Formula 3 - 1998

Model 398

DALLARA AUTOMOBltt IS HAPPY WITH THE CHOICE YOU MADE BUYING THE DALLARA F398,AND WISHES YOU THE VERY BEST IN RACING IT.

For any question, advice or idea you might have, please don't hesitate to contact us. Dallara Automobili Telephone Fax Via Provinciale 33 - 43040 VARANO MELEGARI +39-525-53221 +39-525-53478

- PR - ITALY

(design) (technical assistance) (business)

Mr Ferdinando Concari Mr Jos Claes Mrs Caterina Dallara

Ernail F3adallara.it Email F3@dallara.it Email comm@dallara.it

Dallara has an offdalweb site www.dallara.it where you can find useful informaffon about w m p a n y ,our people and our factory.

Le Mans Cornpany

Le Mans Building 3215 Hiroo Shibuya-ku Tokyo JAPAN

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Contact Telephone

Fax

Mr Katsuhisa Homma +81-3-3400-5086 +81-3-3486-0820

O A W Radng Services Unit 6G Redbrook Business Park Wilthorpe Rd South YorkShire S75 IJN UNITED KINGDOM Contact TBD Telephone +44 1226 240183 Fax +44 1226 284230

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- Barnsley

DALLARA Spare Parts Service Postweg 3 D 89290 Ritzisried GERMANY Contad Mrs Katrin Eichstaedt Telephone +49 7306 921467 Fax +497306921467

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Dallara Automobili

FOREWORD

..............................................................................................................................................................................a .......w..........~a~.......~......a.9.~4.*.~......~................u................................e.+....................

DALLARA DISTRIBUTORS .................................................................................................................................................. 1BASIC INFO%\lATION.

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GENERAL DIMENSIONS AN11 SUPPLIERS ..........................................:............................................................................ 5

VIEWS ........................................................................................................................................... : ...........................................

TIRE INFORMATION ........................................................................................................................................................... 6SUGGESTED SETUP.............................................................................................................................................................. 6 SETUP.ADrnSTMENT.....,.................................................................................................................................................... 7 OPTIONAL TRACKS ............................................................................................................................................................. 8 RIDE HElGHT CHECK AND REFERENCES ....................................................................................................................... 8. .

SUSPENSIONS ..en

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DAMPER DIMENSIONS ........................................................ ..................................................................................... 13 14 DAMPERS DIAGRAM ..................................................................................................................................................... BALL JOINTS AM)NAS BOLTS 15 FRONT SUSPENSION 16 MONODAMPER ROLL- PRELOAD ADSUSTMENT ON BELLEVILLE WACHERS 16 BELLEYILLE STACK CONFIGURATIONS (bellmevrIIe thikness 2.Omm) 16 PRE-LOAD PROCEDURES ............. ....................................................................................................................... 17 FORMERPROCEDURE.. ....................................~............................................................................................................. 17 STEERWG ASSEMBLY 18 FRONT CAS.?XJR ANGLESEmG A ........................................................................................................... 19 REAR SUSPENSION 20 2 REAR SUSPENSION ROLL CENTER AND ANTISQUATSEl77NG .............................................................................. 0 REAR ANTIROLL BAR STIFFNESS i.......... ............................................................................... 2 I ROLL STlFFNESS DISTRIBWTON DIAGRAM ..............................................................................................................2 2 REAR SUSPENSION ROCKER REPLACEMENT ............................................................................................................. 23

.................................................................................................................................................................... g ..............................................................................................................................12 DAMPERS ............................................................................................................................................................................. 13SPRINGS TABLE VERTICAL PRELOAD ADNSTMENT

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POWER FLOW D1FFERENT.U DETAILS AND SETUP AERODYNAMICS

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DEFINITIONS ...................................................................................................................................................................... 28 FRONT WING .............................................................................................................................................................. 29 4

FRONT VIM?C O N F I G U .TIONS .............................................................................................................................. 9 2 29 FRONT W&VGSlDEPW TE HOLES .................................................................................................................................

REAR WEND

RE;IR iprrNG PROFILES

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F R O W N REAR WING SIDEPLATE TABLE .............................................................................................................. I ............................................................................................................... BODYWORK APPENDAGES ....................... 32 3 2 UPPEA DIFFVSER VANE (UDY)................................................................................................................................. TURNING YMES (f73 ..................................................................................................................................................... 32 mRf?GUGURNEY (VG) .............................................................................................................................................. 32 SOWNFQRCH LE3vELs ............................................................................................................................................... 3 3 FRQNT kVD RBAR WIDER TR4CK SUSPENSIONS ..................................................................................................... 33 POW ......................................................................................................................................................... 34

REAR W.iN0~ ~ ~ N F I G U R A ..................................................................................................................................... TION 3 0 30 REAR WINO SIDEPU TE HOLES ....................................................................................................................................

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F398 U U r Htndbaok 1.01

17101198

Page 2 of 57

Dallara Automobili

GENERAL DIMENSIONS & A DSUPPLIERSWheelbase Front Track Rear Track overall height Overall width Overall length Weight Front suspension Rear suspension Chassis 261 1mm 1500mm

1300mm 930 mm (from ground to top of roll hop)1750 mm (wit wide front suspension)

3990 mm (from tip of nosebox to rearmost portion of rear wing)530 Kg (with ballast and driver in cockpit)

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push-rod monodamper push-rod twin damper Carbon and KEVLARTM sandwich with AL / N O M W hlcomb Glass fibre prepreg with NOMEX honeycomb

BodyworkComposites Castings Gearbox Gears and differential

HEXCEL-HERCULESAGUSTA DALLARA five ratios plus reverse gearHEWLAMD

SpringsDampers

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EIBACH 36 mm IDKONl2812-233 (bump and rebound adjustabte)

Fuel cell .. -.Extinguisher system. ,

PREMIER Fr3SPA design (electrical operated)MOM0 260 mm ODSPA design

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i Steering release systemSteering wheel, . . .< 61

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W l e : ~ .

7".

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FiltersRims

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"'.

BEHR

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FIAAM

SPEEDLlNE 9" front,1

- 10.5" rear

Brake system . Battery .. '

BREMBOFlAMM

Seat belt

TRW-SABELTFiat Abarth 16v Alfa Romeo 16v Twin Spark Mugen Honda 94 Mugen Honda 97

Installed epgines

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Opel Spiess 16v Renault 16v Toyota Tom's 'tail head" version and 'small head" version Mitsubishi HKS

F3Q8 Uaar Handbook 1.01

Page 5 of 57

TlRE INFORMATIONere are listed some tire properties for the most widely diffused F3 tires. Data updated at NovllsU1997. Tire,dimensions can change with inflating pressure, rim width and camber angle. stiffness values refer to the recommended inflating pressure.

FRONT TIRE Avon Specification 1801550-13 Free radius (mm) 277.5 Loaded radius (mm) 272 17.0 Vertical stiffness (Kglmm) 1.5 - Hot tire pressure (bar) REARTIRE :' 2501570-13 Specification Free radius (mm) 287.0 Loaded radius (mm) 281.3 17.5 Vertical stiffness (Kglmm) 1.65 Hot tire pressure (hay) -.SUGGESTED SETUP

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Brldgestone 1801550-13 277.2 27 1.5 14.4 1.3-

P

Mlchelin 20154-13 272.3 267.8 20.7 1.55

P

Plrelli 2001530-13 266.3 261.5 17.1 1.5

Yokohama 180/50-13 278:O 273.2 17.0 1.4240145-13 288.0 281.0 17.8 1.45

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2401570-13 286.5 279.0 16.7 1.4

24157-13 289.1 284.0 21.8 1.6

250/575-13 289.4 282.0 17.2 1.55

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The following values are considered with the driver already in the cockpit, with the car ready to go. The front monodamper setting is relative to the preload procedure which doesn't lock the stack under the prelaod value, but just double the nominal stiffness stack. Look in detail at the proper section.

F398 User Handbook 1.03I .

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Dallara AUtomobili

SETUP ADJUSTMENTThe following table gives information about the effect of your adjustment on the car set-up.Positive change in: Height Toe Camber Castor means: Car rises Toe-out Upper part of rim outward Lower part of rim points ahead

FRONTPUSHROD ADJUSTER (+I turn) thread step height change (mm) camber change (deg)

REARMI . ~ ~ R H s + ~ ~ P ' < H s 5.47 13'

M 1.25RHS+24P8LHS4.00 2'

TOE ADJUSTER (+1

turn) thread step toe change (deg)

24f' 35'

-22'15 '

TOE SPACER (+1 mm)

15'lower rear

CAMBER SPACER (+l mm)CASTOR ADJUSTER (+I turn) .. ., wishbone position thread step height change (mm) camber change (deg) toe change (deg) castor change (deg)

lower h n t20P

24P-1.05

-5'

-1.85 -1 0 '5'

-2'22'

-30'

SPRING, . .pLAT,F;OW (+.I turn)..

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thread step (mm)height change (mm)

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WHEEUSPRINGRATIO (vertical)

0.8841.397

1.11

WHEEUBELLEVILLE RATIO (lateral)WHEEUDROP LINK RATIO (roll)

1.64

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* Spacers to adjust front camber, rear toe and rear camber are available on the following thickness: 0.8, I 1.2, 1.5, 2.0 mm. You can combine ihem for finer adjustment. .OnFront and mar wheel to spring, front wheel to Belleville and rear wheel to drop link motion ratios may be considered as constant for all the wheel motion. , i . .Y Toe change is,@tendedat each wheel. , .. 1 . , ',I

"98 User Handbook 1.01

Page 7 of 57

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c 9TIONAL 'TRACKSKinematic wheel/spring ratios and wheelldrop link ratios or wheel/belleville ratios are relative to front and rear track as supplied as standard, Front 1500 mm, Rear 1300 mm. You can also get a narrower front track suspension (1370 mm), which has 1.50:1 Wheel IBelleville ratio (roll motion) and the same Wheel I Spring ratio (vertical motion) Front suspension: we suggest wide for better turn in, narrow for better aerodynamics Available on request a wider rear suspension (1430 mm) with 1.22:l wheel / spring ratio and 1.81:1 wheel / droplink ratio , . Rear suspension: we suggest wide for better traction, narrow for better aerodynamics, J

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RIDE HEIGHT CHECK AND REFERENCES The wheel axis ride height is the basic and most important figure, because ride height is fundamental in setting and changing the aerodynamic performance of the car. It maybe difficult to measure it directly, so alternative references are given. Look at the sketch with an example where front ride height is 15 mm, rear is 40 mm ( at wheel axis ): x = 0.55" with 2610 mm wheelbase, you have 0.55" pitch angle. (40 - 15) 1 2610 = 1 1 tan x On front side of the car you have two alternative references: 1) on the chassis, on wheel axle and ahead the rocker. two bolts 450 mrn from car bottom. Hence, you can measure their distance from the ground as 465 450 = 15mm ride height

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2) under the splitter, a flat surface about 310 mm behind the wheel axis and 50 mm behind the skid leading edge. Hence, you can measure its distance from ground as: (tan0.55' * 310)+ 1 5 = 18mm , .. .

On rear side of the car you have two alternative references to use: 3) on the gearbox, on wheel axle, near top mountings, t o machined areas at 337 mm from car w bottom. Hence, you can measure their distance from the ground as 377 337 = 40mm height

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4) under flat bottom, 50 mm ahead of the end of the wooden plate and 210 mm ahead of rear wheel axis. You can measure its distance from ground as 40 (tan0.55" *2101= 38mm height .-.. . . - $

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F398 U s e r Handbook 1.01

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SPRINGS TABLE

StIffnesa.'

Lhlln

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FreeLength

I D

Wire thickness

Maxdeflect.

Weight

Ka m sL m

mm

ma

mm

m m

Kg

=We do not .hold stock for these springs, please contact directly Eibach ; : * . ... . ..?..s .

To convert spring stiffness from Lb/in to Kglmm divide by 56. For a " .900 " spflng ,'900.1 56 = 16.07 Kglmm stiffness. : , . . ! . ..;, . :;. .,1

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Dallara Automobili

VERTICAL STIFFNESS DISTRIBUTION Graphs are included to show the ratio between the front and the lolal vertical stiffness. Total vertical stiffness Is obtained by combining the springs and llras contrlbullon in serles.

F398 User Handbook 1.01,\.

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Page 11 of Sf

Dallara Autornobili

VERT1CP.L PRELOAD ADJUSTh7ENTRemember that actually some pre-load is given by the damper: this contribution is around 10 Kg anddepends upon choice of damper type and setting and of damper chamber gas pressure. This procedure is valid either for the front and the rear springs. As the push-rod adjuster has to be used just for small and quick adjustment on track field, the ride height can be modified also by turning the spring platform C. This only in a no-pre-loaded condition. Keep push-rod length fixed and turn the platform C to alter ride height. Pre-load is the force that has to be applied on the spring'to modify its length with respect to the static value. To set the preload, turn platform C. As the platform thread step is 2 mm, the preload,P [Kg] is: P (kg) = 2 (mm) K, (spring stiffness in kglrnm) x t (number of turns) (spring stffness Lblin) / 56 = (spring stiffness Kglmm)

Adjust push-rod length according to set-up instructions; screw bolt A away from touching bolt 8; adjust ride height by turning platform C; when desired ride height is achieved, move bolt A just to contact opposite bolt B. turn platform C until1 desired preload force is achieved.

Page 12 of 57

DAMPERS

DAMPER DIMENSIONSStandard dampers are KONI 2812-233. Front and rear have the same open length and installation pads. Please remind it when asking for spares. Damper assembly dimensions are: full open length full closed length (front) (rear) stroke (front) (rear)mm 335297 291

inch 1311% 11%

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When-mounting Koni dampers always use spacer 6 mm thick on front assy to prevent the rocker to lock. If you plan to use alternative products check that maximum stroke to be less than 38 mm. Dallara, on request, delivers kits for PENSKE and QUANTUM dampers. If you want to install other dampers, remind that full open length and full dosed length must be equal to those listed.

F3Q8 Uwr Handbook 1. O l

Dallara Automobili

DAMPERS OIAGRAM' ;

The dampers are adjustable both in bump and rebound by acting on the wheels marked B (for bump adjustment) and R (for rebound adjustment) on the damper.Each wheel has eight different positions. Figure shows different damper characteristics for each position of the wheel.

Damper dlagrarn-bump and rebound240

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F398,Us.r,I

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Handbook i.01

12/01/98

Oallara A~tomobili

BALL JOINTS AND NAS BOLTSYou can find here the bolts and the ball joint type as used in our chassis to help you to get spare bblts and in case of restacking ball joints that showed play after long use.

Dallara Aulomob~liFRONT SUSPENSION

MONODAMPER ROLL- PRELOAD ADJUSTMENT ON BELLEVILLE WACHERSF398 features two alternative ways to set roll - prelaod in the front mono damper.The former is the same as used during for previous years:

Under the preload, the total stiffness is twice the stiffness of one stack, both stacks are working

Over the preload, the total stiffness is the nominal stiffness of one stackThe latter is accomplished with an additional nut and counter nut Under the preload, the rocker doesn't move at all, similarly to the vertical spring preload., - Over the preload, the total stiffness is the nominal stiffness of one stack

The choice between the two systems follows some considerations and driver's preferences, The former features a rocker that in roll never locks. The latter may give you a sharper turn in. just Clearance between the platform and the rocker (B) shall not be more than 6.5mm when ~latforrn touches the belleville stack, with no preload. Pre-load of the front monodamper is the difference between the actual and the static length of the Belleville stack. Procedure below allows you to set-up the front monodamper pre-load. You can achieve a regressive/progressive load/displacement characteristic by combining in series two different stacks and fitting an appropriate pre-load, provided that the total length stays within 28 mm. We recommend to use Bellevillr: ...qsher 2 mm thick: they have a linear loadldeflection characteristic, alternatively you can fit 1.75 mm ti iick washers commercially available For any Belleville stack, in running condition, rocker lateral motion plus the chosen pre-load must never be greater than "Maximum Deflection" (refer to Table 6) to avoid a sudden locking of the rocker. Playing with the preload level requires alatatc;acrt for both setting systems listed below. 3ver the preload, the total sllffne$is reduces to the nomlnal stiffness of one beleville stack. You may like roll preload level in certain conditions (mid corner, over kerbs, etc) and desire to go ,o work the transition point between the two conditions ('the pre-load he preload in some other. Set evel") since the consequent stiffness change is sudden and reflects immediately on balance.

3ELLEVILLE'STACKCONFIGURATIONS (belleville thikness 2.0mrn)I(

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)8 User Handbook 1.01' 8. . I ,

Dallara Automobili Dallara Automobili

PRE-LOAD PROCEDURES" ~ & . J ~

CENTER S E T I N G ~ L L

e Push off C bush and remove latform until Belleville stack is free STEERING ASSEMBLY Front ro I centre can b quickly adjusted by moving the spacer to ib upper or I d ~ f t b i f i ~t ~ ~ & ~ ~ ~ choosing **lowroll centret'~ ~ ~ configuration, pus,tI rod ~

P

~

~ ~ Q Q ~ I ~ ~ R & s~ BA ~~ W & ~R~ .Q @ M q @ t h @ Q ~ b te~ifae~e ~ ~ Q W . W H ~ ~ ~ @ B ~ k r > t ~ r~de height.. 'nior re lac adjustment spacer. When a#justfng tae roll center, you will also change the camber gain as function of the wheel travel Mark this position as the ' zero pre-load " notch on the platform* Turn the platforstep is 1.5mmthe car. Thread

LAITER PRE-LOAD PROCEDURE

:

Static steering ratio Ackerrnann [%I

1IC

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13 steering wheWwheel43.5Pa o 180157 %aOo 1 7 of ST

F3Q8User Handbook 1.01 F388 U s r r Hbndbook 1 .O 1

12/01/98 12/01/98

Dallara Autornobili

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FRONT CASTOR ANGLE SElTlNG When the car is flat, ie with identical front and rear ride height, the hub inclination angle is 1.93" and the front castor angle is 8.58". With different front and rear ride heighls, castor angle changes because of the pitch angle.For instance, with 15 mm front and 40mm rear ride height, measured at wheel axis. (wheelbase is 2610 mmj the pitch angle is 0.55' as: Pitch angle. (40-15)/2610 = 1 / tan 0.55" Current castor angle :8.58"

- 0.55" = 8.03".

FJQ8 U8.r Handbook 1.01

Dallara Au tomobiii

REAR SUSPENSION REAR SUSPENSION ROLL CENTER AND ANTISQUAT SETTINGWe make available some settings of the roll centre and antisquat. Table 8 lists those with reference to the standard setting. Figure 14 presents the mounting onto gearbox needed to achieve the settings.

TRAVEL DIRECTION

@

= USED

o = UNUSED

F398 User Handbook 1.011 :,

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REAR ANTIROLL BAR STIFFNESS

F398 features two antiroll bar adjustable blades,Rear antiroll bars are solid, so you can get the softer ones by milling down the stiffer ones. Standard rear antiroll bar has outer diameter 24 mm. Look at available antiroll bars and their installation stiffness [kglmm] ~he"hvo digits in the columns represent the blade position 1=full soft, 5=full hard

F3Q8 Uaer Handbook 1.010

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Page 21 of 57

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Dallara Automobili

ROLL STIFFNESS DISTRIBUTION DIAGRAMThis diagram helps to evaluate the front percentage of roll stiffness for a given combination of rear anliroll bar and front Belleville stack stiffness (former preload procedure, under the pre-load limit).

F397-roll stiffness distributionFront BelbvlllelRaar anttroll bar conbhatlon70I

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a 0 4 .

Rmrr mlbar OD (mm]I

1--c--ZCM

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Cf64

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...*..2 ...&..

- - ~ l a l - m a -8-Kb(l *mmzstbrd

...&..

24.w

...y.. mIYd

0

m

1 m

1 m

1540

tma

mo

Front Belkvllk stack stnmess [Kglmm] wfth prebad

REAR SUSPENSlON ROCKER REPLACEMENT

Rear rocker spins around the steel pivot A fitted onto the gearbox case by the stud B loctited (LOCTITE 242" ). The steel pivot is forced with interference into its housing. Procedure 4 helps you splitting the rocker assembly, taking off the pivot and the stud. Contact DALLARA's customers service to buy took E and F. Unscrew the nut C. The tightening torque to fit it back is 3.5 Kgm; take off the top cap and the rocker; unscrew nut D with a long 14mm tubular spanner. The tightening torque to fit it back is 5.5 Kgm; Fit extractor F around pivot's outer flange, screwing bolt E in, and remove the oivot remove stud B with the proper tool. The stud is loctited in its insert, be very careful Ghen trying to remove it. When removing the stud, warm the loctited stud's thread with heatgun up to 140 Co.J

F398 .UW . Handbook 1.01

Page 23 of ST

Dallara Automobili

HUB HUB ASSEMBLYTho following procedure helps in changing front and rear hub bearingse

Removal of bearing assembly from hub a) Remove A nuts; .. b) warm the hub to 120C and remove bearing assembly.

Bearing removal a) Remove spigot by removing the 6 screws 3; b) push off drive flange by using two 6x1 screws set on thread C; c) remove seeger; d) press off bearing from carrier by using a centre punch, through holes E; e) push off retainer by means of two 6x1 screws set on thread C.

Replacement of bearing a) Press wheel bearing into bearing carrier; b) fit seeger D; c) press retainer into wheel bearing; d) place spigot in position on drive flange, fit B screws, washers and nuts and tighten to 39 Nm (Caution: this value fit for 12K screws only).0,

Wheel stud removal a) To reduce resistance to Loctite, heat wheel stud and retainer to 180C; b) remove wheel stud.

Wheel stud qeplacementa) Remove pin F; b) clean and degrease retainer thread and wheel stud; c) spray degreaser to threaded area of retainer and wheel stud. Caution: Don't use' petrol; d) apply LOCTITE 638" to wheel stud thread; e) screw wheel stud into retainer and tighten to 245 Nm by forcing on head T; f ) drill wheel stud and insert pin F. ,#.$,

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Bearlng assembly Into hub replacement a) Warm the hub,to 120'C; b),fit me beadng.assernbIy into hub and tighten nuts A to 17 Nrn./

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F398 User Handbook 1.041 ,,* I.':,*,,#