2000 gs town&country caravan voyager diagnostic diesel version incl

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SUSPENSION

TABLE OF CONTENTS

page page

HEEL ALIGNMENT. . . . . . . . . . . . . . . . . . . . . . . . 1RONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . 10

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PRE-WHEEL ALIGNMENT INSPECTION . . . . . . . . 5

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REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . 44

WHEEL ALIGNMENT

TABLE OF CONTENTS

page

ESCRIPTION AND OPERATIONWHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . 1IAGNOSIS AND TESTINGSUSPENSION AND STEERING DIAGNOSIS . . . . . 3ERVICE PROCEDURES

CURB HEIGHT MEASUREMENT . . . . . . . . . . . . . . 5WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . 5PECIFICATIONSWHEEL ALIGNMENT SPECIFICATIONS . . . . . . . . . 9

ESCRIPTION AND OPERATION

HEEL ALIGNMENT

ESCRIPTIONVehicle wheel alignment is the proper adjustment

f all interrelated front and rear suspension angles.hese angles are what affects the handling andteering of the vehicle when it is in motion.The method of checking a vehicle’s front and rearheel alignment will vary depending on the type andanufacturer of the equipment being used. Instruc-

ions furnished by the manufacturer of the equip-ent being used should always be followed to ensure

ccuracy of the alignment, except when alignmentpecifications recommended by DaimlerChrysler Cor-oration differ.Typical wheel alignment angles and measurements

re camber, caster, toe, and thrust angle.

• Camber is the number of degrees the top of thetire and wheel assembly is tilted either inward oroutward (Fig. 1). Camber is a tire wearing angle.Excessive negative camber will cause tread wear atthe inside of the tire, while excessive positive camberwill cause outside tire wear.

• Cross Camber is the difference between left andright camber. To achieve the cross camber reading,subtract the right side camber reading from the left.For example, if the left camber is +0.3° and the rightcamber is 0.0°, the cross camber would be +0.3°.

• Caster is the number of degrees of forward orrearward tilt of the steering knuckle (Fig. 2). For-ward tilt provides a negative caster angle, while rear-ward tilt provides a positive caster angle. Althoughcaster does not affect tire wear, a caster imbalance(side-to-side) on the vehicle may cause the vehicle tolead to the side with the least positive caster. Casteris not adjustable on this vehicle.

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DESCRIPTION AND OPERATION (Continued)

• Cross Caster is the difference between left andight caster.• Toe is measured in degrees or inches and is the

ifference in width between the centered leading andrailing edges of the tires on the same axle (Fig. 3).oe-in means that the front width is more narrowhan the rear. Toe-out means that the front width isider than the rear.• Thrust Angle is defined as the average of the toe

ettings on each rear wheel. If this measurement isut of specification, readjust the rear wheel toe sohat each wheel has 1/2 of the total toe measure-ent. When readjusting, do not exceed the total toe

pecification.Wheel alignment on this vehicle is to be checked

nd all alignment adjustments are to be made withhe vehicle standing at its curb height specification.urb height is the riding height of the vehicle mea-ured from a certain point on the vehicle to theround while the vehicle is setting on a flat, levelurface.

Fig. 1 Camber1 – NEGATIVE2 – POSITIVE

Fig. 2 Caster1 – POSITIVE2 – NEGATIVE

Fig. 3 Toe1 – TOE-IN2 – TOE-OUT

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IAGNOSIS AND TESTING

USPENSION AND STEERING DIAGNOSIS

CONDITION POSSIBLE CAUSES CORRECTION

Front End Whine On Turns 1. Defective wheel bearing 1. Replace wheel bearing

2. Incorrect wheel alignment 2. Check and reset wheel alignment

3. Worn tires 3. Replace tires

Front End Growl OrGrinding On Turns

1. Defective wheel bearing 1. Replace wheel bearing

2. Engine mount grounding 2. Check for motor mount hitting framerail and reposition engine as required

3. Worn or broken C/V joint 3. Replace C/V joint

4. Loose wheel lug nuts 4. Verify wheel lug nut torque



7. Front strut pin in upper strut mount 7. Replace the front strut upper mountand bearing

Front End Clunk Or SnapOn Turns

1. Loose lug nuts 1. Verify wheel lug nut torque


3. Worn or loose tie rod 3. Tighten or replace tie rod end

4. Worn or loose ball joint 4. Tighten or replace ball joint

5. Worn/loose control arm bushing 5. Replace control arm bushing

6. Loose stabilizer bar. 6. Tighten stabilizer bar to specifiedtorque

7. Loose strut mount to bodyattachment

7. Tighten strut attachment to specifiedtorque

8. Loose crossmember bolts 8. Tighten crossmember bolts tospecified torque

Front End Whine WithVehicle Going Straight At AConstant Speed

1. Defective wheel bearing 1. Replace wheel bearing



4. Worn or defective transaxle gears orbearings

4. Replace transaxle gears or bearings

Front End Growl OrGrinding With VehicleGoing Straight At AConstant Speed

1. Engine mount grounding 1. Reposition engine as required


Front End Whine WhenAccelerating OrDecelerating



2 - 4 SUSPENSION NS

DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

Front End Clunk WhenAccelerating Or Decelerating

1. Worn or broken engine mount 1. Replace engine mount



3. Loose lug nuts 3. Verify wheel lug nut torque


5. Worn or loose ball joint 5. Tighten or replace ball joint

6. Worn or loose control arm bushing 6. Replace control arm bushing

7. Loose crossmember bolts 7. Tighten crossmember bolts tospecified torque

8. Worn tie rod end 8. Replace tie rod end

Road Wander 1. Incorrect tire pressure 1. Inflate tires to recommended pressure

2. Incorrect front or rear wheel toe 2. Check and reset wheel toe

3. Worn wheel bearings 3. Replace wheel bearing

4. Worn control arm bushings 4. Replace control arm bushing

5. Excessive friction in steering gear 5. Replace steering gear

6. Excessive friction in steering shaftcoupling

6. Replace steering coupler

7. Excessive friction in strut upperbearing

7. Replace strut bearing

Lateral Pull 1. Unequal tire pressure 1. Inflate all tires to recommendedpressure

2. Radial tire lead 2. Perform lead correction procedure

3. Incorrect front wheel camber 3. Check and reset front wheel camber

4. Power steering gear imbalance 4. Replace power steering gear

5. Wheel braking 5. Correct braking condition causinglateral pull

Excessive Steering FreePlay

1. Incorrect Steering Gear Adjustment 1. Adjust Or Replace Steering Gear

2. Worn or loose tie rod ends 2. Replace or tighten tie rod ends

3. Loose steering gear mounting bolts 3. Tighten steering gear bolts to specifiedtorque

4. Loose or worn steering shaft coupler 4. Replace steering shaft coupler

Excessive Steering Effort 1. Low tire pressure 1. Inflate all tires to recommendedpressure

2. Lack of lubricant in steering gear 2. Replace steering gear

3. Low power steering fluid level 3. Fill power steering fluid reservoir tocorrect level

4. Loose power steering pump drivebelt

4. Correctly adjust power steering pumpdrive belt

5. Lack of lubricant in ball joints 5. Lubricate or replace ball joints

6. Steering gear malfunction 6. Replace steering gear

7. Lack of lubricant in steering coupler 7. Replace steering coupler

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NS SUSPENSION 2 - 5

ERVICE PROCEDURES

RE-WHEEL ALIGNMENT INSPECTIONBefore any attempt is made to change or correct

he wheel alignment, the following inspection andecessary corrections must be made to the vehicle tonsure proper alignment.(1) Be sure the fuel tank is full of fuel. If the fuel

ank is not full, the reduction in weight will affecthe curb height of the vehicle and the alignmentpecifications.(2) The passenger and luggage compartments of

he vehicle should be free of any load that is not fac-ory equipment.

(3) Check the tires on the vehicle. The tires are toe inflated to the recommended air pressure. All tiresust be the same size and in good condition with

pproximately the same tread wear.(4) Check the front tire and wheel assemblies for

xcessive radial runout.(5) Inspect all suspension component fasteners for

ooseness and torque.(6) Inspect the lower front ball joints and all steer-

ng linkage for looseness and any sign of wear oramage.(7) Inspect the rubber bushings on all the suspen-

ion components for signs of wear or deterioration. Ifny bushings show signs of wear or deterioration,hey should be replaced prior to aligning the vehicle.

(8) Check vehicle curb height to verify it is within
pecifications. Refer to CURB HEIGHT MEASURE-
MENT in this section. If curb height is out of speci-fications, check for broken or sagged springs.

CURB HEIGHT MEASUREMENTThe wheel alignment is to be checked and all align-

ment adjustments made with the vehicle at itsrequired curb height specification.

Vehicle height is to be checked with the vehicle ona flat, level surface, preferably a vehicle alignmentrack. The tires are to be inflated to the recommendedpressure. All tires are to be the same size as stan-dard equipment. Vehicle height is checked with thefuel tank full of fuel, and no passenger or luggagecompartment load.

Vehicle height is not adjustable. If the measure-ment is not within specifications, inspect the vehiclefor bent or weak suspension components. Comparethe parts tag on the suspect coil spring(s) to theparts book and the vehicle sales code, checking for amatch. Once removed from the vehicle, compare thecoil spring height to a correct new or known good coilspring. The heights should vary if the suspect springis weak.

(1) Measure from the inboard edge of the wheelopening fender lip directly above the wheel center(spindle), to the floor or alignment rack surface.

(2) When measuring, the maximum left-to-rightdifferential is not to exceed 12.5 mm (0.5 in.).

(3) Compare the measurements to the specifica-tions listed in the following CURB HEIGHT SPECI-FICATIONS chart.

CURB HEIGHT SPECIFICATIONS

VEHICLE FRONT REAR

ALL GAS ENGINED VEHICLESWITH TIRE SIZES P205/75R 14

AND P215/65R 15

747.5 mm 6 10 mm 766.0 mm 6 10 mm

29.43 in. 6 0.39 in. 30.15 in. 6 0.39 in.

ALL GAS ENGINED VEHICLESWITH TIRE SIZES P215/70R 15,P215/65R 16 AND P215/60R 17

753.5 mm 6 10 mm 772.0 mm 6 10 mm

29.66 in. 6 0.39 in. 30.39 in. 6 0.39 in.

CNG AND ELECTRIC VEHICLES783.5 mm 6 10 mm 802.5 mm 6 10 mm

30.85 in. 6 0.39 in. 31.59 in. 6 0.39 in.

HEEL ALIGNMENT(1) Position the vehicle on an alignment rack.(2) Perform the PRE-WHEEL ALIGNMENT

NSPECTION. It can be found elsewhere in this sec-ion.

(3) Install all required alignment equipment onhe vehicle per the alignment equipment manufactur-r’s instructions. On this vehicle, a four-wheel align-ent is recommended.

NOTE: Prior to reading the vehicle’s alignmentreadouts, the front and rear of vehicle should bejounced. Induce jounce (rear first, then front) bygrasping the center of the bumper and jouncingeach end of vehicle an equal number of times. Thebumper should always be released when vehicle isat the bottom of the jounce cycle.

(4) Read the vehicle’s current front and rear align-ment settings. Compare the vehicle’s current align-

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SERVICE PROCEDURES (Continued)

ent settings to the vehicle specifications for camber,aster and toe-in. Refer to WHEEL ALIGNMENTPECIFICATIONS in this section of this serviceanual group.(5) If front camber and caster are not within spec-

fications, proceed to CAMBER AND CASTER below.f caster and camber are within specifications, pro-eed to TOE which can be found following CAMBERND CASTER. Rear camber, caster and toe are notdjustable. If found not to be within specifications,einspect for damaged suspension or body compo-ents and replace as necessary.

AMBER AND CASTERCamber and caster settings on this vehicle are

etermined at the time the vehicle is designed, byhe location of the vehicle’s suspension components.his is referred to as NET BUILD. The result is noequired adjustment of camber and caster after theehicle is built or when servicing the suspensionomponents. Thus, when performing a wheel align-ent, caster and camber are not normally considered

djustable angles. Camber and caster should behecked to ensure they meet vehicle specifications.If front camber is found not to meet alignment

pecifications, it can be adjusted using an availableamber adjustment bolt package. Before installing aamber adjustment bolt package on a vehicle foundo be outside the specifications, inspect the suspen-ion components for any signs of damage or bending.

AUTION: Do not attempt to adjust the vehiclesheel; alignment by heating, bending or by per-

orming any other modification to the vehicle’s frontuspension components or body.

If camber readings are not within specifications,se the following procedure to install the front cam-er adjustment bolt package and then adjust frontamber.

AMBER ADJUSTMENT BOLT PACKAGE INSTALLATIONThe camber adjustment bolt package contains 2

lange bolts, 2 cam bolts, 2 dog bone washers, and 4uts. This package services both sides of the vehicle.se the package to attach the strut clevis bracket to

he steering knuckle after the strut clevis bracketas been modified. To install and adjust the camberdjustment bolt package, follow the procedure below.(1) Raise the vehicle until its tires are not support-

ng the weight of the vehicle.(2) Remove the front tire and wheel assemblies.

AUTION: When removing the steering knucklerom the strut clevis bracket, do not put a strain onhe brake flex hose. Also, do not let the weight ofhe steering knuckle assembly be supported by the

brake flex hose when removed from the strutassembly. If necessary use a wire hanger to sup-port the steering knuckle assembly or if requiredremove the brake flex hose from the caliper assem-bly.

CAUTION: The knuckle to strut assembly attachingbolt shanks are serrated and must not be turnedduring removal. Remove the nuts while holding thebolts stationary.

(3) Remove the top and bottom, strut clevisbracket to steering knuckle attaching bolts (Fig. 4)and discard. Separate the steering knuckle from thestrut clevis bracket and position steering knuckle soit is out of the way of the strut.

CAUTION: When slotting the bottom mounting holeon the strut clevis bracket, do not enlarge the holebeyond the indentations on the sides of the strutclevis bracket (Fig. 5).

(4) Using an appropriate grinder and grindingwheel, slot the bottom hole in both sides of the strutclevis bracket (Fig. 5).

CAUTION: After slotting the strut clevis brackethole, do not install the original attaching bolts whenassembling the steering knuckle to the strut assem-bly. Only the flange bolts, cam bolts, and dog bonewashers from the service package must be used toattach the steering knuckle to the strut after themounting hole is slotted.

Fig. 4 Clevis Bracket To Steering Knuckle AttachingBolts

1 – STRUT CLEVIS BRACKET2 – ATTACHING BOLTS3 – TIE ROD END4 – ROTOR5 – STEERING KNUCKLE

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(5) Position the knuckle back into the strut clevisracket. Install a flanged bolt from the service pack-ge into the upper mounting hole. Install a cam boltnto the bottom mounting hole. Both bolts shouldoint forward once installed (Fig. 6).

Fig. 5 Strut Clevis Bracket Bolt Hole Grinding Area1 – UPPER STRUT TO STEERING KNUCKLE ATTACHING HOLE2 – CAMBER ADJUSTMENT SLOT INDENTATION AREA ON

CLEVIS BRACKET3 – LOWER STRUT TO STEERING KNUCKLE ATTACHING HOLE4 – STRUT CLEVIS BRACKET

Fig. 6 Package Bolts Correctly Installed (LeftShown)

1 – STEERING KNUCKLE2 – FLANGED BOLT IN TOP HOLE3 – CAM BOLT IN BOTTOM HOLE4 – STRUT CLEVIS BRACKET

(6) Install a dog bone washer on the steeringknuckle to strut clevis bracket attaching bolts, theninstall the nuts onto the bolts from the service pack-age (Fig. 7). Tighten the bolts just enough to hold thesteering knuckle in position when adjusting camber,while still allowing the steering knuckle to move inclevis bracket.

(7) Repeat the procedure to the other side strutclevis bracket.

(8) Reinstall both front tire and wheel assembliesand tighten to specifications.

(9) Lower the vehicle. Jounce the front and rear ofvehicle an equal amount of times.

(10) Adjust the front camber to the preferred set-ting by rotating the lower eccentric cam bolt againstthe cam stop areas on the strut clevis bracket (Fig.8). When camber is set, tighten the upper strut clevisbracket bolt and lower cam bolt. Again jounce frontand rear of vehicle an equal amount of times andverify front camber setting. Torque both front strut tosteering knuckle attaching bolts to 90 N·m (65 ft.lbs.) plus an additional 1/4 turn after the requiredtorque is met.

(11) If toe readings obtained are not within therequired specification range, adjust toe to meet thepreferred specification setting. Toe is adjustableusing the following procedure.

Fig. 7 Dog Bone Washer And Nuts Installed OnAttaching Bolts

1 – STEERING KNUCKLE2 – DOG BONE WASHER3 – STRUT CLEVIS BRACKET4 – ATTACHING NUTS

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OE(1) Center the steering wheel and lock in place

sing a steering wheel clamp.

AUTION: Do not twist front inner tie rod to steer-ng gear rubber boots during front wheel Toedjustment.

(2) Loosen front inner to outer tie rod end jamuts (Fig. 9). Grasp inner tie rods at serrations andotate inner tie rods of steering gear (Fig. 9) to setront toe to the preferred toe specification. Refer to

HEEL ALIGNMENT SPECIFICATIONS in thisroup of the service manual for preferred specifica-ion.

Fig. 8 Camber Adjustment Cam Bolt1 – STEERING KNUCKLE2 – CLEVIS BRACKET CAM STOP AREAS3 – LOWER ECCENTRIC CAMBER ADJUSTMENT BOLT

(3) Tighten tie rod jam nuts (Fig. 9) to 75 N·m (55ft. lbs.) torque.

(4) Adjust steering gear to tie rod boots at theinner tie rod.

(5) Remove steering wheel clamp.(6) Remove the alignment equipment.(7) Road test the vehicle to verify the steering

wheel is straight and the vehicle does not wander orpull.

Fig. 9 Front Wheel Toe Adjustment1 – INNER TIE ROD SERRATION2 – OUTER TIE ROD JAM NUT3 – OUTER TIE ROD END4 – INNER TIE ROD5 – STEERING KNUCKLE

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PECIFICATIONS

HEEL ALIGNMENT SPECIFICATIONS

OTE: All specifications are given in degrees.

NOTE: All wheel alignments are to be set at curbheight. Refer to CURB HEIGHT MEASUREMENT inSERVICE PROCEDURES.

FRONT WHEEL ALIGNMENT PREFERRED SETTING ACCEPTABLE RANGE

CAMBER

All vehicles except those with tire sizes P205/75R 15,P215/65R 16 and P215/60R 17

+0.15° -0.25° to +0.55°

Vehicles with tire sizes P205/75R 15, P215/65R 16 andP215/60R 17

+0.05° -0.35° to +0.45°

Cross Camber (Maximum side-to-side difference) 0.0° 0.50°

CASTER* +1.40° +0.40° to +2.40°

Cross Caster (Maximum side-to-side difference) 0.0° 1.00°

TOTAL TOE** +0.10° −0.10° to +0.30°

Maximum side-to-side difference 0.0° 0.06°

REAR WHEEL ALIGNMENT PREFERRED SETTING ACCEPTABLE RANGE

CAMBER* 0.0° -0.25° to +0.25°

ALTERNATIVE FUEL VEHICLES ONLY* -0.10° -0.35° to +0.15°

TOTAL TOE* ** 0.0° −0.40° to +0.40°

THRUST ANGLE* 0.0° -0.30° to +0.30°

Notes:

* For reference only. These are non-adjustable angles.

** TOTAL TOE is the sum of both left and right wheel toe settings. TOTAL TOE must be equally split betweeneach front wheel to ensure the steering wheel is centered after setting toe. Positive toe is toe-in and negative toeis toe-out

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FRONT SUSPENSION

TABLE OF CONTENTS

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ESCRIPTION AND OPERATIONFRONT SUSPENSION SYSTEM. . . . . . . . . . . . . . 10STRUT ASSEMBLY (FRONT) . . . . . . . . . . . . . . . . 12STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . . 12HUB AND BEARING (FRONT) . . . . . . . . . . . . . . . 12LOWER CONTROL ARM . . . . . . . . . . . . . . . . . . . 13BALL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13STABILIZER BAR (FRONT) . . . . . . . . . . . . . . . . . 13IAGNOSIS AND TESTINGSTRUT ASSEMBLY (FRONT) . . . . . . . . . . . . . . . . 14STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . . 14HUB AND BEARING (FRONT) . . . . . . . . . . . . . . . 14LOWER CONTROL ARM . . . . . . . . . . . . . . . . . . . 15BALL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15STABILIZER BAR (FRONT) . . . . . . . . . . . . . . . . . 15ERVICE PROCEDURESLUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15EMOVAL AND INSTALLATIONSTRUT ASSEMBLY (FRONT) . . . . . . . . . . . . . . . . 15

STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . . 17HUB AND BEARING (FRONT) . . . . . . . . . . . . . . . 22LOWER CONTROL ARM . . . . . . . . . . . . . . . . . . . 25STABILIZER BAR (FRONT) . . . . . . . . . . . . . . . . . 29WHEEL MOUNTING STUDS (FRONT) . . . . . . . . . 31ISASSEMBLY AND ASSEMBLYSTRUT ASSEMBLY (FRONT) . . . . . . . . . . . . . . . . 32LOWER CONTROL ARM (BALL JOINT SEAL

BOOT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36LOWER CONTROL ARM (BALL JOINT) . . . . . . . . 37LOWER CONTROL ARM (FRONT BUSHING) . . . . 39LOWER CONTROL ARM (REAR BUSHING) . . . . . 41STABILIZER BAR BUSHING (FRONT) . . . . . . . . . 42PECIFICATIONSFRONT SUSPENSION FASTENER TORQUES . . . 42PECIAL TOOLSFRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . 42


RONT SUSPENSION SYSTEM

ESCRIPTIONThis vehicle has a MacPherson strut type front

uspension design (Fig. 1).

PERATIONThe front suspension allows each wheel on a vehi-

le to adapt to different road surfaces and conditionsithout greatly affecting the opposite wheel and thebility to control the vehicle. Each side of the frontuspension is allowed to pivot so the vehicle can beteered in the direction preferred.

A strut assembly is used in place of the front sus-pension upper control arm and upper ball joint.When a vehicle strikes a bump, the force is trans-ferred through the hub, bearing, and knuckle, intothe strut assembly to absorb the force and dampen it.The top of the strut is mounted directly to the struttower of the vehicle. During steering maneuvers, thestrut assembly (through a pivot bearing in the upperstrut mount) and steering knuckle (through the lowerball joint) turn as an assembly.

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Fig. 1 Front Suspension System
1 – TOWER2 – STRUT ASSEMBLY3 – STABILIZER BAR LINK4 – STABILIZER BAR5 – ISOLATOR BUSHING6 – FRAME RAIL7 – CRADLE/CROSSMEMBER8 – LOWER CONTROL ARM9 – BALL JOINT10 – WHEEL STOP11 – HUB AND BEARING
12 – STEERING KNUCKLE13 – STRUT14 – LOWER SPRING ISOLATOR15 – COIL SPRING16 – JOUNCE BUMPER17 – DUST SHIELD18 – SPRING SEAT19 – PIVOT BEARING20 – UPPER MOUNT21 – NUT

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TRUT ASSEMBLY (FRONT)

ESCRIPTIONA Macpherson type strut assembly is used in place

f a front suspension upper control arm and upperall joint (Fig. 1). The bottom of the strut mountsirectly to the steering knuckle using 2 attachingolts and nuts going through the strut clevis bracketnd steering knuckle. The top of the strut mountsirectly to the strut tower of the vehicle using thehreaded studs on the strut assemblies upper mount.

The strut assembly includes the following compo-ents:• Upper mount• Pivot bearing• Upper spring seat (and isolator)• Dust shield• Jounce bumper• Coil spring• Lower spring isolator• StrutEach component is serviced by removing the strut

ssembly from the vehicle and disassembling it.Coil springs are rated separately for each corner or

ide of the vehicle depending on optional equipmentnd type of vehicle service. If the coil springs requireeplacement, be sure that the springs needingeplacement are replaced with springs meeting theorrect load rating and spring rate for the vehiclend its specific options.

PERATIONThe strut assembly cushions the ride of the vehicle,

ontrolling vibration, along with jounce and reboundf the suspension.The coil spring controls ride quality and maintains

roper ride height.The spring isolators isolate the coil spring at the

op and bottom from coming into metal-to-metal con-act with the upper seat and strut.

The jounce bumper limits suspension travel andetal-to-metal contact under full jounce condition.The strut dampens jounce and rebound motions of

he coil spring and suspension.During steering maneuvers, the strut assembly

through a pivot bearing in the upper strut mount)nd steering knuckle (through the lower ball joint)urn as an assembly.

TEERING KNUCKLE

ESCRIPTIONThe steering knuckle is a single casting with legsachined for attachment of the strut assembly, steer-

ng linkage, disc brake caliper, and lower control armall joint (Fig. 2). The hub and bearing assembly is

mounted in the center of the steering knuckle using4 bolts. The driveshaft’s constant velocity (C/V) stubshaft is splined through the center of the hub andbearing and is held in place using a nut, nut lock andcotter pin.

OPERATIONThe steering knuckle pivots with the strut assem-

bly between the lower ball joint and the pivot bearingin the strut assembly. The steering gear outer tie rodend connects to the trailing end of each knuckle,allowing the vehicle to be steered.

The center of the knuckle supports the hub andbearing and axle shaft.

HUB AND BEARING (FRONT)

DESCRIPTIONThe front wheel bearing and front wheel hub of

this vehicle are a hub and bearing unit type assem-bly. This unit combines the front wheel mountinghub (flange) and the front wheel bearing into asealed one-piece unit. The hub and bearing ismounted to the center of the steering knuckle (Fig.1). It is retained by four mounting bolts accessiblefrom the rear of the steering knuckle. The hub flangehas five wheel mounting studs.

Vehicles equipped with 14 inch wheels have a 4inch wheel mounting stud pattern. Vehicles equippedwith larger wheels have a 4 1/2 inch wheel mountingstud pattern. If a hub and bearing assembly needs tobe replaced, be sure that the replacement assembly

Fig. 2 Steering Knuckle1 – FRONT STRUT ASSEMBLY2 – FRONT STEERING KNUCKLE3 – TIE ROD END4 – STUB AXLE5 – HUB/BEARING ASSEMBLY6 – DISC BRAKE CALIPER MOUNTING BOSSES7 – DISC BRAKE CALIPER ABUTMENT

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as the same size wheel mounting stud pattern ashe original part.

The wheel mounting studs used to mount the tirend wheel to the vehicle are the only replaceableomponents of the hub and bearing assembly. Other-ise, the hub and bearing is serviced only as a com-lete assembly.

PERATIONThe hub and bearing has internal bearings that

llow the hub to rotate with the driveshaft, alongith the tire and wheel. The five wheel mounting

tuds mount the tire and wheel, and brake rotor tohe vehicle.

OWER CONTROL ARM

ESCRIPTIONThe lower control arm is an iron casting with 2

ubber bushings and a ball joint (Fig. 1). The frontower control arm bushing is the spool type and isressed into the lower control arm. The rear lowerontrol arm bushing is a push-on bushing that isushed over a stem on the rear of the lower controlrm. The lower control arm ball joint is pressed intohe outer end of the arm.

The lower control arm is mounted to the front sus-ension crossmember using a pivot bolt through theenter of the front pivot bushing, and a retainerhich traps the rear bushing in the crossmember.The ball joint has a non-tapered stud with a notch

or clamp bolt clearance. The stud is clamped andocked into the steering knuckle leg with a clampolt.

PERATIONThe lower control arm supports the lower end of

he steering knuckle and allows for the up and downovement of the suspension during the jounce and

ebound travel. The lower control arm ball joint con-ects the arm to the steering knuckle.

ALL JOINT

ESCRIPTIONThe ball joint is an integral part of the lower con-

rol arm (Fig. 1). The ball joint has a non-taperedtud that is clamped and locked into the steeringnuckle leg using a pinch bolt. The ball joint studas a notch formed in the side of it for pinch bolt

nstallation.The ball joint has a non-vented seal boot. The seal

oot has an integrated heat shield (Fig. 3).The ball joint used in the lower control arm of this

ehicle is a sealed-for-life ball joint and requires noaintenance lubrication. The ball joint has been

lubricated-for-life during the manufacturing process.Once lubricated-for-life, the grease fitting head issnapped off by the manufacturer. This is done toeliminate the possibility of lubrication latter duringthe ball joints life, thus damaging the non-ventedseal boot.

NOTE: The ball joint does not require any type ofadditional lubrication for the life of the vehicle. Noattempt should be made to ever add any lubricationto the lower ball joint.

The ball joint used on this vehicle is replaceableand if found defective can be serviced as a separatecomponent of the lower control arm assembly. Referto Diagnosis And Testing in this section for propertesting of the ball joint.

OPERATIONThe ball joint is a pivotal joint on the lower control

arm that allows the knuckle to move up and down,and turn with ease.

STABILIZER BAR (FRONT)

DESCRIPTIONThe stabilizer bar interconnects both front struts of

the vehicle and is attached to the front crossmember(Fig. 1).

Attachment of the stabilizer bar to the front cross-member is through 2 rubber-isolator cushion bush-ings and retainers. A double ball jointed stabilizerbar link is used to attach each end of the stabilizerbar to the front strut assemblies. All parts of the sta-

Fig. 3 Ball Joint1 – BALL JOINT SEAL BOOT2 – BALL JOINT STUD3 – LOWER CONTROL ARM4 – SHIELD

bilizer bar are replaceable as individual components.

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The stabilizer bar to front crossmember cushionushings are split for easy removal and installation.he split in the bushings should be positioned towardhe rear of the vehicle, with the square corner facingown, when the stabilizer bar is installed.

PERATIONJounce and rebound movements affecting oneheel are partially transmitted to the opposite wheelf the vehicle through the stabilizer bar. This helpso minimize the body roll of the vehicle during sus-ension movement.Connecting the stabilizer bar links to the strut

ssemblies helps reduce the fore-and-aft rate of thetabilizer bar from the rest of the front suspension.

IAGNOSIS AND TESTING

TRUT ASSEMBLY (FRONT)(1) Inspect for damaged or broken coil springs

Fig. 4).(2) Inspect for torn or damaged strut assembly

ust boots (Fig. 4).(3) Inspect the coil spring isolator on the lower

pring seat, (Fig. 4) for any signs of damage or dete-ioration.

(4) Lift dust boot (Fig. 5) and inspect strut assem-ly for evidence of fluid running from the upper endf fluid reservoir. (Actual leakage will be a stream ofluid running down the side and dripping off lowernd of unit). A slight amount of seepage between the

Fig. 4 Strut Assembly Inspection1 – DUST BOOT2 – COIL SPRING ISOLATOR3 – STRUT ASSEMBLY4 – COIL SPRING

strut rod and strut shaft seal is not unusual and doesnot affect performance of the strut assembly (Fig. 5).Also inspect jounce bumpers for signs of damage ordeterioration.

STEERING KNUCKLEThe front suspension knuckle is not a repairable

component of the vehicles front suspension IT MUSTBE REPLACED.. If bent, broken or damaged in anyway, do not attempt to straighten or repair the steer-ing knuckle.

Service replacement of the front hub/bearingassembly can be done with the front steering knuckleremaining on the vehicle.

HUB AND BEARING (FRONT)The condition of the front hub and bearing assem-

bly is diagnosed using the inspection and testing pro-cedure detailed below.

The bearing contained in the Unit III front hub/bearing assembly will produce noise and vibrationwhen worn or damaged. The noise will generallychange when the bearings are loaded. A road test ofthe vehicle is normally required to determine thelocation of a worn or damaged bearing.

Find a smooth level road surface and bring thevehicle up to a constant speed. When vehicle is at aconstant speed, swerve the vehicle back and forthfrom the left and to the right. This will load andunload the bearings and change the noise level.Where axle bearing damage is slight, the noise is

Fig. 5 Strut Assembly Leakage Inspection1 – DUST BOOT2 – STRUT SHAFT3 – STRUT FLUID RESERVOIR4 – INSPECT THIS AREA FOR EVIDENCE OF EXCESSIVE FLUID

LEAKAGE

usually not noticeable at speeds above 30 m.p.h.

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OWER CONTROL ARMInspect lower control arm for signs of damage from

ontact with the ground or road debris. If lower con-rol arm shows any sign of damage, inspect lowerontrol arm for distortion. Do not attempt to repairr straighten a broken or bent lower control arm. Ifamaged, the lower control arm casting is servicednly as a complete component.The serviceable components of the lower control

rm are: the ball joint, the ball joint grease seal andhe lower control arm isolator bushings.

Inspect both lower control arm isolator bushingsor severe deterioration, and replace as required.nspect the ball joint per the inspection procedure inhis section of the service manual and replace asequired. Refer to BALL JOINT in this section of thiservice manual group.

ALL JOINTWith the weight of the vehicle resting on the roadheels, grasp the grease fitting (which from theanufacturer should have the head missing) on the

ottom of the ball joint and with no mechanical assis-ance or added force attempt to rotate the grease fit-ing.

If the ball joint is worn, the grease fitting willotate easily. If movement is noted, replacement ofhe ball joint is recommended.

TABILIZER BAR (FRONT)Inspect for broken or distorted sway bar bushings,

ushing retainers, and worn or damaged sway bar totrut attaching links. If sway bar to front suspensionradle bushing replacement is required, bushing cane removed from sway bar by opening slit and peel-ng bushing off sway bar.

ERVICE PROCEDURES

UBRICATIONThere are no serviceable lubrication points on the

ront suspension. The front lower ball joints haverease fittings which have had the head snapped offy the manufacturer after they have been filled. Thisas been done to eliminate the possibility of damag-

ng the non-vented seals. Grease will not leak fromhe broken grease fittings. The ball joints are sealedor life and require no maintenance.

AUTION: No attempt should be made to replacehe ball joint grease fitting with a new fitting, thenilling the ball joint with grease. Damage to therease seal can result.

REMOVAL AND INSTALLATION

STRUT ASSEMBLY (FRONT)

REMOVAL

WARNING: DO NOT REMOVE THE NUT FROM THESTRUT ROD WHILE STRUT ASSEMBLY ISINSTALLED IN VEHICLE, OR BEFORE STRUTASSEMBLY SPRING IS COMPRESSED.

(1) Raise the vehicle. See Hoisting in the Lubrica-tion and Maintenance section of this service manualfor the required lifting procedure to be used for thisvehicle.

(2) Remove the wheel and tire assembly from loca-tion on front of vehicle requiring strut removal.

(3) If both strut assemblies are to be removed,mark the strut assemblies right or left according towhich side of the vehicle they were removed from.

(4) Remove the hydraulic brake hose routingbracket and the speed sensor cable routing bracketfrom the strut damper brackets (Fig. 6).

CAUTION: When removing the nut from the stud ofthe stabilizer bar link, do not allow the stud torotate in it’s socket. Hold the stud from rotating byplacing an open-end wrench on the flat machinedinto the stud (Fig. 7).

(5) Remove the stabilizer bar link from the bracketon the strut assembly (Fig. 7). To do so, place anopen-end wrench on the flat machined into the link’s

Fig. 6 Brake Hose And Speed Sensor Cable Routing1 – STRUT DAMPER2 – WHEEL SPEED SENSOR CABLE3 – ROUTING BRACKET4 – HYDRAULIC BRAKE HOSE5 – ATTACHING BOLT6 – ROUTING BRACKET

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REMOVAL AND INSTALLATION (Continued)

ounting stud, then remove the nut while holdinghe wrench in place. Push the stud out of theracket.

AUTION: The steering knuckle to strut assemblyttaching bolts are serrated and must not be turneduring removal. Remove nuts while holding boltstationary in the steering knuckles.

(6) Remove the 2 strut assembly clevis bracket toteering knuckle attaching bolts (Fig. 8).

Fig. 7 Stabilizer Bar Link To Strut Attachment1 – NUT2 – STRUT3 – STABILIZER BAR LINK

Fig. 8 Strut Damper Attachment To SteeringKnuckle

1 – STRUT CLEVIS BRACKET2 – ATTACHING BOLTS3 – TIE ROD END4 – ROTOR5 – STEERING KNUCKLE

(7) Remove the 3 nuts attaching the strut assem-bly upper mount to the strut tower (Fig. 9) andremove the strut assembly from the vehicle.

(8) To disassemble and reassemble the strutassembly, refer to Disassembly And Assembly in thissection.

INSTALLATION(1) Install strut assembly into strut tower, aligning

and installing the 3 studs on the upper strut mountinto the holes in shock tower. Install the 3 upperstrut mount attaching nut/washer assemblies (Fig.9). Then using a crow foot. tighten the 3 attachingnuts to a torque of 28 N·m (250 in. lbs.).

CAUTION: The steering knuckle to strut assemblyattaching bolts are serrated and must not be turnedduring installation. Install nuts while holding boltsstationary in the steering knuckles.

(2) Align strut assembly with steering knuckle.Position arm of steering knuckle into strut assemblyclevis bracket. Align the strut assembly clevisbracket mounting holes with the steering knucklemounting holes. Install the 2 strut assembly to steer-ing knuckle attaching bolts (Fig. 8). If strut assem-bly is attached to steering knuckle using a cambolt, the cam bolt must be installed in the lowerslotted hole on strut clevis bracket. Also,attaching bolts should be installed with thenuts facing the front of the vehicle (Fig. 8).Tighten the strut assembly to steering knuckleattaching bolts to a torque of 88 N·m (65 ft. lbs.)

Fig. 9 Strut Assembly To Strut Tower AttachingNuts

1 – WINDSHIELD WIPER MODULE2 – STRUT TOWER3 – STRUT MOUNT ATTACHING BOLTS4 – UPPER STRUT MOUNT

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lus an additional 1/4 turn after specifiedorque is met.

(3) Install the stabilizer bar link mounting studhrough the bracket on the strut assembly (Fig. 7).

AUTION: When installing the nut on the mountingtud of the stabilizer bar link, do not allow the studo rotate in it’s socket. Hold the stud from rotatingy placing an open-end wrench on the flatachined into the stud (Fig. 7).

(4) Hand thread the nut on the end of the stabi-izer bar link stud. Hold the stud from turning bylacing an open-end wrench on the flat machinednto the link’s mounting stud, then tighten the nuthile holding the wrench in place (Fig. 7). Tighten

he nut to a torque of 88 N·m (65 ft. lbs.).(5) Install the hydraulic brake hose and speed sen-

or cable routing brackets on the strut assemblyrackets (Fig. 6). Tighten the routing bracket attach-ng bolts to a torque of 13 N·m (10 ft. lbs.).

(6) Install the wheel/tire assembly on the vehicle.(7) Install and tighten the wheel mounting stud

uts in proper sequence until all nuts are torqued toalf specification. Then repeat the tighteningequence to the full specified torque of 135 N·m (100t. lbs.).

TEERING KNUCKLE

EMOVAL(1) Raise vehicle on jack stands or centered on a

rame contact type hoist. Refer to Hoisting in theubrication And Maintenance section of this manual

or the required lifting procedure to be used for thisehicle.(2) Remove the cotter pin and nut lock (Fig. 10)

rom the end of the stub axle.(3) Remove the wheel and tire assembly from the

ehicle.(4) Remove the wave washer (Fig. 11) from the end

f the stub axle

AUTION: Wheel bearing damage will result if afteroosening hub nut, vehicle is rolled on the groundr the weight of the vehicle is allowed to be sup-orted by the tires.

(5) With the vehicle’s brakes applied to keep hubfrom turning, loosen and remove the stub axle tohub nut.

Fig. 10 Hub And Bearing To Stub Axle Retaining Nut1 – HUB/BEARING2 – NUT LOCK3 – COTTER PIN4 – STUB AXLE

Fig. 11 Wave Washer1 – HUB/BEARING ASSEMBLY2 – WAVE WASHER3 – STUB AXLE

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(6) Remove the 2 front disc brake caliper to steer-ng knuckle attaching bolts (Fig. 12).

(7) Remove the disc brake caliper from the steer-ng knuckle. Caliper is removed by first rotating topf caliper away from steering knuckle and thenemoving bottom of caliper out from under machinedbutment on steering knuckle (Fig. 13).

(8) Support disc brake caliper assembly by using aire hook and suspending it from the strut assembly

Fig. 14). Do not allow the brake caliper assem-ly to hang by the brake flex hose.

Fig. 12 Front Disc Brake Caliper Attaching Bolts1 – DISC BRAKE CALIPER ASSEMBLY2 – STEERING KNUCKLE3 – DISC BRAKE CALIPER MOUNTING BOLTS4 – DRIVESHAFT

Fig. 13 Brake Caliper Mounting To Steering Knuckle1 – CALIPER ASSEMBLY2 – ROTOR3 – STEERING KNUCKLE4 – MACHINED ABUTMENT

(9) Remove the brake rotor from the hub and bear-ing assembly (Fig. 15).

Fig. 14 Correctly Supported Disc Brake Caliper1 – STEERING KNUCKLE2 – BRAKE FLEX HOSE3 – CALIPER ASSEMBLY4 – WIRE HANGER5 – STRUT ASSEMBLY

Fig. 15 Remove/Install Brake Rotor1 – HUB2 – STEERING KNUCKLE3 – BRAKING DISC (ROTOR)4 – WHEEL MOUNTING STUD

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(10) Remove nut attaching outer tie rod end toteering knuckle (Fig. 16). Nut is to be removedrom tie rod end using the following procedure,old tie rod end stud with a 11/32 socket while

oosening and removing nut with a wrench.

(11) Remove tie rod end from steering knucklesing Remover, Special Tool MB-991113 (Fig. 17).

Fig. 16 Removing Tie Rod End Attaching Nut1 – TIE ROD END2 – STEERING KNUCKLE3 – WRENCH4 – 11/32 SOCKET5 – TIE ROD END STUD

Fig. 17 Tie Rod End Removal From SteeringKnuckle Arm

1 – TIE ROD END2 – SPECIAL TOOL MB-9911133 – STUD4 – STEERING KNUCKLE ARM

(12) Remove the front wheel speed sensor (Fig. 18)from the steering knuckle.

(13) If equipped, remove the wheel stop (Fig. 19)from the steering knuckle. When installing thepinch bolt when assembling the steeringknuckle to the ball joint, the pinch bolt must beinstalled from the rear facing the front on thevehicle.

Fig. 18 Front Wheel Speed Sensor1 – MOUNTING BOLT2 – WHEEL SPEED SENSOR3 – STEERING KNUCKLE

Fig. 19 Wheel Stop Location On Steering Knuckle1 – STEERING KNUCKLE2 – WHEEL STOP3 – LOWER CONTROL ARM4 – ROTOR

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(14) Remove the steering knuckle to ball jointtud, clamping nut and bolt (Fig. 20) from the steer-ng knuckle.

(15) Using a pry bar, separate steering knucklerom ball joint stud (Fig. 21). Note: Use cautionhen separating ball joint stud from steeringnuckle, so ball joint seal does not get cut.

Fig. 20 Control Arm To Steering KnuckleAttachment

1 – CLAMPING NUT/BOLT2 – LOWER CONTROL ARM3 – BALL JOINT4 – STEERING KNUCKLE5 – ROTOR

Fig. 21 Separating Ball Joint Stud From SteeringKnuckle

1 – STEERING KNUCKLE2 – BALL JOINT STUD3 – BALL JOINT SEAL4 – LOWER CONTROL ARM5 – PRY BAR

NOTE: Care must be taken not to separate theinner C/V joint during this operation. Do not allowdriveshaft to hang by inner C/V joint after removingouter C/V Joint from the hub/bearing assembly insteering knuckle, end of driveshaft must be sup-ported.

(16) Pull steering knuckle assembly out and awayfrom the outer C/V joint of the driveshaft assembly(Fig. 22).

CAUTION: The steering knuckle to strut assemblyattaching bolts are serrated and must not be turnedduring removal. Remove nuts while holding boltsstationary in the steering knuckles.

(17) Remove the 2 steering knuckle to strutdamper clevis bracket attaching bolts (Fig. 23).

(18) Remove the steering knuckle from the strut.(19) If the hub and bearing needs to be trans-

ferred, remove the 4 bolts attaching the hub andbearing to the knuckle and remove the hub and bear-ing from the steering knuckle.

INSTALLATION(1) If the hub and bearing needs to be installed in

the knuckle, place the hub and bearing squarely intothe center hole of the steering knuckle aligning thethreaded mounting holes of the hub and bearing withthe mounting holes in the steering knuckle. Installthe 4 mounting bolts and tighten them to a torque of65 N·m (45 ft. lbs.).

Fig. 22 Steering Knuckle Separation FromDriveshaft

1 – DRIVESHAFT STUB AXLE2 – HUB/BEARING ASSEMBLY3 – LOWER CONTROL ARM4 – BALL JOINT5 – STEERING KNUCKLE

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AUTION: The steering knuckle to strut assemblyttaching bolts are serrated and must not be turneduring installation. Install nuts while holding boltstationary in the steering knuckles.

AUTION: If the vehicle being serviced is equippedith eccentric strut assembly attaching bolts, theccentric bolt must be installed in the bottom (slot-

ed) hole on the strut clevis bracket (Fig. 24).

Fig. 23 Strut To Steering Knuckle Attaching Bolts1 – STRUT CLEVIS BRACKET2 – ATTACHING NUTS/BOLTS3 – STEERING KNUCKLE

Fig. 24 Correctly Installed Eccentric Attaching Bolt1 – STEERING KNUCKLE2 – FLANGED BOLT IN TOP HOLE3 – CAM BOLT IN BOTTOM HOLE4 – STRUT CLEVIS BRACKET

(2) Install steering knuckle back in clevis bracketof strut damper assembly (Fig. 23). Install the strutdamper to steering knuckle attaching bolts. Tightenboth attaching bolts to a torque of 90 N·m (65 ft. lbs.)plus an additional 1/4 turn.

(3) Slide drive shaft back into front hub and bear-ing assembly. Then install steering knuckle onto thestud of the ball joint assembly (Fig. 22).

(4) Install a new steering knuckle to ball jointstud, clamping bolt and nut (Fig. 20). Tighten theclamping bolt and nut to a torque of 145 N·m (105 ft.lbs.).

(5) Install tie rod end into steering knuckle. Startattaching nut onto stud of tie rod end. While holdingstud of tie rod end stationary using a 11/32 socket,(Fig. 16) tighten tie rod end to steering knuckleattaching nut. Then using a crowfoot and 11/32socket (Fig. 25), tighten the tie rod end attaching nutto a torque of 54 N·m (40 ft. lbs.).

(6) Install braking disc on hub and bearing assem-bly (Fig. 15).

(7) Install disc brake caliper assembly on steeringknuckle. Caliper is installed by first sliding bottom ofcaliper under abutment on steering knuckle, andthen rotating top of caliper against top abutment(Fig. 13).

(8) Install disc brake caliper assembly to steeringknuckle attaching bolts (Fig. 12). Tighten the discbrake caliper assembly attaching bolts to a torque of22 N·m (195 in. lbs.).

Fig. 25 Torquing Tie Rod End Attaching Nut1 – STEERING KNUCKLE2 – TIE ROD END3 – CROWFOOT4 – 11/32 SOCKET5 – TORQUE WRENCH

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(9) Clean all foreign matter from the threads ofhe outer C/V joint stub axle. Install the washer andtub axle to hub/bearing assembly nut on stub axlend securely tighten nut.(10) Install wheel speed sensor and mounting bolt

Fig. 18) on steering knuckle. Tighten the speed sen-or attaching bolt to a torque of 7 N·m (60 in. lbs.).(11) Install front wheel and tire assembly. Install

nd tighten the wheel mounting stud nuts in properequence until all nuts are torqued to half theequired specification. Then repeat the tighteningequence to the full specified torque of 135 N·m (100t. lbs.).

(12) Lower vehicle.(13) With the vehicle’s brakes applied to keep hub

rom turning, tighten the hub nut to a torque of 244·m (180 ft. lbs.) (Fig. 26).

(14) Install the spring wave washer on the end ofhe stub axle.

(15) Install the hub nut lock, and a new cotter pinFig. 10). Wrap cotter pin prongs tightly around theub nut lock as shown in (Fig. 10).(16) Set front Toe on vehicle to required specifica-

ion. Use procedure listed under Wheel Alignment, inhe Suspension section of this service manual.

UB AND BEARING (FRONT)

EMOVAL

OTE: Replacement of the Unit III front hub/bearingssembly can be normally done without having toemove the steering knuckle from the vehicle. In thevent that the hub/bearing is frozen in the steeringnuckle and cannot be removed by hand it will haveo be pressed out of the steering knuckle. Theteering knuckle will require removal from the vehi-

Fig. 26 Torquing Front Stub Axle To Hub Nut1 – TORQUE WRENCH

cle to allow the hub/bearing assembly to bepressed out of the steering knuckle. Refer to FrontSteering Knuckle in this section of the service man-ual for the required removal and installation proce-dure.

(1) Remove the cotter pin, and nut lock from thestub axle (Fig. 27).

(2) Remove the spring wave washer (Fig. 28) fromthe end of the stub axle.

Fig. 27 Cotter Pin And Nut Lock1 – HUB/BEARING2 – NUT LOCK3 – COTTER PIN4 – STUB AXLE

Fig. 28 Nut Lock Wave Washer1 – HUB/BEARING ASSEMBLY2 – WAVE WASHER3 – STUB AXLE

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AUTION: Wheel bearing damage will result if afteroosening hub nut, vehicle is rolled on the groundr the weight of the vehicle is allowed to be sup-orted by the tires.

(3) With the aid of a helper applying the brakes toeep the front hub from turning, loosen but do notemove the hub nut. The hub and driveshaft areplined together through the knuckle (bearing)nd retained by the hub nut.(4) Raise vehicle on jack stands or centered on a

rame contact type hoist. See Hoisting in the Lubri-ation and Maintenance section of this manual, forhe required lifting procedure to be used for thisehicle.(5) Remove wheel lug nuts, and front tire andheel assembly.(6) Remove front disc brake caliper to steering

nuckle attaching bolts. (Fig. 29).

(7) Remove disc brake caliper assembly from steer-ng knuckle. Caliper is removed by first rotating topf caliper away from steering knuckle, and thenemoving bottom of caliper out from under machinedbutment. (Fig. 30)(8) Support disc brake caliper assembly using aire hook, (Fig. 31) do not hang caliper assemblyy hydraulic hose.

Fig. 29 Front Disc Brake Caliper Mounting Bolts1 – DISC BRAKE CALIPER ASSEMBLY2 – STEERING KNUCKLE3 – DISC BRAKE CALIPER MOUNTING BOLTS4 – DRIVESHAFT

Fig. 30 Brake Caliper Assembly Removal/Installation1 – CALIPER ASSEMBLY2 – ROTOR3 – STEERING KNUCKLE4 – MACHINED ABUTMENT

Fig. 31 Supporting Brake Caliper1 – STEERING KNUCKLE2 – BRAKE FLEX HOSE3 – CALIPER ASSEMBLY4 – WIRE HANGER5 – STRUT ASSEMBLY

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(9) Remove the braking disc from the front hub/earing assembly.(10) Remove the retaining nut and the washer

Fig. 32) from the end of the stub axle.

(11) Remove the four hub and bearing assemblyounting bolts from the rear of steering knuckle

Fig. 33).

Fig. 32 Hub/Bearing To Stub Axle Retaining Nut AndWasher

1 – RETAINING NUT2 – TIE ROD END3 – STUB AXLE4 – WASHER5 – HUB/BEARING ASSEMBLY6 – STEERING KNUCKLE

Fig. 33 Hub/Bearing Assembly Mounting Bolts1 – FRONT HUB2 – STEERING KNUCKLE3 – HUB/BEARING MOUNTING BOLTS (4)4 – DRIVESHAFT

(12) Remove the hub and bearing assembly fromthe steering knuckle (Fig. 34).

INSTALLATION

CAUTION: Hub and bearing assembly mountingsurfaces on the steering knuckle and halfshaft (Fig.35) must be smooth and completely free of foreignmaterial or nicks prior to installing hub and bearingassembly.

Fig. 34 Hub and Bearing Assembly Removal FromSteering Knuckle

1 – STUB AXLE2 – HUB/BEARING ASSEMBLY3 – STEERING KNUCKLE4 – BEARING SEAL

Fig. 35 Hub And Bearing Assembly MountingSurfaces

1 – BEARING SEAL2 – STUB AXLE3 – THESE SURFACES MUST BE CLEAN AND FREE OF NICKS

BEFORE INSTALLING BEARING ASSEMBLY4 – STEERING KNUCKLE

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AUTION: When installing hub and bearing assem-ly into steering knuckle, be careful not to damage

he bearing seal (Fig. 35) on the outer C/V joint.

(1) Install hub/bearing assembly onto stub axlend into steering knuckle until squarely seated onhe face of the steering knuckle.

(2) Install the 4 hub/bearing assembly to steeringnuckle attaching bolts (Fig. 33). Equally tighten allmounting bolts in a criss-cross pattern until hub/

earing assembly is squarely seated against front ofteering knuckle. Then tighten the 4 hub and bearingssembly mounting bolts to a torque of 65 N·m (45t.lbs.)

(3) Install the hub/bearing assembly to stub shaftasher and retaining nut (Fig. 36). Tighten, but doot torque the hub nut at this time.

(4) Install the braking disk on the hub and bearingssembly.(5) Install front brake caliper back over braking

isc and align with caliper mounting holes on steer-ng knuckle (Fig. 30). Caliper is installed by firstnstalling bottom of caliper under machined abut-

ent on bottom of steering knuckle and then rotat-ng top of caliper toward steering knuckle. Install theisc brake caliper to steering knuckle attaching boltsFig. 29) and tighten to a torque of 19 N·m (168 in.bs.).

Fig. 36 Hub/Bearing To Stub Axle Washer AndRetaining Nut

1 – RETAINING NUT2 – TIE ROD END3 – STUB AXLE4 – WASHER5 – HUB/BEARING ASSEMBLY6 – STEERING KNUCKLE

(6) Install wheel and tire assembly on vehicle.Tighten the wheel mounting stud nuts in propersequence until all nuts are torqued to half specifica-tion. Then repeat the tightening sequence to the fullspecified torque of 129 N·m (95 ft. lbs.).

(7) Lower vehicle to the ground.

CAUTION: When tightening hub/bearing assemblyto stub shaft retaining nut, do not exceed the max-imum torque of 244 N·m (180 ft. lbs.).

(8) With vehicle brakes applied to keep vehiclefrom moving, torque stub shaft to hub/bearing assem-bly retaining nut to 244 N·m (180 ft. lbs.).

(9) Check the Toe setting on the vehicle and resetif not within specifications.

LOWER CONTROL ARM

REMOVE(1) Raise vehicle on jack stands or centered on a

frame contact type hoist. See Hoisting in the Lubri-cation and Maintenance section of this manual, forthe required lifting procedure to be used for thisvehicle.

(2) Remove wheel and tire assembly from the sideof vehicle requiring service to the lower control arm.

(3) Remove the wheel stop (Fig. 37) from the steer-ing knuckle. When installing the pinch bolt whenassembling the steering knuckle to the balljoint, the pinch bolt must be installed from therear facing the front on the vehicle (Fig. 37).

Fig. 37 Wheel Stop Location On Steering Knuckle1 – STEERING KNUCKLE2 – WHEEL STOP3 – LOWER CONTROL ARM4 – ROTOR

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(4) Remove the nut and bolt clamping the steeringnuckle to the ball joint stud. (Fig. 38)

OTE: The attaching bolts for the cradle plate aref two different thread sizes. Nine of the bolts are a-14 thread and one of the bolts is a M-12 thread.efer to (Fig. 39) for the cradle plate attaching bolt

ocations.

(5) Remove the 10 bolts (Fig. 39) attaching the cra-le plate to the front suspension cradle. Then removehe cradle plate from the cradle.

AUTION: Pulling steering knuckle out from vehi-le after releasing from ball joint can separate inner/V joint. See Driveshafts.

(6) Using a pry bar, separate steering knucklerom ball joint stud (Fig. 40). Use caution wheneparating ball joint stud from steeringnuckle, so ball joint seal does not get cut.(7) Loosen but do not remove the pivot bolt (Fig.

1) attaching the front bushing of the lower controlrm to the front suspension cradle.(8) Remove retainer (Fig. 42) attaching rear bush-

ng of lower control arm to front suspension cradle.

Fig. 38 Control Arm To Steering KnuckleAttachment

1 – CLAMPING NUT/BOLT2 – LOWER CONTROL ARM3 – BALL JOINT4 – STEERING KNUCKLE5 – ROTOR

CAUTION: Make location reference marks wherethe front suspension cradle is mounted against thefront frame rails before loosening and lowering thecradle. This is required so the cradle can be re-in-stalled in the design location to achieve properfront suspension alignment.

Fig. 39 Front Suspension Cradle Plate AndMounting Bolts

1 – FRONT SUSPENSION CRADLE2 – CRADLE PLATE ATTACHING BOLT M12 (1)3 – CRADLE PLATE TO CRADLE ATTACHING BOLTS M14 (9)

Fig. 40 Separating Ball Joint Stud From SteeringKnuckle

1 – STEERING KNUCKLE2 – BALL JOINT STUD3 – BALL JOINT SEAL4 – LOWER CONTROL ARM5 – PRY BAR

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(9) Loosen but not fully removing the 2 left sideuspension cradle to frame rail attaching bolts (Fig.3).

OTE: When removing the left lower control armrom the vehicle, the front suspension cradle needso be lowered for the pivot bolt to clear the tran-axle.

Fig. 41 Lower Control Arm Bushing To Cradle PivotBolt

1 – FRONT SUSPENSION CRADLE2 – CONTROL ARM PIVOT BUSHING BOLT3 – CONTROL ARM REAR BUSHING RETAINER4 – LOWER CONTROL ARM

Fig. 42 Control Arm Bushing To Suspension CradleRetainer

1 – SUSPENSION CRADLE2 – BUSHING RETAINER3 – LOWER CONTROL ARM

(10) Lower the left front corner of the suspensioncradle until pivot bolt will clear end of transaxle (Fig.44). Remove the pivot bolt and the lower control armfrom the cradle.

INSTALL

NOTE: If the left lower control arm is beinginstalled on the vehicle the front suspension cradleneeds to be lowered for the pivot bolt to clear thetransaxle.

Fig. 43 Suspension Cradle To Frame Rail MountingBolts

1 – FRAME RAIL2 – FRONT SUSPENSION CRADLE3 – MOUNTING BOLT4 – MOUNTING BOLT

Fig. 44 Lowering Front Suspension Cradle1 – PRY BAR2 – TRANSAXLE3 – LOWER CONTROL ARM PIVOT BOLT4 – FRONT SUSPENSION CRADLE

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(1) Position lower control arm assembly into frontuspension cradle. If installing the left lower con-rol arm, pry down on the left front corner ofhe suspension cradle until the pivot bolt clearshe end of the transaxle (Fig. 44). Install pivotolt attaching front bushing of lower control arm toront suspension cradle (Fig. 45). Do not tighten ororque pivot bolt at this time.

(2) Install retainer (Fig. 46) attaching rear bush-ng of lower control arm to front suspension cradle.

hen installing retainer, be sure raised rib onear bushing (Fig. 46) is positioned in theroove on the retainer. Do not torque attachingolts at this time.

OTE: If reference marks were not put on therame rails prior to lowering the suspension cradle,efer to group 13 Frame And Bumpers for the cra-le positioning procedure.

(3) Raise the front suspension cradle against theront frame rails. Align the cradle with the referencearks on the frame rails.(4) Tighten the 4 mounting bolts for the front sus-

ension cradle to a torque of 163 N·m (120 ft. lbs.).(5) Install lower control arm ball joint stud into

teering knuckle. Then install the bolt and nut,lamping the steering knuckle to the ball joint studFig. 38). Tighten the clamping bolt to a torque of45 N·m (105 ft. lbs.).(6) Install the cradle plate on front suspension cra-

le and then install the 10 cradle plate to cradlettaching bolts (Fig. 39). Tighten the 9 M-14 attach-ng bolts (Fig. 39) to a torque of 165 N·m (123 ft.bs.). Tighten the 1 M-12 attaching bolt (Fig. 39) to aorque of 108 N·m (80 ft. lbs.).

Fig. 45 Lower Control Arm Bushing Pivot BoltCorrectly Installed

1 – LOWER CONTROL ARM BUSHING PIVOT BOLT2 – LOWER CONTROL ARM3 – FRONT SUSPENSION CRADLE

CAUTION: When locating jack stands under lowercontrol arm, do not place the jack stands under theball joints (Fig. 47).

(7) Position jack stands under the lower controlarms as close to the ball joints as possible (Fig. 47).Lower the vehicle onto the jack stands, until the jackstands are supporting the total weight of the vehicle(Fig. 47).

Fig. 46 Installing Lower Control Arm Rear BushingRetainer

1 – LOWER CONTROL ARM2 – BUSHING RETAINER3 – GROOVE4 – FRONT SUSPENSION CRADLE5 – RAISED RIB6 – REAR BUSHING

Fig. 47 Jack Stands Supporting Vehicle Weight1 – LOWER CONTROL ARMS2 – BALL JOINT3 – JACK STANDS4 – BALL JOINT

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(8) Tighten front lower control arm pivot bolt (Fig.5) to a torque of 183 N·m (135 ft. lbs.) first, thenighten rear lower control arm bushing retainerttaching bolts (Fig. 42) to a torque of 68 N·m (50 ft.bs.).

(9) Install the wheel/tire assembly on the vehicle.(10) Install and tighten the wheel mounting stud

uts in proper sequence until all nuts are torqued toalf specification. Then repeat the tighteningequence to the full specified torque of 135 N·m (100t. lbs.).

(11) Remove jack stands and lower vehicle to theround.

TABILIZER BAR (FRONT)

EMOVAL(1) Raise vehicle on jack stands or centered on a

rame contact type hoist. See Hoisting in the Lubri-ation and Maintenance section of this manual, forhe required lifting procedure to be used for thisehicle.

OTE: The attaching bolts for the cradle plate aref two different thread sizes. Nine of the bolts are a-14 thread and one of the bolts is a M-12 thread.efer to (Fig. 48) for the cradle plate attaching bolt

ocations.

(2) Remove the 10 bolts (Fig. 48) attaching the cra-le plate to the front suspension cradle. Then removehe cradle plate from the cradle.

Fig. 48 Cradle Plate And Mounting Bolts1 – FRONT SUSPENSION CRADLE2 – CRADLE PLATE ATTACHING BOLT M12 (1)3 – CRADLE PLATE TO CRADLE ATTACHING BOLTS M14 (9)

CAUTION: When removing the nut from the stud ofthe stabilizer bar link, do not allow the stud torotate in it’s socket. Hold the stud from rotating byplacing an open-end wrench on the flat machinedinto the stud (Fig. 49).

(3) Remove the stabilizer bar links from each endof the stabilizer bar (Fig. 49). To do so, place an open-end wrench on the flat machined into the link’smounting stud, then remove the nut while holdingthe wrench in place. Push each stud out of the holein the stabilizer bar.

(4) Remove the stabilizer bar bushing retainersfrom the front suspension cradle (Fig. 50).

(5) Remove the stabilizer bar and bushings as anassembly from the front suspension cradle.

Fig. 49 Stabilizer Bar Link To Stabilizer BarAttachment

1 – RATCHET2 – WRENCH3 – STRUT4 – STABILIZER BAR LINK5 – NUT6 – STABILIZER BAR

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NSTALLATION(1) If the stabilizer bar to front suspension cradle

ushings require replacement at time of inspection,nstall new bushings before installing stabilizer bar.ushings are replaced by opening slit on bushingsnd peeling them off stabilizer bar. Install new bush-ngs on stabilizer bar by spreading bushing at slitnd forcing them on the stabilizer bar. Bushingsust be installed on stabilizer bar so slit in

ushing will be facing toward the rear of vehi-le with the square corner toward the ground,hen the stabilizer bar is installed on the vehi-

le (Fig. 51).(2) Position stabilizer bar into front suspension

radle so stabilizer bar bushings are aligned withepressions in cradle. Install stabilizer bar bushingetainers onto crossmember aligning raised bead onetainer with cutouts in bushings (Fig. 52). Do notighten Stabilizer bar bushing retainers at thisime.

(3) Check position of the stabilizer bar in the frontuspension cradle. The center of the curved section ofhe stabilizer bar must be aligned with the raisedine in the center of the front suspension cradle (Fig.3).(4) Install the stabilizer bar link mounting stud

hrough the hole in each end of the stabilizer barFig. 49).

AUTION: When installing the nut on the mountingtud of the stabilizer bar link, do not allow the studo rotate in it’s socket. Hold the stud from rotating

Fig. 50 Front Stabilizer Bar Bushing Retainers1 – STEERING GEAR2 – SWAY BAR3 – RAISED BEAD4 – FRONT SUSPENSION CRADLE5 – SWAY BAR BUSHING RETAINERS

by placing an open-end wrench on the flatmachined into the stud (Fig. 49).

(5) Hand-thread the nut on the end of each stabi-lizer bar link stud. Hold the studs from turning byplacing an open-end wrench on the flat machinedinto the link’s mounting stud, then tighten each nutwhile holding the wrench in place (Fig. 49). Tighteneach nut to a torque of 88 N·m (65 ft. lbs.).

Fig. 51 Correctly Installed Stabilizer Bar To CradleBushing

1 – SWAY BAR ISOLATOR BUSHING2 – SLIT IN SWAY BAR BUSHING3 – SWAY BAR

Fig. 52 Stabilizer Bar Bushing Retainer Installation1 – SWAY BAR2 – SWAY BAR BUSHING3 – BUSHING SPLIT4 – FRONT SUSPENSION CRADLE5 – BUSHING CUT-OUT6 – BUSHING RETAINER7 – RAISED BEAD

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(6) Tighten the stabilizer bar bushing retainer toradle attaching bolts (Fig. 50) to 68 N·m (50 ft. lbs.)orque.

(7) Install the cradle plate on front suspension cra-le and then install the 10 cradle plate to cradlettaching bolts (Fig. 48). Tighten the 9 M-14 attach-ng bolts (Fig. 48) to a torque of 165 N·m (123 ft.bs.). Tighten the 1 M-12 attaching bolt (Fig. 48) to aorque of 108 N·m (80 ft. lbs.).

(8) Lower the vehicle.

HEEL MOUNTING STUDS (FRONT)

EMOVAL

AUTION: If a wheel mounting stud needs to beeplaced in the hub and bearing assembly, thetuds CANNOT be hammered out of the hub flange.f a stud is removed by hammering it out of theearing flange, damage to the hub and bearingssembly will occur leading to premature bearing

ailure.

(1) Raise vehicle on jackstands or centered on arame contact type hoist. See Hoisting in the Lubri-ation and Maintenance section of this manual forhe required lifting procedure to be used for thisehicle.(2) Remove the front wheel and tire assembly from

he vehicle.(3) Remove the disc brake caliper assembly from the

teering knuckle (Fig. 54). Refer to the Brake section ofhis service manual for the removal procedure.

Fig. 53 Stabilizer Bar Correctly Positioned In Cradle1 – RAISED BEAD2 – SWAY BAR3 – WHEN INSTALLING SWAY BAR THE RAISED BEAD ON THE

SUSPENSION CRADLE MUST BE IN THE CENTER OFRADIUS IN SWAY BAR

4 – FRONT SUSPENSION CRADLE

(4) Remove brake rotor from hub, by pulling itstraight off wheel mounting studs. (Fig. 55)

Fig. 54 Disc Brake Caliper Mounting1 – DISC BRAKE CALIPER ASSEMBLY2 – STEERING KNUCKLE3 – DISC BRAKE CALIPER MOUNTING BOLTS4 – DRIVESHAFT

Fig. 55 Removing Brake Rotor1 – HUB2 – STEERING KNUCKLE3 – BRAKING DISC (ROTOR)4 – WHEEL MOUNTING STUD

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(5) Install a lug nut on the wheel stud to beemoved from the hub and bearing assembly, so thehreads on the stud are even with end of lug nut.nstall Remover, Special Tool C-4150A on hub andearing assembly flange and wheel stud (Fig. 56).

(6) Tightening down on special tool will pushheel stud out of the hub and bearing assembly

lange. When shoulder of wheel stud is past flangeemove special tool from hub and bearing assembly.emove lug nut from stud and remove wheel stud

rom flange.

NSTALLATION(1) Install replacement wheel stud into flange of

ub and bearing assembly. Install washers on wheeltud, then install a wheel lug nut on stud with flatide of lug nut against washers (Fig. 57).(2) Tighten the wheel lug nut, pulling the wheel

tud into the flange of the hub and bearing assembly.hen the head of the stud is fully seated against the

earing flange, remove lug nut and washers fromheel stud.(3) Install the brake rotor back on the hub and

earing assembly. (Fig. 55)(4) Install front brake caliper back over brake

otor and align with caliper mounting holes on steer-ng knuckle (Fig. 54). Refer to the Brake section ofhis service manual for the disc brake caliper instal-ation procedure.

(5) Install wheel and tire assembly on vehicle.ighten the wheel mounting lug nuts in properequence until all nuts are torqued to half specifica-

Fig. 56 Wheel Stud Removal1 – LUG NUT2 – HUB / BEARING ASSEMBLY3 – SPECIAL TOOL C-4150A4 – STEERING KNUCKLE5 – WHEEL STUD

tion, then repeat the tightening sequence to the fullspecified torque of 135 N·m (100 ft. lbs.).

(6) Lower vehicle to the ground.

DISASSEMBLY AND ASSEMBLY

STRUT ASSEMBLY (FRONT)The Strut assembly must be removed from the

vehicle for it to be disassembled and assembled.Refer to REMOVAL AND INSTALLATION in thissection for the required procedure.

For the disassembly and assembly of the strutassembly, use strut spring compressor, Pentastar Ser-vice Equipment (PSE) tool W-7200, or the equivalent,to compress the coil spring. Follow the manufactur-er’s instructions closely.

DISASSEMBLY(1) If both struts are being serviced at the same

time, mark the coil spring and strut assembly accord-ing to which side of the vehicle the strut wasremoved from, and which strut the coil spring wasremoved from.

(2) Position the strut assembly in the strut coilspring compressor following the manufacturersinstructions (Fig. 58). The strut clevis bracket shouldbe positioned outward. Position the upper hooks ontop of the coil spring upper seat (Fig. 59). Place aclamp on the lower end of the coil spring, so the strutis held in place once the strut shaft nut is removed(Fig. 58).

Fig. 57 Installing Wheel Stud Into Hub And Bearing1 – WASHERS2 – HUB / BEARING ASSEMBLY3 – WHEEL LUG NUT4 – STEERING KNUCKLE


DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 58 Strut Assembly In Compressor1 – STRUT SPRING COMPRESSOR2 – CLAMP3 – CLEVIS BRACKET4 – STRUT ASSEMBLY

Fig. 59 Upper Hooks Positioned1 – UPPER HOOKS2 – UPPER SEAT3 – UPPER MOUNT

WARNING: DO NOT REMOVE THE STRUT SHAFTNUT BEFORE THE COIL SPRING IS COMPRESSED.THE COIL SPRING IS HELD UNDER PRESSUREAND MUST BE COMPRESSED, REMOVING SPRINGTENSION FROM THE UPPER MOUNT AND PIVOTBEARING, BEFORE THE SHAFT NUT IS REMOVED.

(3) Compress the coil spring until all coil springtension is removed from the upper mount.

(4) Install Strut Nut Socket, Special Tool 6864, onthe strut shaft retaining nut (Fig. 60). Next, install a10 mm socket on the hex on the end of the strutshaft. While holding the strut shaft from turning,remove the nut from the strut shaft.

(5) Remove the upper mount from the strut shaft.(6) If the upper pivot bearing needs to be serviced,

remove it from the top of the coil spring upper seatby pulling it straight up.

(7) Remove the clamp from the bottom of the coilspring and remove the strut out through the bottomof the coil spring.

NOTE: If the coil spring or upper mount need to beserviced, proceed with the next step, otherwise,proceed with step 10.

(8) Release the tension from the coil spring bybacking off the compressor drive fully. Push back thecompressor upper hooks and remove the upper springseat.

(9) Remove the coil spring from the spring com-pressor.

Fig. 60 Retaining Nut Removal/Installation1 – UPPER MOUNT2 – SPECIAL TOOL 6864

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DISASSEMBLY AND ASSEMBLY (Continued)2000 NS Service ManualPublication No. 81-370-0005TSB 26-03-00 March, 2000

(10) Remove the dust shield and jounce bumperFig. 61) as an assembly from the strut shaft by pull-ng both straight up and off the strut shaft. The dusthield cannot be separated from the jounce bumperntil after it is removed from strut shaft.

(11) Remove the jounce bumper from the dusthield. The jounce bumper is removed from the dusthield by collapsing the dust shield until the jounceumper can be pulled free from the dust boot.(12) Remove the spring isolator from the lower

pring seat on the strut (Fig. 62).

(13) Inspect the strut assembly components for theollowing and replace as necessary:

Fig. 61 Dust Shield/Jounce Bumper1 – JOUNCE BUMPER2 – STRUT SHAFT3 – DUST SHIELD

Fig. 62 Strut Lower Spring Seat Isolator1 – STRUT ASSEMBLY SPRING SEAT2 – STRUT ASSEMBLY3 – COIL SPRING ISOLATOR4 – RETAINING TABS (2)

• Inspect the strut for any condition of shaft bind-ing over the full stroke of the shaft.

• Check the upper mount for cracks and distortionand its retaining studs for any sign of damage.

• Check the upper seat for severe deterioration ofthe rubber isolator

• Check for binding of the strut assembly pivotbearing.

• Inspect the dust shield for rips and deteriora-tion.

• Inspect the jounce bumper for cracks and signsof deterioration.

ASSEMBLY

NOTE: If the coil spring has been removed from thespring compressor, proceed with the next step, oth-erwise, proceed with step 5.

(1) Place the coil spring in the compressor follow-ing the manufacturers instructions (Fig. 63). Properorientation of the spring to the strut (once installed)is necessary. Consider the following when placing thecoil spring in the compressor: From above, the com-pressor back is at the 12 o’clock position and you,standing in the front of the machine, are at the 6o’clock position. For left side springs, place the lowercoil spring end at the 7 o’clock position. For rightside springs, place the lower coil spring end at the 5o’clock position.

(2) Install the upper seat on top of the coil spring.Position the notch in the perimeter of the upper seattoward the front of the compressor (Fig. 64).

Fig. 63 Coil Spring Positioned1 – SPRING COMPRESSOR LOWER HOOKS2 – END OF SPRING COIL

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(3) Position the upper hooks on top of the coilpring upper seat so the upper hooks span the outerhoulder of the upper seat.(4) Compress the coil spring.(5) If the pivot bearing has been removed form the

pper seat, install the pivot bearing on the top of thepper spring seat (Fig. 65). The bearing must be

nstalled on upper seat with the smaller diameteride of the pivot bearing toward the spring seat. Beure the pivot bearing is sitting flat on the springeat once mounted.

(6) Install the spring isolator on the lower springeat of the strut (Fig. 62). When installing the springsolator, be sure the 2 retaining tabs on the spring

Fig. 64 Upper Seat Notch Position1 – PIVOT BEARING2 – NOTCH3 – FRONT OF COMPRESSOR4 – UPPER SEAT

Fig. 65 Pivot Bearing Installation1 – PIVOT BEARING2 – UPPER SEAT

isolator are installed in the 2 holes in the springseat. When installed, the oversize holes in the springseat should line up with the holes in the spring iso-lator.

(7) Install the jounce bumper (Fig. 66) on the strutshaft. The jounce bumper is to be installed with thesmall end pointing downward (Fig. 66).

(8) Install the dust shield (Fig. 67) on the strut.Collapse and stretch the dust shield down over thetop of the jounce bumper until the dust shield snapsinto the slot on the jounce bumper. Return the dustshield to its fully extended length.

Fig. 66 Jounce Bumper On Strut Shaft1 – STRUT SHAFT2 – JOUNCE BUMPER3 – STRUT4 – SPRING SEAT

Fig. 67 Installing Dust Shield1 – DUST BOOT2 – STRUT SHAFT3 – JOUNCE BUMPER4 – STRUT

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(9) Install the strut through the bottom of the coilpring until the lower spring seat contacts the lowernd of the coil spring. The clevis bracket on the struthould point straight outward away from the com-ressor (to the 6 o’clock position). Install the clampn the lower end of the coil spring and strut, so thetrut is held in place (Fig. 58). Proper orientation ofhe coil spring to the strut is necessary. Verify theower end of the coil spring is contacting the strut’sower spring seat at the proper location using the fol-owing figure (Fig. 68). The strut’s clevis bracket isointing straight outward to the 6 o’clock position.or left side struts and springs, the lower coil springnd should contact the strut’s lower spring seat athe 7 o’clock position. For right side struts andprings, the lower coil spring end should contact thetrut’s lower spring seat at the 5 o’clock position.

(10) Install the strut mount over the strut shaftnd onto the top of the pivot bearing and upper seats shown (Fig. 59). Loosely install the retaining nutn the strut shaft.(11) Install Strut Nut Socket (on the end of a

orque wrench), Special Tool 6864, on the strut shaftetaining nut (Fig. 60). Next, install a 10 mm socketn the hex on the end of the strut shaft. While hold-ng the strut shaft from turning, tighten the struthaft retaining nut to a torque of 94 N·m (70 ft. lbs.).

Fig. 68 Top View Lower Spring Seats1 – LEFT STRUT2 – CLEVIS BRACKET3 – RIGHT STRUT4 – COIL SPRING END5 – LOWER SPRING SEAT6 – COIL SPRING END

(12) Slowly release the tension from the coil springby backing off the compressor drive fully. As the ten-sion is relieved, make sure the upper mount, pivotbearing and upper seat align properly. Remove theclamp from the lower end of the coil spring and strut.Push back the spring compressor upper and lowerhooks, then remove the strut assembly from thespring compressor.

(13) Install strut assembly on the vehicle.

LOWER CONTROL ARM (BALL JOINT SEALBOOT)

DISASSEMBLY(1) Using a screw driver or other suitable tool, pry

the seal boot off of the ball joint assembly (Fig. 69)

ASSEMBLY

CAUTION: When installing the ball joint seal on theball joint/lower control arm, the shield (Fig. 70) onthe ball joint seal must be positioned as shown.

(1) Install a NEW seal boot by hand as far as pos-ible on the ball joint. Installation of the seal boot iso be with the shield positioned as shown (Fig. 70).

AUTION: Do not use an arbor press to install theealing boot on the ball joint. Damage to the seal-

ng boot will occur if excessive pressure is appliedo the sealing boot when it is being installed.

Fig. 69 Ball Joint Seal Boot Removal1 – LOWER CONTROL ARM2 – BALL JOINT STUD3 – SEAL BOOT4 – SCREW DRIVER5 – BALL JOINT ASSEMBLY

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(2) Place Installer, Special Tool 6758 over seal bootnd squarely align it with bottom edge of seal bootFig. 71). Apply hand pressure to Special Tool 6758ntil seal boot is pressed squarely against top surfacef lower control arm.

AUTION: A replacement ball joint is not pre-lubri-ated. Properly lubricate the replacement ball jointsing Mopar Multi–Mile grease or an equivalent.ubricate ball joint after seal boot is installed butrior to top of seal boot being pushed down belowotch in ball joint stud. Air must vent out of theeal boot at notch when grease is pumped into balloint, failure to do so will balloon and damage sealoot. Do not over grease the ball joint, this will pre-ent the seal boot from pushing down on the studf the ball joint.

AUTION: After the ball joint is properly greased,lip the end of the grease fitting off below the hex.he ball joint seal boot is non-purgeable and furtherreasing is not required and can result in damage

o the seal boot.

Fig. 70 Ball Joint Seal Boot Installed Position1 – BALL JOINT SEAL BOOT2 – BALL JOINT STUD3 – LOWER CONTROL ARM4 – SHIELD

LOWER CONTROL ARM (BALL JOINT)

NOTE: To perform the following procedure, thelower control arm must be removed from the vehi-cle. Refer to Removal And Installation in this sec-tion for that procedure.

DISASSEMBLY(1) Using a screw driver or other suitable tool, pry

the seal boot off of the ball joint assembly (Fig. 72)

Fig. 71 Installing Ball Joint Seal Boot1 – SHIELD2 – SPECIAL TOOL 67583 – LOWER CONTROL ARM4 – BALL JOINT SEAL BOOT

Fig. 72 Ball Joint Seal Boot Removal1 – LOWER CONTROL ARM2 – BALL JOINT STUD3 – SEAL BOOT4 – SCREW DRIVER5 – BALL JOINT ASSEMBLY

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(2) Position receiving cup, Special Tool 6758 toupport lower control arm when removing ball jointssembly (Fig. 73). Install Remover, Special Tool919 on top of the ball joint assembly (Fig. 73).

(3) Using the arbor press, press the ball jointssembly completely out of the lower control arm.

SSEMBLY

OTE: When installing ball joint in lower controlrm, position the ball joint in control arm so notch

n ball joint stud is in the direction shown (Fig. 74).his will ease assembly of the ball joint to theteering when installing pinch bolt.

(1) By hand, position ball joint into ball joint boref lower control arm. Be sure ball joint is notocked in the bore of the control arm, this willause the ball joint to bind when being pressednto control arm.

(2) Position control arm with installed ball joint, inn arbor press with Receiving Cup, Special Tool 6758upporting the lower control arm (Fig. 75). Then cen-er Installer, Special Tool 6908-4 on the bottom of theall joint (Fig. 75)(3) Carefully align all pieces. Then press the ball

oint into the lower control arm until it is completelyeated against surface of lower control arm. The balloint is correctly installed when there is no gapetween the ball joint and the lower control arm (Fig.6). Do not apply excessive force against theall joint or the lower control arm.

Fig. 73 Ball Joint Removal From Lower Control Arm1 – ARBOR PRESS2 – SPECIAL TOOL 69193 – BALL JOINT4 – SPECIAL TOOL 67585 – LOWER CONTROL ARM

CAUTION: When installing the ball joint seal on theball joint/lower control arm, the shield (Fig. 77) onthe ball joint seal must be positioned as shown.

(4) Install a NEW seal boot by hand as far as pos-sible on the ball joint. Installation of the seal boot isto be with the shield positioned as shown (Fig. 77).

CAUTION: Do not use an arbor press to install thesealing boot on the ball joint. Damage to the seal-ing boot will occur if excessive pressure is appliedto the sealing boot when it is being installed.

Fig. 74 Installation Position Of Ball Joint In ControlArm

1 – NOTCH2 – BALL JOINT STUD3 – BALL JOINT4 – LOWER CONTROL ARM

Fig. 75 Installing Ball Joint In Control Arm1 – ARBOR PRESS2 – SPECIAL TOOL 6908–43 – BALL JOINT4 – LOWER CONTROL ARM

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(5) Place Installer, Special Tool 6758 over seal bootnd squarely align it with bottom edge of seal bootFig. 78). Apply hand pressure to Special Tool 6758ntil seal boot is pressed squarely against top surfacef lower control arm.

Fig. 76 Correctly Installed Lower Ball Joint1 – SPECIAL TOOL 6908–42 – BALL JOINT3 – BALL JOINT IS CORRECTLY INSTALLED WHEN NO GAP IS

PRESENT HERE4 – LOWER CONTROL ARM

Fig. 77 Ball Joint Seal Boot Installed Position1 – BALL JOINT SEAL BOOT2 – BALL JOINT STUD3 – LOWER CONTROL ARM4 – SHIELD

CAUTION: A replacement ball joint is not pre-lubri-cated. Properly lubricate the replacement ball jointusing Mopar Multi–Mile grease or an equivalent.Lubricate ball joint after seal boot is installed butprior to top of seal boot being pushed down belownotch in ball joint stud (Fig. 74). Air must vent outof the seal boot at notch when grease is pumpedinto ball joint, failure to do so will balloon and dam-age seal boot. Do not over grease the ball joint, thiswill prevent the seal boot from pushing down onthe stud of the ball joint.

CAUTION: After the ball joint is properly greased,clip the end of the grease fitting off below the hex.The ball joint seal boot is non-purgeable and furthergreasing is not required and can result in damageto the seal boot.

(6) Reinstall lower control arm on vehicle.

LOWER CONTROL ARM (FRONT BUSHING)

DISASSEMBLY(1) Remove the lower control arm from the front

suspension cradle. Refer to Lower Control Arm in theRemoval And Installation Section in this section ofthe service manual for the required procedure.

Fig. 78 Installing Ball Joint Seal Boot1 – SHIELD2 – SPECIAL TOOL 67583 – LOWER CONTROL ARM4 – BALL JOINT SEAL BOOT

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(2) Securely mount the lower control arm in a vise.(3) Assemble for removal of the front bushing, theushing Receiver, Special Tool 6908–2, Bushingemover, Special Tool 6908–1, Nut, Special Tool908–3 thrust washer, threaded rod and small nut,s shown in (Fig. 79) on the lower control arm andront bushing.

(4) To remove front bushing from lower controlrm, hold the threaded rod stationary and tightenhe Nut, Special Tool 6908–3 (Fig. 79). This will forcehe front bushing out of the lower control arm andnto Bushing Receiver, Special Tool 6908–2 (Fig. 79).

SSEMBLY(1) Securely mount the lower control arm in a vise.

OTE: The lower control arm front bushing is airectional bushing. It must be installed in the lowerontrol arm positioned as shown in (Fig. 80).

(2) Position the front bushing in the lower controlrm so that the 2 rubber blocks on the bushing areositioned horizontally as shown in (Fig. 80).(3) Assemble for installation of the front bushing,

he Bushing Receiver, Special Tool 6908–5, Bushingnstaller, Special Tool 6908–4, Nut, Special Tool908–3 thrust washer, threaded rod and small nut,s shown in (Fig. 81) on the lower control arm andront bushing.

Fig. 79 Tools Assembled For Removal Of FrontBushing

1 – THRUST BEARING2 – SPECIAL TOOL 6908–13 – LOWER CONTROL ARM4 – NUT5 – SPECIAL TOOL 6908–26 – FRONT BUSHING7 – SPECIAL TOOL 6908–38 – THREADED ROD

(4) To install the front bushing in lower controlarm, hold the threaded rod stationary and tightenthe Nut, Special Tool 6908–3 (Fig. 81). This will pullthe front bushing into the lower control arm.

Fig. 80 Installation Position Of Lower Control ArmFront Bushing

1 – LOWER CONTROL ARM2 – LOWER CONTROL ARM REAR BUSHING3 – RUBBER BLOCKS4 – LOWER CONTROL ARM FRONT BUSHING

Fig. 81 Tools Assembled For Installation Of FrontBushing

1 – THRUST WASHER2 – SPECIAL TOOL 6908–53 – LOWER CONTROL ARM4 – FRONT BUSHING5 – NUT6 – SPECIAL TOOL 6908–47 – SPECIAL TOOL 6908–98 – THREADED ROD

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(5) Continue pulling the bushing into the lowerontrol arm until bushing is seated squarely againsthe lower control arm and there is no gap betweenhe bushing and the lower control arm (Fig. 82).

(6) Install the lower control arm on the front sus-ension cradle. Refer to Lower Control Arm in theemoval And Installation Section in this group of theervice manual for the required procedure.

OWER CONTROL ARM (REAR BUSHING)

ISASSEMBLY(1) Remove the lower control arm from the front

uspension cradle. Refer to Lower Control Arm in theemoval And Installation Section in this group of theervice manual for the required procedure.(2) Mount the lower control arm in a vise without

sing excessive clamping force.(3) Using a sharp knife, (such as a razor) slit the

ushing lengthwise (Fig. 83) to allow its removalrom the lower control arm (Fig. 83).

(4) Remove the bushing from the lower controlrm.

SSEMBLY

AUTION: Do not apply grease or any other type ofubricant other than the silicone lubricant specifiedelow to the control arm bushing.

Fig. 82 Correctly Installed Lower Control ArmBushing

1 – WHEN BUSHING IS CORRECTLY INSTALLED NO GAP IS TOBE VISIBLE BETWEEN BUSHING AND CONTROL ARMHERE

2 – SPECIAL TOOL 6908–43 – BUSHING4 – LOWER CONTROL ARM5 – SPECIAL TOOL 6908–5

(1) Apply Mopar Silicone Spray Lube or an equiv-alent, to the hole in lower control arm rear bushing.This will aid in the installation of the bushing on thelower control arm.

(2) With the lower control arm held securely in avise, install bushing on lower control arm. Installbushing by pushing and rocking the bushing until itis fully installed on lower control arm. Be sure thatwhen bushing is installed it is past the upset on theend of the lower control arm (Fig. 84).

(3) The rear bushing of the lower control arm,when correctly installed, is to be positioned on thelower control arm as shown (Fig. 84).

Fig. 83 Slit Lower Control Arm Rear Bushing1 – LOWER CONTROL ARM REAR BUSHING2 – SLIT CUT IN BUSHING3 – LOWER CONTROL ARM

Fig. 84 Correctly Installed Lower Control ArmBushing

1 – ROUND SURFACE OF BUSHING2 – LOWER CONTROL ARM3 – LOWER CONTROL ARM REAR BUSHING4 – UPSET5 – FLAT SURFACE OF BUSHING

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TABILIZER BAR BUSHING (FRONT)If stabilizer bar to front suspension cradle bush-

ngs require replacement at time of inspection, installew bushings before installing stabilizer bar back onhe vehicle.

ISASSEMBLY(1) Stabilizer bar bushings are replaced by opening

he slit on the bushings and peeling them off the sta-ilizer bar.

SSEMBLY(1) Install new bushings on stabilizer bar by

preading bushing at slit and forcing them onto sta-ilizer bar.

OTE: Bushings must be installed on stabilizer baro the square corner of the bushing will be downnd slit in bushing will be facing the rear of theehicle when the stabilizer is installed (Fig. 85).

Fig. 85 Correctly Installed Stabilizer Bar To CradleBushing

1 – SLIT IN SWAY BAR BUSHING.2 – SQUARE CORNER3 – SWAY BAR4 – SWAY BAR ISOLATOR BUSHING

SPECIFICATIONS

FRONT SUSPENSION FASTENER TORQUES

DESCRIPTION TORQUEStrut Assembly:

Strut Tower Attaching Nuts . . . . . . . . . . . 28 N·m(250 in. lbs.)

Steering Knuckle Attaching bolts . . . . . . 88 N·m(65 ft. lbs.) Plus 1/4 Additional Turn

Strut Shaft Nut . . . . . . . . . . 100 N·m (75 ft. lbs.)Steering Knuckle:

Ball Joint Stud Nut/Bolt . . 145 N·m (105 ft. lbs.)Disc Brake Caliper Bolts . . . . 41 N·m (30 ft. lbs.)Wheel Stop . . . . . . . . . . . . . . 95 N·m (70 ft. lbs.)

Hub And Bearing:Mounting Bolts . . . . . . . . . . . 65 N·m (45 ft. lbs.)Hub Nut . . . . . . . . . . . . . . . 244 N·m (180 ft. lbs.)Wheel Mounting Lug Nuts . . 135 N·m (100 ft. lbs.)

Lower Control Arm:Lower Control Arm Pivot Bolt . . . . . . . . 185 N·m

(137 ft. lbs.)Lower Control Arm Rear BushingRetainer Bolt . . . . . . . . . . . . . 68 N·m (50 ft. lbs.)

Stabilizer Bar:Bushing Retainer Cradle AttachingBolts . . . . . . . . . . . . . . . . . . . 70 N·m (50 ft. lbs.)Attaching Link Nuts . . . . . . . 88 N·m (65 ft. lbs.)

Front Suspension Cradle:Body Attaching Bolts . . . . . 163 N·m (120 ft. lbs.)Reinforcement Plate AttachingBolts M-12 . . . . . . . . . . . . . . 108 N·m (80 ft. lbs.)Reinforcement Plate AttachingBolts M-14 . . . . . . . . . . . . . 166 N·m (123 ft. lbs.)

SPECIAL TOOLS

FRONT SUSPENSION

Installer Ball Joint 6758


SPECIAL TOOLS (Continued)

Wrench Strut Rod Nut 6864

Remover Ball Joint 6919

Remover/Installer Control Arm Bushing 6908

Remover Tie Rod End MB–991113

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REAR SUSPENSION

TABLE OF CONTENTS

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ESCRIPTION AND OPERATIONREAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . 44LEAF SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . 44JOUNCE BUMPER. . . . . . . . . . . . . . . . . . . . . . . . 45SHOCK ABSORBERS . . . . . . . . . . . . . . . . . . . . . 45HUB AND BEARING (REAR) . . . . . . . . . . . . . . . . 46TRACK BAR (REAR) . . . . . . . . . . . . . . . . . . . . . . 46STABILIZER BAR (REAR). . . . . . . . . . . . . . . . . . . 47IAGNOSIS AND TESTINGHUB AND BEARING (REAR) . . . . . . . . . . . . . . . . 47EMOVAL AND INSTALLATIONLEAF SPRINGS (FWD). . . . . . . . . . . . . . . . . . . . . 48
LEAF SPRINGS (AWD). . . . . . . . . . . . . . . . . . . . . 50
LEAF SPRING FRONT MOUNT . . . . . . . . . . . . . . 52LEAF SPRING REAR MOUNT . . . . . . . . . . . . . . . 52SHOCK ABSORBER (REAR) . . . . . . . . . . . . . . . . 53STABILIZER BAR (REAR). . . . . . . . . . . . . . . . . . . 54TRACK BAR (REAR) . . . . . . . . . . . . . . . . . . . . . . 54TRACK BAR MOUNT . . . . . . . . . . . . . . . . . . . . . . 55JOUNCE BUMPER. . . . . . . . . . . . . . . . . . . . . . . . 55HUB AND BEARING (REAR) . . . . . . . . . . . . . . . . 56WHEEL MOUNTING STUDS (REAR) . . . . . . . . . . 61ISASSEMBLY AND ASSEMBLYSHOCK ABSORBER UPPER BUSHING (REAR) . . 62PECIFICATIONS
REAR SUSPENSION FASTENER TORQUES . . . . 63

EAR SUSPENSION

ESCRIPTIONThe rear suspension design on this vehicle uses

eaf springs, and a tube and casting axle (Fig. 1) (Fig.). The leaf springs used on the rear suspension ofhis vehicle are of either a mono-leaf or multi-leafesign.There are 3 different rear suspension designs

vailable:• Front-Wheel-Drive• All-Wheel-Drive• Front-Wheel-Drive Commercial (fleet use only)The rear axle used on Front-Wheel-Drive applica-

ions of this vehicle is mounted to the rear leafprings using isolator bushings at the axle mountingrackets.The rear axle used on All-Wheel-Drive applications

f this vehicle is also mounted to the rear leafprings, but does not use isolator bushings betweenhe rear axle and the leaf springs.

The rear suspension used on the Front-Wheel-rive commercial version of this vehicle is unique.he leaf spring used on the commercial version ofhis vehicle is a multi-leaf spring. The rear axle isimilar to the standard FWD axle, but is heavy duty.t is mounted to the rear leaf springs, but unlike theon-commercial application of this vehicle, does notse any isolators between the spring and the axle.Each side of the rear suspension consists of theseajor components:• Leaf spring

• Jounce bumper• Shock absorber• Hub and bearing• Track bar• Stabilizer bar

OPERATIONThis rear suspension is designed to handle the var-

ious load requirements of the vehicle yet allow for acomfortable ride.

The rear leaf spring shackle angle’s provideincreasing suspension rates as the vehicle is loaded.This provides a comfortable unloaded ride and alsoample rear suspension travel when the vehicle isloaded.

The shock absorbers are mounted at an angle,more parallel to the springs. This design providesgreater stability in addition to controlling ridemotion.

The rear wheel bearings used are similar to thebearings used in the front suspension. A hub andbearing assembly is used.

LEAF SPRING

DESCRIPTIONThe leaf springs used on the rear suspension of

this vehicle are of either a mono-leaf or multi-leafdesign depending on model and options.

The leaf spring used on the commercial version ofthis vehicle is a multi-leaf spring, but is a uniquedesign for the commercial application.

Since the rear springs come in various designs andrates, be sure the correct spring is in use.

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PERATIONThe leaf spring controls ride quality and maintains

ide height.

OUNCE BUMPER

ESCRIPTIONThere are two jounce bumpers used in the rear

uspension. One mounts to each frame rail above theear axle.

PERATIONThe jounce bumper limits suspension travel andetal-to-metal contact of the rear axle with the

rame under full jounce conditions.

HOCK ABSORBERS

ESCRIPTIONThere is one shock absorber on each side of the

ear suspension (Fig. 1). The top of each shockbsorber is bolted to the frame rail. The bottom ofach shock absorber is bolted to the rear axle.

Fig. 1 Front-Wheel-D1 – JOUNCE BUMPER2 – TRACK BAR3 – LEAF SPRINGS

This vehicle is available with either standard typeor load-leveling shock absorbers. On the exterior,load-leveling shock absorbers are larger in diameterthan standard shock absorbers. The load-levelingshock absorbers mount the same as the standardshock absorbers, but use longer fasteners. Althoughthe fasteners are longer, the torque specificationsremain the same.

OPERATIONThe shock absorber dampens jounce and rebound

motions of the spring and suspension.Each load-leveling shock absorber is a self-leveling,

self-contained vehicle leveling system and shockabsorber combined. It does not require an externalcompressor, hoses, or height leveling sensors. All theheight leveling sensors, hydraulic pump, etc., arecontained inside the shock absorber. It uses roadinputs (bumps, stops, starts, turns, acceleration,deceleration, etc.) to activate pumping, which resultsin the extension and compression of the shockabsorber.

Rear Suspension4 – SHOCK ABSORBERS5 – AXLE ASSEMBLY

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UB AND BEARING (REAR)ESCRIPTIONThe rear wheel bearing and rear wheel hub of this

ehicle are a one-piece sealed unit, or hub and bear-ng unit type assembly. The hub and bearing is

ounted to the center of the rear axle using 4ounting bolts. It has five wheel mounting studs on

he hub flange.All-Wheel-Drive vehicles have a hub and bearing

nit with a splined hole in the center of the hub forear driveshaft acceptance.

AUTION: If a vehicle is equipped with antilockrakes, the tone wheel for the rear wheel speedensor is pressed onto the hub and bearing. Makeure any replacement bearing has the tone wheeln it before installation.

PERATIONThe hub and bearing has internal bearings that

llow the hub to rotate with the tire and wheel assem-

Fig. 2 All-Wheel-Dri1 – JOUNCE BUMPER2 – DRIVESHAFT3 – REAR DRIVELINE MODULE4 – DRIVESHAFT5 – JOUNCE BUMPER

bly (and driveshaft on All-Wheel-Drive vehicles). Thefive wheel mounting studs mount the tire and wheelassembly, and disc brake rotor to the vehicle.

On All-Wheel-Drive vehicles, the splined mating ofthe driveshaft and hub allows the driveshaft torotate with the hub and wheel.

Front-Wheel-Drive vehicles equipped with antilockbrakes have a tone wheel mounted to the rear of thehub and bearing that is used in conjunction with thewheel speed sensor to measure wheel speed.

TRACK BAR (REAR)

DESCRIPTIONOn front-wheel-drive applications of this vehicle

that are equipped with single leaf rear springs, atrack bar is used on the rear axle (Fig. 3).

The track bar connects the rear axle to the frame/body of the vehicle. The track bar is isolated from thebody of the vehicle by an isolator bushing located ineach end of the track bar.

ear Suspension6 – LEAF SPRING7 – SHOCK ABSORBER8 – AXLE9 – SHOCK ABSORBER10 – LEAF SPRING

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PERATIONThe track bar (Fig. 3) prevents excessive side-to-

ide movement of the rear axle. The track bar is usedo keep the location of the axle in the correct positionor optimum handling and control of the vehicle.

TABILIZER BAR (REAR)ESCRIPTIONThe stabilizer bar (Fig. 4) interconnects both sides

f the rear axle and attaches to the rear frame railssing 2 rubber isolated link arms.

Fig. 4 St1 – BUSHINGS AND RETAINER2 – REAR AXLE3 – FRAME RAIL BRACKET

Fig. 3 Rear Track Bar1 – REAR TRACK BAR

Attachment to the rear axle tube, and rear framerails is through rubber-isolated bushings. All partsare serviceable, and the stabilizer bar to axle bush-ings are split for easy removal and installation. Thesplit in the bushing should be positioned up whenthe stabilizer bar is installed on the vehicle.

The 2 rubber isolated link arms are connected tothe rear frame rails by brackets. These brackets arebolted to the bottom of the frame rails.

OPERATIONJounce and rebound movements affecting one

wheel are partially transmitted to the opposite wheelto reduce body roll.

DIAGNOSIS AND TESTING

HUB AND BEARING (REAR)The condition of the hub and bearing assembly is

diagnosed using the inspection and testing proceduredetailed below.

The bearing contained in the hub and bearingassembly will produce noise and vibration when wornor damaged. The noise will generally change whenthe bearings are loaded. A road test of the vehicle isnormally required to determine the location of aworn or damaged bearing.

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Find a smooth level road surface and bring theehicle up to a constant speed. When vehicle is at aonstant speed, swerve the vehicle back and forthrom the left and to the right. This will load andnload the bearings and change the noise level.hen bearing damage is slight, the noise is usually

ot noticeable at speeds above 30 m.p.h..

EMOVAL AND INSTALLATION

EAF SPRINGS (FWD)

EMOVAL(1) Raise vehicle on frame contact hoist to a com-

ortable working position.(2) Support axle with a jack stand. Pad should just

ontact axle.(3) Begin removal of the shock absorber lowerounting bolt (Fig. 5).

OTE: If shock absorber bolt deflects upward dur-ng removal, raise axle by adjusting support jack. Ifhock absorber bolt deflects downward duringemoval, lower axle by adjusting support jack (or byulling on axle).

(4) Using 2 jack stands positioned under the outernds of the axle, raise the axle enough to remove theeight of the axle from the rear springs.(5) Loosen and remove the axle plate bolts from

he rear axle (Fig. 6).(6) Remove the axle plate from the rear axle and

he leaf spring (Fig. 7).

Fig. 5 Rear Shock Mounting Bolt1 – SHOCK BOLT

(7) Using the jack stands slowly lower the rearaxle, permitting the rear springs to hang free.

(8) Loosen and remove the 4 bolts (Fig. 8) from thefront mount of the leaf spring.

(9) Loosen and remove the nuts from the springhanger (Fig. 9) for the rear leaf spring. Then removethe hanger plate from the hanger and remove thespring from the spring hanger (Fig. 9).

(10) Remove the leaf spring from the vehicle (Fig.10).

(11) Loosen and remove the pivot bolt from thefront mount of the rear leaf spring. (Fig. 11).

Fig. 6 Axle Plate Bolts1 – AXLE PLATE

Fig. 7 Axle Plate1 – AXLE PLATE

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RONT BUSHING REPLACEMENT(1) Install leaf spring in a proper holding fixture.(2) Install leaf spring press Special Tool C-4212–F.(3) Install adapter Special Tool C-4212–3.(4) Tighten leaf spring press until bushing is

xtracted from leaf spring.(5) Remove leaf spring press from leaf spring.(6) Insert replacement bushing into the leaf spring

ye. Verify that the bushing flange is on the leftide of the leaf spring when leaf spring is in then vehicle installed position.

(7) Install leaf spring press Special Tool C-4212–F.(8) Install adapter Special Tool C-4212–4.(9) Tighten leaf spring press until bushing flange

ottoms solidly against leaf spring eye.(10) Remove leaf spring press and adapter.

Fig. 8 Leaf Spring Front Mount1 – FRONT SPRING MOUNT

Fig. 9 Rear Spring Hanger1 – SHACKLE PLATE2 – SPRING HANGER

(11) Bend the bushing tabs so that they are con-tacting the leaf spring.

INSTALLATION(1) Assemble front spring mount to front of spring

eye and install pivot bolt and nut. Do not tighten.

CAUTION: Pivot bolt must face inboard to preventstructural damage during installation of spring.

(2) Raise front of spring and install four hangerbolts, tighten to 61 N·m (45 ft. lbs.) torque.

(3) Install rear of spring onto rear spring shackle.Install shackle plate. Do not tighten.

(4) Verify lower leaf spring isolator is in position.

Fig. 10 Leaf Spring Remove/Install1 – LEAF SPRING

Fig. 11 Leaf Spring Front Mount1 – LEAF SPRING2 – SPRING MOUNT

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(5) Raise axle into correct position on leaf springith axle centered under spring locator post (Fig.2).

(6) Verify that the leaf spring isolator is correctlyositioned in the axle plate.(7) Install axle plate on the spring.(8) Install axle plate bolts. Tighten bolts to 101·m (75 ft. lbs.) torque.(9) Install shock absorber bolts. Do not tighten.(10) Lower vehicle to floor so that the full curbeight of vehicle is supported by the tires.(11) Tighten component fasteners as follows:• Front pivot bolt—156 N·m (115 ft. lbs.)• Shackle nuts—61 N·m (45 ft. lbs.)• Shock absorber bolts—101 N·m (75 ft. lbs.)(12) If the vehicle is not equipped with antilock

rakes, raise vehicle and the connect the actuator forhe height sensing proportioning valve on the reareaf spring. Adjust the height sensing proportioningalve. Refer to the Adjustment Section in this groupf the service manual for the required adjustmentrocedure.

EAF SPRINGS (AWD)

EMOVAL(1) Raise vehicle on frame contact hoist to a com-

ortable working position.(2) Remove the driveshaft from the side of the

ehicle that requires the removal of the leaf spring.efer to Group 3 Driveline in this service manual for

he procedure covering the removal of the rear drive-hafts.(3) Support axle with a jack stand. Pad should just

ontact axle.

Fig. 12 Leaf Spring Locator Post1 – LEAF SPRING ISOLATOR2 – LEAF SPRING3 – LOCATOR POST

NOTE: If shock absorber bolt deflects upward dur-ing removal, raise axle by adjusting support jack. Ifshock absorber bolt deflects downward duringremoval, lower axle by adjusting support jack (or bypulling on axle).

(4) Begin removal of the shock absorber lowermounting bolt (Fig. 13).

(5) Using 2 jack stands positioned under the outerends of the axle, raise the axle enough to remove theweight of the axle from the rear springs.

(6) Loosen and remove the axle plate bolts fromthe rear axle (Fig. 14).

Fig. 13 Rear Shock Absorber Mounting Bolt1 – SHOCK BOLT

Fig. 14 Axle Plate Bolts1 – LEAF SPRING2 – AXLE PLATE BOLTS (4)3 – AXLE PLATE4 – AXLE

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(7) Using the jack stands slowly lower the rearxle, permitting the rear springs to hang free.(8) Loosen and remove the 4 bolts (Fig. 15) at the

ront mount of the rear leaf spring.

(9) Loosen and remove the 2 bolts and the 2 nutsrom the spring hanger (Fig. 16) for the rear leafpring. Then remove the inner half of the springanger from the outer half hanger of the springanger and the spring. (Fig. 16).

(10) Remove the rear leaf spring from the outeralf of the spring hanger(11) Remove the leaf spring from the vehicle (Fig.

7).

Fig. 15 Leaf Spring Front Mount1 – FRONT SPRING MOUNT

Fig. 16 Rear Spring Hanger1 – LEAF SPRING2 – NUTS3 – SPRING HANGER INNER HALF4 – LEAF SPRING REAR HANGER5 – SPRING HANGER OUTER HALF6 – BOLTS

(12) Loosen and remove the pivot bolt from thefront mount of the rear leaf spring. (Fig. 18).

FRONT BUSHING REPLACEMENT(1) Install leaf spring in a proper holding fixture.(2) Install leaf spring press Special Tool C-4212–F.(3) Install adapter Special Tool C-4212–3.(4) Tighten leaf spring press until bushing is

extracted from leaf spring.(5) Remove leaf spring press from leaf spring.(6) Insert replacement bushing into the leaf spring

eye. Verify that the bushing flange is on the outboardside of the leaf spring.

(7) Install leaf spring press Special Tool C-4212–F.(8) Install adapter Special Tool C-4212–4.(9) Tighten leaf spring press until bushing flange

bottoms solidly against leaf spring eye.

Fig. 17 Leaf Spring Remove/Install1 – LEAF SPRING

Fig. 18 Leaf Spring Front Mount1 – LEAF SPRING2 – SPRING MOUNT

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(10) Remove leaf spring press and adapter.(11) Bend the tabs on the bushing until they are

ontacting the leaf spring.

NSTALLATION

AUTION: Pivot bolt must face inboard to preventtructural damage during installation of spring.

(1) Install the front of the rear leaf spring into thepring mount (Fig. 18). Install the pivot bolt and nut.o not tighten the pivot bolt at this time.(2) Position the front spring mount for the rear

eaf spring against the floor pan of the vehicle.nstall the 4 mounting bolts for the spring mount.ighten the 4 mounting bolts to a torque of 61 N·m

45 ft. lbs.).(3) Install the rear of the leaf spring onto the outer

alf of the rear hanger. Install the inner half of theear hanger. Install the nut and bolts on the rearanger but do not tighten at this time.(4) Raise axle assembly into correct position with

xle centered under spring locator post.(5) Install axle plate bolts. Tighten bolts to 101·m (75 ft. lbs.) torque.(6) Install shock absorber bolts. Do not tighten.(7) Lower vehicle to floor and with full weight of

ehicle on wheels. Tighten component fasteners asollows:

AUTION: The following sequence must be fol-owed when tightening the pin nuts on the rearanger for the rear leaf spring. First the hanger pinuts must be tightened to the specified torquehown below. Then tighten the retaining bolts forhe inner to outer half of the spring hanger to theorque specification listed below. This sequenceust be followed to properly seat the bushings into

he springs and to avoid bending the spring hanger.• Front pivot bolt-156 N·m (115 ft. lbs.)• Rear spring hanger pin nuts-61 N·m (45 ft. lbs.)• Rear spring hanger inner to outer half retaining

olts-61 N·m (45 ft. lbs.)• Shock absorber mounting bolt-101 N·m (75 ft.

bs.)(9) If the vehicle is not equipped with antilock

rakes, raise vehicle and connect the actuator for theeight sensing proportioning valve on the rear leafpring. Adjust the height sensing proportioningalve. Refer to the Adjustment Section in this groupf the service manual for the required adjustmentrocedure.

LEAF SPRING FRONT MOUNT

REMOVAL(1) Loosen the pivot bolt attaching the front of the

leaf spring to the spring mount (Fig. 19).(2) Install a jackstand under the side of the axle

having the leaf spring mount removed. Using thejackstand support the weight of the axle and leafspring.

(3) Remove the lower mounting bolt from theshock absorber.

(4) Remove the bolts attaching the leaf springfront mount (Fig. 19) to the body of the vehicle.

(5) Lower the leaf spring and remove the frontmount from the spring.

INSTALLATION(1) For installation, reverse removal procedure. Do

not tighten front pivot bolt fully until vehicle is low-ered and the full vehicle weight is applied to the rearwheels. Tighten leaf spring front mount bolts to 61N·m (45 ft. lbs.). Tighten leaf spring front pivot boltto 156 N·m (115 ft. lbs.).

LEAF SPRING REAR MOUNT

REMOVE(1) Remove the attaching nuts and bolts from the

leaf spring rear shackle (Fig. 20) and (Fig. 21).(2) Install a jackstand under the side of the axle

having the leaf spring mount removed. Using thejackstand, support the weight of the axle and leafspring.

(3) Remove the lower mounting bolt from theshock absorber.

(4) Remove the bolts attaching the leaf spring rearmount to the body of the vehicle (Fig. 22).

Fig. 19 Leaf Spring Front Mount1 – LEAF SPRING FRONT MOUNT

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(5) Lower the jackstand and the rear of the leafpring. Remove the shackle from the leaf springushing.

NSTALL

AUTION: The following sequence must be fol-owed when tightening the pin nuts on the rearanger for the rear leaf spring. First the hanger pinuts must be tightened to the specified torque.hen tighten the retaining bolts for the inner touter half of the spring hanger to the specified

orque. This sequence must be followed to avoidending the spring hanger.

Fig. 20 Leaf Spring Shackle Nuts (FWD)1 – SHACKLE PLATE

Fig. 21 Leaf Spring Shackle Nuts/Bolts (AWD)1 – LEAF SPRING2 – NUTS3 – SPRING HANGER INNER HALF4 – LEAF SPRING REAR HANGER5 – SPRING HANGER OUTER HALF6 – BOLTS

(1) For installation, reverse removal procedure. Donot tighten rear spring shackle nuts fully until vehi-cle is lowered and the full vehicle weight is appliedto the rear wheels. Tighten rear spring mount boltsto 61 N·m (45 ft. lbs.). Tighten shackle nuts to 61N·m (45 ft. lbs.).

SHOCK ABSORBER (REAR)

REMOVAL(1) Raise vehicle. Vehicle is to be raised and sup-

ported on jackstands or on a frame contact typehoist. See Hoisting in the Lubrication And Mainte-nance section of this service manual.

(2) Support the rear axle of the vehicle using 2jackstands positioned at the outer ends of the axle.

NOTE: If the shock absorber lower mounting boltdeflects upward during removal, raise axle byadjusting the support jack. If the lower shockabsorber bolt deflects downward during removal,lower the axle by adjusting the support jack.

(3) Remove the shock absorber lower mountingbolt.

(4) While holding shock absorber, remove theshock absorber upper mounting bolt and shockabsorber.

INSTALLATION(1) While holding shock absorber in position

against the frame rail, install the shock absorberupper mounting bolt.

(2) Install the shock absorber lower mounting boltsecuring the lower end of the shock absorber to theaxle.

(3) Remove the support jack.

Fig. 22 Rear Spring Mount1 – LEAF SPRING MOUNT

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(4) Lower the vehicle to the ground so the full curbeight of the vehicle is supported by the suspension.(5) Tighten the upper and lower shock absorberounting bolt to a torque of 101 N·m (75 ft. lbs.).

TABILIZER BAR (REAR)

EMOVAL(1) Raise vehicle. Vehicle is to be raised and sup-

orted on jack stands or on a frame contact typeoist. See Hoisting in the Lubrication and Mainte-ance section of this service manual.(2) Remove the 2 lower bolts which hold the stabi-

izer bar to the link arm on each side of the vehicle.(3) Loosen but do not fully remove the four bolts

hat attach the stabilizer bar bushing retainers tohe rear axle brackets.

(4) While holding the stabilizer bar in place. Fullyemove the 4 bolts loosened in step 3.(5) Remove the stabilizer bar from the vehicle.(6) If the link arms need to be serviced, remove

he upper link arm to bracket bolt. Then remove linkrm from frame rail attaching bracket.

NSPECTIONInspect for broken or distorted clamps, retainers,

nd bushings. If bushing replacement is required, thetabilizer bar to axle bushings can be removed fromhe stabilizer bar by opening the split.

NSTALLATION(1) Install the link arms onto the frame rail brack-

ts. DO NOT TIGHTEN.(2) Position the axle to stabilizer bar bushings on

he stabilizer bar with the slit in the bushings facingp.(3) Lift the stabilizer bar onto the rear axle and

nstall the retainers and the four mounting bolts. DOOT TIGHTEN.(4) Install the two lower link arm bolts on the sta-

ilizer bar. DO NOT TIGHTEN.(5) Lower the vehicle so that the full weight of the

ehicle is on all four tires. With the vehicle at itsurb height, tighten all attaching bolts to the torquesisted below.

• Stabilizer bar bushing to axle bracket bolts 61·m (45 ft. lbs.)• Link arm to frame rail bracket 61 N·m (45 ft.

bs.)• Stabilizer bar to link arm 61 N·m (45 ft. lbs.)• Frame rail bracket to frame rail 61 N·m (45 ft.

bs.)

TRACK BAR (REAR)

REMOVAL(1) Remove the nut and bolt mounting the track

bar to the rear axle (Fig. 23).

(2) Remove the nut and bolt attaching the trackbar to the track bar mount on the body of the vehicle.Remove the track bar from the track bar mount.

INSTALLATION(1) Install the track bar first into the body mount

for the track bar (Fig. 24). Install the track bar boltwith the head of the bolt facing toward the rear ofthe vehicle (Fig. 25). Do not tighten.

Fig. 23 Track Bar Mounting To Axle1 – LOWER TRACK BAR BOLT INSTALLATION

Fig. 24 Track Bar Installation1 – TRACK BAR REPLACEMENT

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(2) Install the track bar into its mounting bracketn the rear axle (Fig. 23). Install the track bar boltith the head of the bolt facing toward the rear of

he vehicle. Do not tighten.(3) Lower the vehicle to the ground until the fulleight of the vehicle is supported by the wheels.ighten both track bar attaching bolts to a torque of5 N·m (70 ft. lbs.).

RACK BAR MOUNT

EMOVE(1) Remove the track bar from the track barount.(2) Remove the three bolts attaching the track barount to the body (Fig. 26).

Fig. 25 Track Bar Bolt Installation1 – TRACK BAR BOLT

Fig. 26 Track Bar Mount1 – TRACK BAR MOUNT

INSTALLATION(1) For installation, reverse removal procedure.

Tighten bolts to 61 N·m (45 ft. lbs.).

JOUNCE BUMPERThere are two types of jounce bumpers available

depending on which suspension option the vehicle isequipped with.

REMOVAL-STANDARDThe jounce bumper is serviced as an assembly. The

jounce bumper mounts to the frame rail at a weldnut located on the frame rail (Fig. 27).

(1) Using the proper tool, remove the bolt attach-ing the jounce bumper to frame rail.

(2) Remove the jounce bumper from the frame rail.

INSTALLATION-STANDARD(1) For installation, reverse the removal procedure.

Tighten the jounce bumper mounting bolt to a torqueof 33 N·m (290 in. lbs.).

REMOVAL-HEAVY DUTYThe jounce bumpers are serviced as an assembly.

The jounce bumpers screw into a weld nut located inthe frame rail (Fig. 28).

(1) Using slip-joint pliers grasp the base of thejounce bumper. Turn the base counterclockwise (Fig.29).

(2) Remove the jounce bumper from the frame rail.

INSTALLATION-HEAVY DUTY(1) For installation, reverse the removal procedure.

Tighten the jounce bumper to a torque of 33 N·m(290 in. lbs.).

Fig. 27 Jounce Bumper-Standard1 – JOUNCE BUMPER

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UB AND BEARING (REAR)

RONT-WHEEL-DRIVE VEHICLES

EMOVAL(1) Raise vehicle on jackstands or centered on a

rame contact type hoist. See Hoisting in the Lubri-ation and Maintenance section of this service man-al for required lifting procedure.(2) Remove wheel and tire.(3) Remove brake drum from hub/bearing.(4) Remove rear wheel speed sensor from rear hub/

earing (Fig. 30). This will prevent damage to thepeed sensor during removal and installation of theub/bearing. The rear wheel speed sensor boltso the hub/bearing. It can not be removednless the speed sensor is removed first.

Fig. 28 Jounce Bumper-Heavy Duty1 – JOUNCE BUMPERS

Fig. 29 Bumper Replacement1 – BUMPER REPLACEMENT

CAUTION: When working in the area of the rearhub/bearing and when removing it from the rearaxle, care must be used so the teeth on the tonewheel are not damaged. Damage to the teeth on thetone wheel will result in false ABS cycling and cor-rosion of the tone wheel.

(5) Remove the 4 bolts (Fig. 31) attaching the hub/bearing to the rear axle.

Fig. 30 Rear Wheel Speed Sensor1 – BRAKE SUPPORT PLATE2 – REAR AXLE3 – TONE WHEEL4 – WHEEL SPEED SENSOR5 – MOUNTING BOLT

Fig. 31 Rear Hub/Bearing Mounting Bolts1 – REAR AXLE FLANGE2 – HUB/BEARING MOUNTING BOLTS (4)3 – HUB/BEARING ASSEMBLY4 – TONE WHEEL (WHEN ABS EQUIPPED)

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AUTION: Corrosion may occur between the hub/earing and the axle. If this occurs the hub/bearingill be difficult to remove from the axle. If the hub/earing will not come out of the axle by pulling on

t by hand, do not pound on the hub/bearing toemove it from the axle. Pounding on the hub/bear-ng to remove it from the axle will damage the hub/earing. This damage will result in noise or failuref the bearing.

(6) If hub/bearing cannot be removed from the axley hand, use Remover Special Tool 8214 (Fig. 32) andollowing procedure to press the hub/bearing out ofhe axle.

(a) Place Special Tool 8214-1 over tone wheeland against cast flange of hub/bearing (Fig. 32)

(b) Put a dab of grease in the bolt pilot hole onthe back of Special Tool 8214-1.

(c) Insert Special Tool 8214-2 into the hole in thebottom of the end casting on the axle (Fig. 32).Special Tool 8214-2 should be against and sup-ported by the axle plate (Fig. 32) when pressingthe wheel bearing out of the axle. If Special Tool8214-2 will not fit into the hole in the endcasting, file or grind the flashing from thehole until tool fits properly.

(d) Align bolt in Special Tool 8214-2 with pilothole in Special Tool 8214-1. Tighten bolt againstSpecial Tool 8214-1.

(e) Press hub/bearing out of axle by continuingto tighten bolt in Special Tool 8214-2 against Spe-cial Tool 8214-1.(7) Remove the hub/bearing from the rear axle and

rake support plate (Fig. 33).

Fig. 32 Special Tool 8214 Installed1 – BRAKE SUPPORT PLATE2 – SPECIAL TOOL 8214–13 – SPECIAL TOOL 8214–24 – AXLE PLATE

INSTALLATION(1) Install the 4 hub/bearing to axle mounting

bolts into the holes in the flange of the rear axle.(2) Install the rear brake support plate on the 4

mounting bolts installed in the flange of the rearaxle.

(3) Align the rear hub/bearing with the 4 mount-ing bolts and start mounting bolts into hub/bearing.Tighten the 4 bolts in a criss-cross pattern until thehub/bearing and brake support plate is fully andsquarely seated onto flange of rear axle.

(4) Tighten the 4 hub/bearing mounting bolts (Fig.31) to a torque of 129 N·m (95 ft. lbs.)

(5) Install the rear wheel speed sensor on the rearhub/bearing flange (Fig. 30). Install the speed sensorattaching bolt and tighten to a torque of 12 N·m (105in. lbs.).

(6) Install brake drum on hub/bearing.(7) Install wheel and tire.(8) Tighten the wheel stud nuts in the proper

sequence to a torque of 135 N·m (100 ft. lbs.).(9) Adjust the rear brakes as necessary, Refer to

Adjustments in the Brake section in this servicemanual.

ALL-WHEEL-DRIVE VEHICLES

REMOVAL(1) Set the parking brake. The parking brake is

set to keep the hub/bearing and axle shaft fromrotating when loosening the hub nut.

(2) Raise vehicle. Vehicle is to be raised and sup-ported on jackstands or on a frame contact typehoist. See Hoisting in the Lubrication And Mainte-nance section of this service manual.

(3) Remove the wheel/tire assembly.

Fig. 33 Removing Rear Hub/Bearing From Axle1 – BRAKE SUPPORT PLATE2 – HUB/BEARING ASSEMBLY

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(4) Remove the cotter pin and nut retainer (Fig.4) from the stub shaft of the outer C/V joint.

(5) Remove the spring washer (Fig. 35) from thetub shaft of the outer C/V joint.

(6) Remove the hub nut and washer (Fig. 36) fromhe stub shaft of the outer C/V joint.

(7) Remove the 6 bolts (Fig. 37) mounting theriveshaft inner joint to the output shaft of the rearrive line module.

Fig. 34 Cotter Pin And Nut Retainer1 – CALIPER2 – COTTER PIN3 – ROTOR4 – NUT RETAINER5 – OUTER C/V JOINT

Fig. 35 Spring Washer1 – HUB NUT2 – STUB SHAFT3 – ROTOR4 – SPRING WASHER

(8) Remove the rear wheel speed sensor (Fig. 38)from the rear hub/bearing.

(9) Release the parking brake.(10) Remove the disc brake caliper to adapter

guide pin bolts (Fig. 39).(11) Remove rear caliper from adapter using the

following procedure. First rotate rear of caliper upfrom the adapter. Then pull the front of the caliperand the outboard brake shoe anti-rattle clip out fromunder the front abutment on the adapter (Fig. 40).

Fig. 36 Hub Nut And Washer1 – CALIPER2 – HUB NUT3 – WASHER4 – ROTOR5 – ADAPTER

Fig. 37 Driveshaft Attachment To Driveline Module1 – DRIVESHAFT2 – BOLTS3 – DRIVE LINE MODULE4 – DRIVESHAFT INNER JOINT

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(12) Support caliper to prevent the weight of thealiper from damaging the flexible brake hose (Fig.1).(13) Remove the rotor from the hub/bearing.(14) Remove driveshaft from rear drive line mod-

le and hub/bearing. Driveshaft is removed by firstompressing the inner joint on the driveshaft andemoving it from the drive line module. Then, slidehe outer joint of the driveshaft out of the hub/bear-ng.

Fig. 38 Wheel Speed Sensor1 – MOUNTING BOLT2 – WHEEL SPEED SENSOR

Fig. 39 Caliper Guide Pin Bolts1 – STUD PIN BOLTS2 – DISC BRAKE CALIPER3 – DRIVESHAFT4 – AXLE5 – DISC BRAKE CALIPER ADAPTER

Fig. 40 Removing / Installing Caliper1 – LIFT THIS END OF CALIPER AWAY FROM ADAPTER FIRST2 – DISC BRAKE CALIPER3 – ADAPTER ABUTMENT4 – OUTBOARD BRAKE SHOE HOLD DOWN CLIP5 – OUTBOARD BRAKE SHOE6 – ROTOR7 – ADAPTER

Fig. 41 Correctly Supported Caliper1 – WIRE2 – CALIPER3 – ADAPTER4 – ROTOR5 – INNER FENDER

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(15) Remove the hub/bearing to axle mountingolts (Fig. 42).

AUTION: Corrosion may occur between the hub/earing and the axle. If this occurs the hub/bearingill be difficult to remove from the axle. If the hub/earing will not come out of the axle by pulling on

t by hand, do not pound on the hub/bearing toemove it from the axle. Pounding on the hub/bear-ng to remove it from the axle will damage the hub/earing. This damage will result in noise or failuref the hub/bearing. To remove a hub/bearing which

s corroded to the axle, lightly tap the disc brakealiper adapter using a soft faced hammer. This willemove both the disc brake caliper adapter andub/bearing from the axle. The hub/bearing will

hen need to be removed from the caliper adapter.

(16) Remove the hub/bearing from the axle. (Fig.3).(17) If the disc brake caliper adapter and hub/

earing were removed as an assembly from the axlend the hub/bearing cannot be removed from thedapter by hand, use the following procedure toemove it from the adapter. With a helper supportinghe caliper adapter in his hands, position Remover,pecial Tool 8214-1 on the cast housing of hub/bear-

ng (Fig. 44). Do not position special tool onnner race of hub/bearing. Lightly strike Remover,pecial Tool 8214-1 with a hammer to remove theub/bearing from the caliper adapter.

NSTALLATION(1) Install hub/bearing on end of axle. (Fig. 43).

Fig. 42 Hub/Bearing Mounting Bolts1 – HUB/BEARING2 – AXLE3 – MOUNTING BOLTS4 – CALIPER ADAPTER

(2) Install the hub/bearing mounting bolts. In aprogressive criss-cross pattern, tighten the 4 hub/bearing mounting bolts (Fig. 42) until the disc brakecaliper adapter and hub/bearing are squarely seatedagainst the axle. Then tighten the hub/bearingmounting bolts to a torque of 129 N·m (95 ft. lbs.).

(3) Install driveshaft in hub/bearing and on outputshaft of rear drive line module. Driveshaft isinstalled by first sliding the outer joint of the drive-shaft into the hub/bearing and then compressing theinner joint on the driveshaft and installing it on theoutput shaft the drive line module.

(4) Install rotor on hub/bearing.

Fig. 43 Hub/Bearing Removal And Installation1 – PARK BRAKE BRAKE SHOE2 – HUB/BEARING3 – PARK BRAKE BRAKE SHOE

Fig. 44 Hub/Bearing Removal From Caliper Adapter1 – SPECIAL TOOL 8214-12 – PARK BRAKE CABLE3 – DISC BRAKE CALIPER ADAPTER4 – HUB/BEARING

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(5) Carefully lower disc brake caliper and brakehoes over rotor and onto caliper adapter by revers-ng the removal procedure (Fig. 40).

AUTION: When installing guide pin bolts extremeaution should be taken not to cross-thread the cal-per guide pin bolts.

(6) Install the disc brake caliper guide pin boltsFig. 39). Tighten the guide pin bolts to a torque of2 N·m (192 in. lbs.).(7) Clean all foreign material off the threads of the

uter C/V joint stub shaft. Install the washer andub nut (Fig. 36) on the stub shaft of the outer C/V

oint.(8) Lower vehicle.(9) Set the park brake. This is required to keep

he driveshaft from rotating when tighteningnd torquing the hub nut and driveshaft inneroint to driveline module mounting nuts.

(10) Raise vehicle.(11) Tighten the driveshaft inner joint to drive lineodule output shaft mounting bolts (Fig. 37) to a

orque of 61 N·m (45 ft. lbs.).(12) Tighten the outer C/V joint hub nut (Fig. 36)

o a torque of 244 N·m (180 ft. lbs.).(13) Install the spring washer (Fig. 35) on the stub

haft of the outer C/V joint.(14) Install the nut retainer and cotter pin (Fig.

4) on the stub shaft of the outer C/V joint.(15) Install the wheel speed sensor on the hub/

earing and adapter. Install the wheel speed sensorttaching bolt (Fig. 38). Tighten the wheel speed sen-or attaching bolt to a torque of 12 N·m (105 in. lbs).(16) Install wheel and tire.(17) Tighten the wheel mounting stud nuts in

roper sequence until all nuts are torqued to halfpecification. Then repeat the tightening sequence tohe full specified torque of 135 N·m (100 ft. lbs.).

(18) Remove jackstands or lower hoist.

AUTION: Before moving vehicle, pump the brakeedal several times to insure the vehicle has a firmrake pedal to adequately stop vehicle.

(19) Road test vehicle to ensure proper operationf the brake system.

WHEEL MOUNTING STUDS (REAR)

REMOVAL

CAUTION: If a wheel attaching stud needs to bereplaced in the hub and bearing assembly the studscannot be hammered out of the hub flange. If a studis removed by hammering it out of the bearingflange, damage to the hub and bearing assemblywill occur leading to premature hub and bearingfailure.

(1) Raise vehicle on jackstands or centered on aframe contact type hoist. See Hoisting in the Lubri-cation and Maintenance section of this manual forthe required lifting procedure to for this vehicle.

(2) Remove the rear wheel and tire assembly.(3) Remove the rear brake drum.(4) Install a lug nut on the wheel stud to be

removed from the hub and bearing assembly (Fig. 45)so the threads on stud are even with end of lug nut.Install Remover, Special Tool C-4150A on hub andbearing assembly flange and wheel stud (Fig. 45).

(5) Tightening down on special tool will pushwheel stud out of the hub and bearing assemblyflange. Remove lug nut from stud and remove wheelstud from flange.

Fig. 45 Removing Wheel Stud From Hub AndBearing

1 – HUB/BEARING ASSEMBLY2 – LUG NUT3 – WHEEL STUD4 – SPECIAL TOOL C-4150–A

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NSTALLATION(1) Install replacement wheel stud into flange of

ub and bearing assembly. Install washers on wheeltud, then install a wheel lug nut on stud with flatide of lug nut against washers (Fig. 46).

(2) Tighten the wheel lug nut, pulling the wheeltud into the flange of the hub and bearing assembly.hen the head of the stud is fully seated against the

earing flange, remove lug nut and washers fromheel stud.(3) Install the rear brake drum on the hub and

earing assembly.(4) Install wheel and tire assembly on vehicle.

ighten the wheel mounting stud nuts in properequence until all nuts are torqued to half specifica-ion. Then repeat the tightening sequence to the fullpecified torque of 135 N·m (100 ft. lbs.).(5) Lower vehicle to the ground.

ISASSEMBLY AND ASSEMBLY

HOCK ABSORBER UPPER BUSHING (REAR)

OTE: This procedure is to be used only on thepper bushing of load-leveling shock absorbers.he shock absorber lower bushing on load-levelinghock absorbers is not serviceable.

ISASSEMBLY(1) Remove the shock absorber from the vehicle.efer to REMOVAL AND INSTALLATION in thisection for the procedure.

Fig. 46 Installing Wheel Stud Into Hub And Bearing1 – LUG NUT2 – HUB/BEARING ASSEMBLY3 – WASHERS4 – WHEEL STUD

(2) Install the Receiver, Special Tool 8526-1, intothe cup of the Ball Joint Press, Special Tool C-4212F,and tighten the set screw. Install the Driver, SpecialTool 8526-2, on the tip of the Ball Joint Press screwdrive as shown (Fig. 47).

NOTE: It works well to place the Ball Joint Press,Special Tool C-4212F, in a bench vise as shown(Fig. 47) to perform this procedure.

(3) Place the shock absorber upper mounting eyein the Receiver so the notch in the Receiver clearsthe shock absorber body (Fig. 48).

Fig. 47 Special Tools Positioned For Removal1 – SCREW DRIVE

Fig. 48 Removing Bushing From Shock Absorber1 – SCREW DRIVE2 – SHOCK ABSORBER3 – NOTCH

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(4) Tighten the screw drive until the Driver con-acts the outer circumference of the bushing evenlyFig. 48). Continue to tighten the screw drive untilhe bushing is pressed completely out of the shockbsorber eye and into the Receiver.(5) Back off the screw drive and remove the bush-

ng from the Receiver.

SSEMBLY(1) Install the Receiver, Special Tool 8526-1, into

he cup of the Ball Joint Press, Special Tool C-4212F,nd tighten the set screw. Install the Driver, Specialool 8526-2, on the tip of the Ball Joint Press screwrive as shown (Fig. 49). Position the Driver this wayo seat the bushing to its correct depth.

(2) Place the shock absorber upper mounting eyen the Receiver so the notch in the Receiver clearshe shock absorber body (Fig. 50).

(3) Position the bushing between the shockbsorber eye and the Driver (Fig. 50). Tighten thecrew drive until the Driver, bushing, and shockbsorber eye are touching and squarely aligned.(4) Press the bushing into the shock absorber eye

ntil the Driver bottoms against the face of the eye.(5) Back off the Ball Joint Press screw drive and

emove the shock absorber from the press.(6) Install the shock absorber on the vehicle. Refer

o REMOVAL AND INSTALLATION in this sectionor the procedure.

Fig. 49 Special Tools Positioned For Installation1 – SCREW DRIVE

SPECIFICATIONS

REAR SUSPENSION FASTENER TORQUES

DESCRIPTION TORQUEShock Absorber:Mounting Bolts (All) . . . . . . . . 101 N·m (75 ft. lbs.)Leaf Spring:Spring Plate To Axle Attaching

Bolts . . . . . . . . . . . . . . . . . . 101 N·m (75 ft. lbs.)Rear Mount To Body Bolts . . . . 61 N·m (45 ft. lbs.)Front Mount To Body Bolts . . . . 61 N·m (45 ft. lbs.)To Front Hanger Mounting

Nut . . . . . . . . . . . . . . . . . . 156 N·m (115 ft. lbs.)Shackle Plate Nuts . . . . . . . . . . 61 N·m (45 ft. lbs.)Jounce Bumper:Mounting Bolt . . . . . . . . . . . . 33 N·m (290 in. lbs.)Track Bar:Axle And Mounting Bracket Pivot

Bolt . . . . . . . . . . . . . . . . . . . . 95 N·m (70 ft. lbs.)Bracket To Body Attaching . . . . 61 N·m (45 ft. lbs.)Stabilizer Bar:Bushing Retainer To Axle Attaching

Bolts . . . . . . . . . . . . . . . . . . . 61 N·m (45 ft. lbs.)Attaching Link Nuts . . . . . . . . . 61 N·m (45 ft. lbs.)Frame Rail Bracket Mounting

Bolts . . . . . . . . . . . . . . . . . . . 61 N·m (45 ft. lbs.)Link Arm To Frame Rail

Bracket . . . . . . . . . . . . . . . . . 61 N·m (45 ft. lbs.)Hub And Bearing:To Axle Mounting Bolts . . . . . . 129 N·m (95 ft. lbs.)Stub Axle Nut . . . . . . . . . . . . 224 N·m (180 ft. lbs.)Wheel Mounting Lug Nut . . . 135 N·m (100 ft. lbs.)

Fig. 50 Installing Bushing In Shock Absorber1 – BUSHING2 – SCREW DRIVE3 – SHOCK ABSORBER4 – NOTCH

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