I took this pic which is also poor! But does show washer positions. There are no washers that go ‘within’ the Wishbone itself – that is just a diagrammatic error of the exploded view.

I’m not sure if mine is right or wrong but I can confirm that the Nylon washers face contact with the wishbone. Also, be aware that when you torque up these fulcrum bolts, they must be under full load. That is to say the weight of the car is on the wheels/ground and not on axle stands.

 

Thanks PKWise! Then there is the washer no 3, "Plain washer" according to SNG Barratt. Where is it supposed to go?

 

Higgins, So in my assembly, Washer #3 is metal and goes between the bush in the end plate and the nylon Washer #5 that contacts the Wishbone.

Unfortunately in my poor quality photo, the Nylon washer #5 is dirty and darker than the metal washer #3 !

The exploded view has errors. It is trying to show that a nylon Washer #5 is positioned on both sides of the Wishbone but the dotted line is definitely wrong because there is no way these washers can fit WITHIN the wishbone end opening. What is also wrong with the diagram is that on my assembly the other Washer #5 has a different outside diameter - as evident in photo. This however could be a legitimate change - my car is late 2003 and has many factory changes.

 

In that case, the washer #3 is for spacing? Because on the other side of the wishbone, the Fulcrum washer with the nylon has to cope by itself with the wishbone on one side and a pendulum bush on the other

 

Higgins,
I think Washer #3 has 2 functions. Spacing AND distribution of thrust to not deform the Nylon washer #5.

If you consider the mis-assembly scenario, with the Nylon washer #5 facing the Bush (instead of the metal washer #3), the Nylon will touch only the inner bush metal hub in the end plate which is a very small area and would very likely compress and deform.

 

Thanks for the advice! Really appreciate it