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SUSPENSION

CONTENTS

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ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1FRONT SUSPENSION 2WD . . . . . . . . . . . . . . . . 6

FRONT SUSPENSION 4WD . . . . . . . . . . . . . . . 15REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . 22

ALIGNMENT

INDEX

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GENERAL INFORMATIONWHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . 1

SERVICE PROCEDURESPRE-ALIGNMENT INSPECTION . . . . . . . . . . . . . . 1

SUSPENSION HEIGHT (4WD) . . . . . . . . . . . . . . . 4WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . 4

SPECIFICATIONSFRONT WHEEL ALIGNMENT SPECIFICATIONS . . 5

GENERAL INFORMATION

WHEEL ALIGNMENTWheel alignment involves the correct positioning of

the wheels in relation to the vehicle. The positioning

i s a c com p li s h ed t h r o ug h s u s pe n si on a n d s t e er i n g

l in k a g e a d ju s t men t s . An a l i gn m en t i s con s id er edessential for efficient steering, good directional stabil-

i t y a n d t o m i n i m iz e t i r e w e a r . Th e m o s t i m por t a n t

m ea s u r em en t s of a n a l i gn m en t a r e ca s t e r, ca m b er

and toe (Fig. 1).

NOTE: Routine inspection of the front suspension

and steering components is a good preventativemaintenance practice. Inspection also helps toensure safe operation of the vehicle.

C AS TE R i s t h e f or w a r d or r ea r w a r d t i lt of t h e

steering knuckle from vertical . Tilt ing t he t op of the

knuckle forward provides negative caster. Tilt ing t hetop of the knuckle rearward provides positive caster.

P o s it i v e ca s t e r p r om ot e s d i r ect i on a l s t a bi l it y. Th i s

a n g l e e n a bl es t h e f r on t w h e e ls t o r e t u r n t o a s t r a i g h t

a h e a d p o s i t i o n a f t e r t u r n s .

C AM B E R i s t h e i nw a r d or ou t w a r d t i lt of t h e

wheel relat ive to t he center of th e vehicle. Tilt ing t he

t o p o f t h e w h e el i n w a r d p r ov i de s n e g a t i v e c a m be r.

Tilting t he t op of t he w heel outw ar d provides positive

ca m b er. I n cor r ect ca m b er w i l l ca u s e w e a r on t h e

inside or outside edge of the t ire.

TOE is th e difference between t he leading inside

ed g es a n d t r a i li n g i n si d e e d ge s of t h e f r on t t i r es .

Uneven wheel toe position causes unstable steering,

uneven tire wear and steering wheel off- center. The

wheel toe position is the final front wheel al ignmentadjustment.

S TE E R I N G AX I S I N C L I N ATI O N AN G L E i smeasured in degrees. It is the angle that the steering

knuckles are t i l ted. The inclination angle has a fixed

r ela t ion sh ip w it h t h e ca m ber a n gle. I t w il l n ot

ch a n g e e xce pt w h e n a s pi n dl e or b a l l s t u d i s d a m -

a g e d o r b en t . Th e a n g le i s n ot a d ju s t a b le a n d t h e

dama ged component(s) must be replaced to correct

mis- al ignment.

CAUTION: Do not attempt to modify any suspen-

sion or steering component by heating and bend-ing.

SERVICE PROCEDURES

PRE-ALIGNMENT INSPECTIONB e f or e s t a r t i n g w h e el a l i gn m en t , t h e f ol low i n g

inspection an d necessary corrections must be com-

p le t ed . R ef er t o S u s pen s ion a n d S t e er i ng S y s t em

Di a g n o si s C h a r t f or a d d i t i on a l i n for m a t i o n .

(1) Tires wit h th e same recommended a ir pressure,

s i ze , a n d t r e a d w e a r . R e f er t o G r ou p 2 2, Wh e el s a n d

Tires for diagnosis information.

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(2) Inspect front wheel bearings for wear or adjust-

ment.

(3) I n s pe ct f r on t w h e e ls f or e xce ss i ve r a d i a l , l a t -

er a l r un ou t a n d u nb a la n ce. R efer t o G r ou p 22,

Wheels and Tires for diagnosis information.

(4) I n s pe ct b a l l s t u ds , l in k a g e p iv ot p oi n t s a n d

steering gear for looseness, roughness, binding or as t i ck i n g con d i t i on . R e fe r t o Gr o u p 19, St e e r in g f or

additional information.

(5) I n s p ect s u s pe n si on com p on e n t s f or w e a r a n d

noise. Check components for correct torque.

Fig. 1 Wheel Alignment Measurements

2 - 2 SUSPENSI ON AN

SERVICE PROCEDURES (Continued)

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SUSPENSION AND STEERING SYSTEM DIAGNOSIS



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SUSPENSION HEIGHT (4WD)Th e f r on t s u s pe n si on of a n e w v eh i cl e w i ll s et t l e

sligh tly dur ing th e first 2,000 miles/3,200 km of oper-

at ion. To compensat e for this, the front suspension

height is sl ightly higher t ha n the service specification

height. A vehicle with less tha n 2,000 miles/3,200

k m , SH O U L D NO T be a d ju s t e d d o w n w a r d . T h e t o r -s i o n b a r s h a v e n o t s e t a n d c a n b e n o m o r e t h a n 0 . 5

inch (12.7 mm) higher than specifications.

(1 ) C l e a n t h e s u r f a c e a r e a s w h e r e t h e s u s p e n s i o n

arm height wil l be measured (Fig. 2).

(2) Measure the suspension ar m height according

to the following instructions:

I n n er m e a s u r em e n t f r om t h e f loor s u r fa c e t o

t h e u n d er s i d e of t h e p iv ot bor e s be t w e en t h e w e bs

(Fig. 2).

O ut e r m e a s u r em e n t f r om t h e f l oor s u r fa c e t o

the underside of the rear edge inboard of the steering

stop (Fig. 2).

(3) Th e h ei gh t of e a ch f r on t s u sp en s ion a r m i s

a d ju s t e d by t u r n i n g t h e t o r s i o n ba r a d ju s t m e n t bo l t

(Fig. 3).

CLOCKWISE to raise the vehicle.

COUNTERCLOCKWISE to lower the vehicle.

(4) Af t er e a ch a d ju s t me nt , jou n ce t h e v eh i cl e

b ef or e m ea s u r in g t o d et e rm in e t h e e ff ect s of t h e

adjustment.

NOTE: The suspension arm heights at both sidesof the vehicle must be measured even if only oneside was adjusted.

(5) The difference in height between the inner and

ou t e r m e a s u r em e n t s h ou l d be 38.00 m m (1.50 i n .)

plus or minus 6.4 mm (1/4 in.). The side-to-side

h e ig h t d i ff er e n ce s h ou l d n ot be m o r e t h a n 6.4 m m

(0.25 in.).

WHEEL ALIGNMENT

CAMBER AND CASTER ADJUSTMENT

C a m ber a n d ca s t er a n g le a d ju st m en t s i nv ol ve

ch a n g i n g t h e p os i t ion of t h e u p pe r s u s pe n si on a r mpivot bar (Fig. 4).

CASTER: Move only the rear position of the pivot

ba r i n o r o u t . T h i s w i l l c h a n g e t h e c a s t e r a n g l e s i g -

n i f ica n t l y a n d ca m be r a n g l e on l y s l ig h t l y. To r e t a i n

t h e ca m b er w h i le a d ju s t in g ca s t e r, m ov e t h e r ea r

p iv ot b a r i n or ou t . M ov e t h e f or w a r d p iv ot v er y

slightly in the opposite direction.

Fig. 2 Height Measurement (4WD)

Fig. 3 Suspension Arm Height Adjustment

Fig. 4 Caster & Camber Adjustment Location



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NOTE: For example, to increase a positive casterangle, move the rear position of the pivot barinward (toward the engine). Move the front of pivotbar outward (away from the engine) slightly untilthe original camber angle is obtained.

C AM B E R : M ov e o n ly t h e f or w a r d p os i t ion of t h e

p iv ot b a r i n or ou t . Th i s w i ll ch a n g e t h e ca m b er

angle significantly and caster angle only sl ightly. The

camber angle should be adjusted as close as possible

t o t h e service specification.Af t er a d ju s t men t i s m a d e t i gh t en t h e p iv ot b a r

nuts to 210 Nm (155 ft . lbs.) torque.

TOE ADJUSTMENT

Th e w h e e l t oe p os i t ion a d ju st m e n t s h ou l d be t h e

f i n a l a d ju st m e n t .

(1) S t a r t t h e en g in e a n d t u rn w h eel s b ot h w a y s

bef or e s t r a i g h t e n in g t h e w h e e ls . Se cu r e t h e s t e er i n g

w h e el w i t h t h e f r on t w h e el s i n t h e s t r a i gh t -a h e a dposition.

(2) L oos en t h e t i e r od a d ju s t men t s le ev e cl a m p

bolt s/nu t s.

NOTE: Each front wheel should be adjusted forone-half of the total toe position specification. This

will ensure the steering wheel will be centeredwhen the wheels are positioned straight-ahead.

(3) Adjust the w heel t oe position by turning the t ie

rod a djustment sleeves a s n ecessar y (Fig. 5) and (Fig.

6).

(4) Tighten the t ie rod adjustment;

2WD locknuts: 75 Nm (55 ft. lbs.)

4WD clamp bolts: 23 Nm (17 ft . lbs.)

NOTE: Position the clamp nut/bolt so that it does

not extend above the top of the sleeve.

SPECIFICATIONS

FRONT WHEEL ALIGNMENT SPECIFICATIONS

Fig. 5 Toe Adjustment (2WD)

Fig. 6 Toe Adjustment (4WD)



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FRONT SUSPENSION2WD

INDEX

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DESCRIPTION AND OPERATION

2WDSUSPENSION COMPONENTS . . . . . . . . . 6DIAGNOSIS AND TESTING

LOWER BALL STUD . . . . . . . . . . . . . . . . . . . . . . 6SHOCK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 7

UPPER BALL STUD . . . . . . . . . . . . . . . . . . . . . . . 7REMOVAL AND INSTALLATION

COIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8LOWER SUSPENSION ARM . . . . . . . . . . . . . . . . 9SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . 7

STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . 10STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . . 8

UPPER SUSPENSION ARM . . . . . . . . . . . . . . . . . 9

WHEEL BEARINGS (2WD) . . . . . . . . . . . . . . . . . 10WHEEL STUDS . . . . . . . . . . . . . . . . . . . . . . . . . 11

DISASSEMBLY AND ASSEMBLYLOWER BALL STUD . . . . . . . . . . . . . . . . . . . . . . 11

UPPER BALL STUD . . . . . . . . . . . . . . . . . . . . . . 12CLEANING AND INSPECTION

WHEEL BEARING . . . . . . . . . . . . . . . . . . . . . . . 13SPECIFICATIONS

TORQUE CHART2WD . . . . . . . . . . . . . . . . . . . 13

SPECIAL TOOLSFRONT SUSPENSION 2WD . . . . . . . . . . . . . . . . 14


2WD SUSPENSION COMPONENTSTh e f r on t s u sp en s ion i s d es ig n ed t o a l l ow e a ch

w h e el t o a d a p t t o d if fe re nt r oa d s u rf a ce s i n de pe n-

dently. The wheels are mounted to hubs that r ide on

t a p er e d bea r i n g s on t h e s t e er i n g k n u ck l e s p i n dl e.

The bearings can be removed for service, adjustment,

repacking, replacement, etc. The steering knuckles

turn (pivot) on ball studs mounted on the upper and

lower suspension arms.

The 2WD front suspension is comprised of (Fig. 1): Dual-action shock absorbers

Coil springs

Steering knuckles

Suspension arms

St a bi l i z e r ba r

J ounce bumpers

Shock Absorbers: Ride control is accomplishedthrough the use of dual-action shock absorbers. The

shocks da mpen the jounce and rebound as the vehicle

tra vels over va rious road conditions. The t op of the

shock absorbers are bolted to the frame. The bottom

of the shocks are bolted to the lower suspension arm.

Coil Springs: The coil springs control ride qualitya n d m a in t a in pr oper r id e h eig ht . Th e s pr in gs

m ou n t ed u p i n a w e ll (p ock et ) i n a b r a ck et t h a t i s

p a r t o f t h e f r a m e r a i l . T h e r e i s a r u bbe r (d o u g h n u t )

i s ol a t o r be t w e en t h e t o p of t h e s p r i n g a n d br a c ke t .

T h e bo t t o m o f t h e s p r i n g s e a t s i n t h e l o w e r s u s p e n -

s i o n a r m .

Suspension Arms: Th e u p pe r s u s pe n si on a r m su s e a cr os s s h a f t b ol t ed t o t h e f r a m e r a i l b r a ck et s .

Th e cr os s s h a f t i sol a t es r oa d n oi se b y t h e u s e o f

r e pl a ce a bl e bu s h i n g s i n t h e s u s pe n si on a r m s . Th e

u pp er s u sp en s ion a r m cr os s s h a f t a l s o a l low s f or

caster and camber adjustment. The lower suspension

a r m s u s e r e p l a c e a bl e p r e s s e d i n bu s h i n g s t o i s o l a t e

r oa d n oi s e. Th e s u s pe n si on a r m s a r e bol t ed t o t h e

f r a m e a n d p iv ot t h r o ug h r u bbe r bu s h in g s . Th e s u s -

p en s i on a r m t r a v e l (jou n ce or r e bou n d ) i s l i mi t e d

through the use of rubber bumpers.

Stabilizer Bar: The stabil izer bar is used to min-imize vehicle front sway during turns. The bar helps

t o m a i n t a i n a f la t a t t i t u d e t o t h e r oa d s u rf a ce . Th e

bar extends across the front underside of the chassis

a n d con n e ct s t o t h e f r a m e r a i l s. Th e l i n k s a r e c on -

nected to the lower suspension brackets. All mount-ing points of the stabil izer bar are isolated by rubber

bushings.

NOTE: All suspension components that use rubberbushings should be tightened with the vehicle atnormal height. If springs are not at their normal ride

position, vehicle ride comfort could be affectedalong with premature rubber bushing wear. Rubberbushings must never be lubricated.

DIAGNOSIS AND TESTING

LOWER BALL STUD(1) R a i s e t h e f r on t of t h e v eh i cl e. I n s t a l l s a f et y

floor stands under both lower suspension arms as far

ou t boa r d a s p os s ibl e. Th e u p pe r s u s pe n si on a r m s

must not contact the rebound bumpers.

(2) I n s t a l l a d i a l i n d i ca t or a n d c l a m p a s s e m bl y t o

the lower suspension arm.

(3) Position indicator plunger against knuckle arm

and zero indicator.


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(4) R a i s e a n d l ow e r t h e w h e el a n d t i r e w i t h a p ry

b a r u n d e r t h e c e n t e r o f t h e t i r e . M e a s u r e t h e a x i a l

movement of the knuckle with respect to the suspen-

s i o n a r m .

(5) If the travel of the suspension arm is 0.51 mm

(0.020 inch) or more, replace the ball joint.

UPPER BALL STUD

(1) P os i t ion a f loor ja c k u n d er t h e l ow e r s u s pe n -s i o n a r m . R a i s e t h e w h e e l a n d t i r e s o i t l i g h t l y c o n -

ta cts the floor (vehicle w eight relieved from the t ire).

(2) G r a s p t h e t o p of t h e t i r e a n d a p p ly f o r ce i n a n d

ou t . L ook f or a n y m ov em en t at the ball jointsb et w e en t h e u pp er s u sp en s ion a r m a n d s t eer i ng

knuckle.

(3) If any lateral movement is evident, replace the

ball joint.

SHOCK DIAGNOSISA n oi s e f r om a s h ock a bs or ber m a y be c a u s ed by

m ov em en t b et w e en m ou n t in g b u sh i ng s a n d m et a l

br a c ke t s or a t t a c h i n g com p on e n t s . Th i s n oi s e c a nu s u a l l y be s t o p p e d by t i g h t e n i n g t h e a t t a c h i n g n u t s .

I f t h e n o i s e p e r s i s t s , i n s p e c t f o r d a m a g e d a n d w o r n

bu s h i n g s , a n d a t t a c h i n g c o m p o n e n t s . R e p a i r a s n e c -

essary i f any of these conditions exist .

Th e s h ock a bs or ber s a r e n ot r e fi ll a bl e o r a d ju st -

a b l e. I f a m a l fu n ct i on occu r s, t h e s h ock a b s or b er

must be replaced. To test a shock a bsorber, hold it in

an upright position and force the piston in and out of

the cylinder four or five times. The action throughout

each stroke should be smooth and even.

Th e s h ock a bs or ber bu sh i n g s d o n o t r e q u ir e a n y

t y p e o f l u br ica t i o n . Do n ot a t t e m pt t o s t o p bu s h i n g

n oi se b y l ub r ica t i n g t h e m. G r e a s e a n d m i ne ra l oi l-

base lubricants wil l deteriorate the bushing rubber.

REMOVAL AND INSTALLATION

SHOCK ABSORBER

REMOVAL

(1) Remove the hardware from the shock absorber

stud (Fig. 2).

(2) R a i s e t h e v eh i cl e, r e mov e t h e l ow e r bol t s a n d

remove the shock absorber.

INSTALLATION

(1 ) I n s t a l l t h e l o w e r r e t a i n e r a n d g r o m m e t o n t h e

s h ock a bs or ber s t u d . I n s e rt t h e r e pl a c em e n t s h ock

a b s or b er t h r ou g h t h e f r a m e h ol e. I n s t a l l t h e l ow e r

bolts.

(2) Tighten the bolts to 23 Nm (17 ft. lbs./200 in.

lbs.).

Fig. 1 Front Suspension2WD

Fig. 2 Front Shock Absorber2WD


DIAGNOSIS AND TESTING (Continued)

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(3 ) I n s t a l l t h e u p p e r g r o m m e t a n d r e t a i n e r o n t h e

s hock a b sor ber s t ud . I n st a l l t h e b a y on et n u t a n d

tighten to 41 Nm (30 ft . lbs.).

COIL SPRING

REMOVAL

(1) Raise and support the vehicle.

(2) Remove the applicable front wheel.

(3) Di s con n e ct t h e s t a bi l iz er ba r f r om t h e l ow e r

suspension arm.

(4) Remove the shock absorber.

(5) Install Spring Compressor DD-1278 up through

the lower suspension arm and coil spring.

(6) Ti gh t e n t h e t ool n u t t o com pr es s t h e coi l

s p r i n g . T h i s w i l l r e t a i n t h e s p r i n g i n p l a c e u n t i l t h e

lower suspension arm is detached from and lowered

for spring removal .

(7 ) P l a c e t w o ja c k s t a n d s u n d e r t h e l o w e r s u s p e n -

s i o n a r m i m m e d i a t e l y o u t w a r d f r o m w h e r e t h e bu s h -i n g s a r e l o c a t e d . A d ju s t t h e ja c k s t a n d s a g a i n s t t h e

lower suspension arm.

(8) R e m ov e t h e l ow e r s u s pe n si on a r m m ou n t i n g

bo l t s f r o m t h e f r a m e r a i l .

(9 ) L o w e r t h e ja c k s t a n d s a n d r e m o v e t h e s p r i n g

compressor tool, coil spring and isolator pad from the

vehicle.

INSTALLATION

NOTE: The top of the spring is flat or closed with

groves at the end of the coil. The ramped or open

end of the coil spring is the bottom.

(1) Ta p e t h e i sol a t or p a d t o t h e t op of t h e coi l

s pr i n g . P os i t ion t h e s pr i n g i n t h e l ow e r s u s pe n si on

a r m w e l l. B e s u r e t h a t t h e c oi l s pr i n g i s s e a t e d i n t h e

well.

(2) Install Spring Compressor DD-1278 up through

the lower suspension arm and coil spring.

(3) Ti gh t e n t h e t ool n u t t o com pr es s t h e coi l

spring.

(4 ) P l a c e t w o ja c k s t a n d s u n d e r t h e l o w e r s u s p e n -

s i o n a r m i m m e d i a t e l y o u t w a r d f r o m w h e r e t h e bu s h -

ings are located.

(5) Raise the jack sta nds unti l the isolat or pad/coilspring is correctly seated top and bottom.

(6) I ns t a l l t h e l ow e r s u sp en s ion a r m b ol t s a n d

nuts. Tighten t he front nut to 176 Nm (130 ft . lbs.)

a n d t h e r e a r n u t t o 1 08 N m (80 f t . l bs.).

(7) R em ov e t h e s pr i n g com p r es s or t o ol a n d t h e

ja c k s t a n d s .

(8) I n s t a l l t h e s t a bi l iz er ba r .

(9) Instal l the shock absorber.

(10) I n s t a l l t h e w h e el a n d t i r e a s s em bly.

STEERING KNUCKLE

REMOVAL

(1) R a i se a n d s u pp or t t h e v eh i cl e. P l a c e a ja c k

under outer end of lower suspension arm.

(2) Remove the wheel and t ire assembly.

(3) R e m ov e d i s c br a k e ca l i p er, r e fe r t o Gr o u p 5B r a k e s .

(4) R em ov e t i e -r od f r om s t e er i n g k n u ck le a r m ,

refer to Group 19 Steering.

(5) R e m ov e A B S s en s or w i r e f r om l ow e r s u s pe n -

s ion a r m . R em ov e t h e r ot or d u st s h ie ld a n d AB S

pick-up from knuckle (Fig. 3).

(6) R e m ov e c ot t e r p in s a n d n u t s f r om u p pe r a n d

l ow e r ba l l s t u d s .

(7) Use Ball Stud Remover C-3564A to free upperand lower ball joints from steering knuckle.

(8) Remove t ool an d steering knuckle a ssembly.

(9) R em ov e s t e er i n g a r m f r om s t e er i n g k n u ck l e

(Fig. 4).

INSTALLATION

(1) I n s t a l l s t e er i n g a r m on k n u ck l e. Ti g h t en t h e

nuts to 294 Nm (217 ft. lbs.).

(2) P osition steering knuckle on upper an d lower

ba l l s t u d s a n d i n s t a l l n u t s . Ti g h t en l ow e r n u t t o 1 83

Fig. 3 Remove ABS Sensor From Knuckle


REMOVAL AND INSTALLATION (Continued)

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Nm (135 ft. lbs.). Tighten upper nut to 142 Nm (105

f t . l bs .) a n d i n s t a l l n e w cot t e r p in s .

(3) I n s t a l l r ot or d u st s h ie ld a n d AB S s en s or onsteering knuckle. Tighten bolts to 24 Nm (18 ft. lbs.).

(4) Instal l t ie rod to steering knuckle arm, refer to

Group 19 Steering.

(5) Ins t a l l ABS s e ns or wi re t o l owe r s us pe ns i on a rm .

(6) I n s t a l l t h e d i sc br a k e ca l i p er, r e fe r t o G r ou p 5

B r a k e s .

(7) I n s t a l l t h e w h e el a n d t i r e a s s em bl y.

LOWER SUSPENSION ARM

REMOVAL

(1) Raise and support vehicle.

(2) R em ov e d is c b ra k e ca l ip er f rom s t eer in gknuckle and rotor. Refer to Group 5, Brakes.

(3) Remove shock absorber.

(4) Fo l low t h e p r oce d ur e ou t l i n ed i n C o il Sp r i n g

Removal.

(5) Position Ball Stud Remover C-3564A as shown

(Fig. 5). Rotate threaded portion of tool to apply force

t o t h e l o w e r ba l l s t u d .

(6) Strike steering knuckle sharply with a hammer

to loosen ball stud from knuckle. Do not force ballstud out from knuckle with the tool.

(7) Se pa r a t e ba l l s t u d f r om s t e er i n g k n u ck l e a r m .

INSTALLATION

(1) L o os el y a t t a c h s u s pe n si on a r m t o f r a m e s i d e

rail brackets.

(2) F ol low t h e p r oce d ur e ou t l i n ed i n C o il Sp r i n g

I n s t a l l a t i o n .

(3) Position steering knuckle on ball studs. Instal l

b a l l s t u d r et a i n i ng n u t s. Ti gh t en l ow e r n u t t o 183


f t . l bs.) a n d i n s t a l l n e w cot t e r p in s .

(4) Insta l l the rotor a nd disc brake caliper. Refer to

Gr o u p 5 , B r a k e s .

(5) L ow e r t h e v eh i cl e. Ti g h t en s u s pe n si on a r m

f r on t n u t t o 1 76 N m (130 f t . l bs .) a n d r ea r n u t t o

108 Nm (80 ft. lbs.).

UPPER SUSPENSION ARM

REMOVAL


(2) Remove wheel and t ire assembly.

(3) Re m ove d i s c b ra ke ca l i per, re fe r t o G roup 5 Br a ke s .


(5) I n st a l l S p r in g C om pr es sor D D -1278. U s e a

piece of pipe to fabricate a spacer positioned betw een

t h e t o o l a n d s u s p e n s i o n a r m .

(6) Ti g h t en t o ol n u t a g a i n s t bel l-s h a p ed a d a p t er

tool fing er-tig ht a nd loosen 1/2 of-a -tu rn .

(7) R em ov e cot t e r p in a n d n u t f r om u pp er b a l ls t u d .



t o t h e l o w e r ba l l s t u d .

Fig. 4 Steering Knuckle

Fig. 5 Separate Ball Stud

Fig. 6 Separate Upper Ball Stud



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(10) S epa r a t e u pper b a ll s tu d fr om s teer in g

knuckle.

(11) R e m ov e s u s pe n si on a r m p iv ot ba r n u t s a n d

remove suspension arm (Fig. 7).

INSTALLATION

(1) P os i t ion s u s pe n si on a r m p iv ot ba r on a d ju st -m e n t bo l t s . I n s t a l l n u t s a n d t i g h t e n (t e m p o r a r i l y ) t o

136 Nm (100 ft. lbs.).

(2) P os i t ion s t e er i n g k n u ck l e o n u p pe r ba l l s t u d .

Tighten t he upper ball stud nut to 142 Nm (105 ft .

l bs .) a n d i n s t a l l a n e w c o t t e r p i n .

(3) R e m ov e s pr i n g com p r es s or t o ol . I n s t a l l t h e

shock absorber.

(4) Instal l the disc brake caliper. Refer to Group 5,

B r a k e s .


(6) A d ju s t a l i g n m en t ca s t e r a n d ca m be r. R e fe r t o

Front Wheel Alignment in this Group.

STABILIZER BAR

REMOVAL


(2) Remove the nut and washer from the stabil izer

b a r l in k b ol t a t t h e l ow e r s u sp en s ion a r m on e a ch

side of the vehicle (Fig. 8).

(3) Remove the l ink bolt , retainers, insulators and

spacer from each lower suspension arm.

(4) Remove the bolts from the U-shaped retainer.

R em ov e t h e r et a i n er, a n d s t a b il iz er b a r f r om t h e

vehicle.

(5) If necessary, remove the bushings from the sta-

bil izer bar.

INSTALLATION

NOTE: Ensure the stabilizer bushings are pre-aligned before the bar is installed to the bracket.

(1 ) I f r e m o v e d , i n s t a l l t h e bu s h i n g s o n t h e s t a bi -

l izer bar.

(2) P l a c e t h e s t a b il iz er b a r a d ja c en t t o t h e f r a m e

s i d e r a i l br a c k e t s . I n s t a l l t h e U - s h a p e d r e t a i n e r a n d

the bolts. Tighten the bolts finger-tight.

NOTE: Check the alignment of the bar to ensure

there is no interference with the either frame rail orchassis component. Spacing should be equal onboth sides.

(3) Instal l the l ink bolt , retainers, spacer and insu-

l a t o r s a t t h e l o w e r s u s p e n s i o n a r m o n e a c h s i d e .

(4 ) I n s t a l l t h e w a s h e r s a n d t h e n u t s o n t h e a n c h o r

bolts. Tighten the nuts to 23 Nm (17 ft . lbs.) torque.

(5) Tighten the U-sha ped support bracket bolts to

54 Nm (40 ft. lbs.).

WHEEL BEARINGS (2WD)

REMOVAL

(1) Block brake pedal in up position.



(4) R em ov e d is c b ra k e ca l iper f rom s t eer in g

knuckle and rotor. Refer to Group 5, Brakes.

(5) Remove the dust cap, cotter pin, and remaining

hub components from spindle (Fig. 9).

Fig. 7 Upper Suspension Arm

Fig. 8 Stabilizer Bar



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CAUTION: Use care to prevent inner wheel bearingand seal from contacting spindle threads duringremoval.

(6) C ar efully slide t he h ub/rotor from spindle.

(7) Remove the seal and inner wheel bearing from

the hub/rotor. Remove t he inner bearing races from

hub/rotor w ith a pin punch.

INSTALLATION

NOTE: Refer to bearing cleaning and inspectionbefore installation.

(1) I n s t a l l t h e n e w bea r i n g cu p (s ) w i t h a n a p p r o-

priate instal lation tool .

(2) Ap pl y a coa t i n g of M OP AR Wh ee l B e a r i n g

Gr e a s e (or a n e q u iv a l en t l u br i ca n t ) t o e n t i r e i n n e r

surface a rea of hub/rotor. Insta l l inner wheel bearing

in t he hub/rotor. Insta l l a new bearing seal .

(3) I n s p ect bea r i n g a n d s ea l con t a ct s u r fa c es on

spindle for burrs or roughness.

(4) R e m ov e a l l r ou g h con t a c t s u r fa c es f r om s pi n -

dle. Apply a coating of lubricant.

(5) C a r e f u ll y s l id e t h e h u b/r ot o r on t o s pi n d le .

I n s t a l l o u t er w h e el b ea r i n g, w a s h e r a n d r et a i n i ng

n u t .

(6) Tighten the nut to 41-54 Nm (30-40 ft. lbs.) to

p r el oa d bea r i n g w h i l e r ot a t i n g t h e h u b/r ot o r. St o p

hub/rotor and loosen nut to completely release bear-

ing preload torque. Tighten t he nut finger-tight and

i n s t a l l t h e n u t l o c k . I n s t a l l a n e w c o t t e r p i n .

(7) The adjustment (above) should have 0 to 0.076

mm (0 to 0.003 in.) end play.

(8) C l e a n t h e d u s t ca p a n d a p p ly a coa t i n g l u br i-

ca n t t o t h e i n t er n a l s u rf a ce . Do not fill the dustcap with lubricant. I n s t a l l t h e c a p .

(9) I n s t a l l d i sc b r a k e ca l i pe r. R ef er t o G r o up 5,

B r a k e s .

(10) Instal l wheel and t ire assembly.

WHEEL STUDS

REMOVAL


(2) Remove disc brake rotor, refer G roup 5 B ra kes.

(3 ) P l a c e r o t o r o n f l a t s u r f a c e a n d d r i v e s t u d s o u t

o f t h e w i t h a h a m m e r a n d p u n c h .

INSTALLATION

(1) Turn the rotor over a nd place in a vise.

(2) D r i v e n e w s t u ds i n t o t h e r ot or w i t h h a m m er

a n d p u n c h .

(3) Instal l rotor, refer to Group 5 Brakes.(4) I n s t a l l w h e e l a n d t i r e a s s em bly.

DISASSEMBLY AND ASSEMBLY

LOWER BALL STUD

REMOVAL



(3) R em ov e d is c b ra k e ca l iper f rom s t eer in g

knuckle and rotor. Refer to Group 5 Brakes.

Fig. 9 Brake Rotor/Hub and Wheel Bearings



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(5) I n st a l l S p r in g C om pr es s or D D -1278. U s e a

piece of pipe to fabricate a spacer positioned between

t h e t o ol a n d s u s pe n si on a r m .

(6) Ti g h t en t o ol n u t a g a i n s t bel l-s h a p ed a d a p t er

tool fing er-tig ht a nd loosen 1/2 of-a -tu rn .

(7) Remove cotter pins and nuts from ball studs.(8) Position Ball Stud Remover C-3564A as shown

i n (Fi g . 5 ) . R o t a t e t h r e a d e d p o r t i o n o f t o o l t o a p p l y

f o r c e t o t h e l o w e r ba l l s t u d .



(10) Remove ball stud seal. U se Remover/Inst a ller

C-4212 to press the ball stud from lower suspension

arm bore (Fig. 10).

INSTALLATION

(1) P r e ss n e w ba l l s t u d i n l o w e r s u s p en s i on a r m

w ith Remover/In sta ller C-4212 (Fig. 11).

(2) P o s it i on n e w s ea l ov er ba l l s t u d . U s e a s ock et

to force retaining l ip of seal unti l securely locked in-

place.(3) Position steering knuckle on ball studs. Instal l

b a l l s t u d r et a i n i ng n u t s . Ti gh t e n l ow e r n u t t o 183



(4) R em ov e s pr i ng com pr es sor t ool a n d i n st a l l

shock absorber.

(5) I n s t a l l t h e d i sc br a k e ca l i p er, r e fe r t o G r ou p 5

B r a k e s .


UPPER BALL STUD

REMOVAL

(1) P l a ce a ja c k u n d e r ou t e r e n d o f l ow e r s u s pe n -

sion arm. Raise and support the vehicle.


(3) R em ov e cot t e r p in a n d n u t f r om u pp er b a l l

s t u d .

(4) Position Ball Stud Remover C-3564A as shown(Fig. 6). Rotate threaded portion of tool to apply force

t o t h e u p p e r ba l l s t u d .



(6) Remove ball stud seal .

(7) U s e R em ov a l /I n s t a l la t i on Tool C -3561 t o

u n t h r e a d ba l l s t u d f r o m s u s p e n s i o n a r m .

INSTALLATION

(1) Th r e a d n e w ba l l s t u d i n w i t h Tool C -3561.

Tighten ball stud to 170 Nm (125 ft . lbs.). The gap

b e t w e e n b a l l s t u d H e x a n d s u s p e n s i o n a r m b o r e i s0.25 to 1.25mm (0.01 to 0.05 inch).

(2) I n s t a l l n e w s ea l ov er ba l l s t u d . M a k e s u r e s e a l

is securely locked in-place.

(3) P o s it i on s t e er i n g k n u ck l e o n u p pe r ba l l s t u d .



(4 ) I n s t a l l t h e w h e e l a n d t i r e a s s e m bl y

Fig. 10 Lower Ball Stud Removal

Fig. 11 Lower Ball Stud Installation


DISASSEMBLY AND ASSEMBLY (Continued)

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CLEANING AND INSPECTION

WHEEL BEARING(1) Thoroughly clea n the interior of hub/rotor (Fig.

12).

(2 ) C l e a n t h e be a r i n g s w i t h s o l v e n t a n d t o w e l d r y .

(3) Af t er cl ea n i n g , a p p ly e n gi n e oi l t o e a ch bea r -

ing.

(4) R ot a t e e a ch b ea r i n g s low l y w h i le a p pl y in gd o w n w a r d f o r c e . E x a m i n e t h e r o l l e r s f o r p i t t i n g a n d

roughness, replace bearing i f worn or defective.

(5) Remove the engine oil from each bearing. Pack

e a c h be a r i n g w i t h m u l t i - p u r p o s e NL GI , g r a d e 2 , E P -

type lubricant (or an equivalent lubricant).

NOTE: Ensure that lubricant is forced into all thecavities between the bearing cage and rollers.

SPECIFICATIONS

TORQUE CHART 2WD

DESCRIPTION TORQUE

Sh ock Absorber

Upper Nut . . . . . . . . . . . . . . . . .41 Nm (30 ft . lbs.)

Lower B olts. . . . . . . . . . . . . . .23 Nm (200 in. lbs.)

Lower Suspension ArmFront Nut . . . . . . . . . . . . . . .176 Nm (130 ft . lbs.)

Rear Nut . . . . . . . . . . . . . . . . .108 Nm (80 ft . lbs.)

B all S tud Nut . . . . . . . . . . . .183 Nm (135 ft . lbs.)

Upper Suspension Arm

Pivot Bar Nuts. . . . . . . . . . . .210 Nm (155 ft . lbs.)


St a bi l i z e r B a r

Clam p B olt . . . . . . . . . . . . . . . .54 Nm (40 ft . lbs.)

Link Nut . . . . . . . . . . . . . . . . . .23 Nm (17 ft . lbs.)

Support B ra cket B olts . . . . . .30 Nm (22.5 ft . lbs.)

Fig. 12 Brake Rotor/Hub and Wheel Bearings


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SPECIAL TOOLS

FRONT SUSPENSION 2WD

Compressor, Coil Spring DD-1278

Puller, Knuckle Arm C-3564A

Press, Ball Joint C-4212F

Socket, Ball Joint C-3561


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FRONT SUSPENSION4WD

INDEX

page page


4WDSUSPENSION COMPONENTS . . . . . . . . . 15DIAGNOSIS AND TESTING

LOWER BALL STUD . . . . . . . . . . . . . . . . . . . . . . 16SHOCK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 16

UPPER BALL STUD . . . . . . . . . . . . . . . . . . . . . . 16REMOVAL AND INSTALLATION

LOWER SUSPENSION ARM . . . . . . . . . . . . . . . . 17SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . 16STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . 18

STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . 19

TORSION BAR . . . . . . . . . . . . . . . . . . . . . . . . . . 16

UPPER SUSPENSION ARM . . . . . . . . . . . . . . . . 17WHEEL HUB/BEARINGS (4WD) . . . . . . . . . . . . . 20WHEEL MOUNTING STUDS . . . . . . . . . . . . . . . . 20


UPPER BALL STUD . . . . . . . . . . . . . . . . . . . . . . 20SPECIFICATIONS

TORQUE CHART4WD . . . . . . . . . . . . . . . . . . . 21SPECIAL TOOLS

FRONT SUSPENSION 4WD . . . . . . . . . . . . . . . . 21


4WD SUSPENSION COMPONENTSTh e f r on t s u sp en s ion i s d es ig n ed t o a l l ow e a ch

w h e el t o a d a p t t o d if fe re nt r oa d s u rf a ce s i n de pe n-

d en t l y. Th e w h e el s a r e m ou n t ed t o h u b/b ea r i n g

d e si g n u n i t . Th e s t e er i n g k n u ck l es t u r n (p iv ot ) on

ba l l s t u d s m o u n t e d o n t h e u p p e r a n d l o w e r s u s p e n -

sion arms.

The 4WD front suspension is comprised of (Fig. 1);

Dual-action shock absorbers

Torsion-ba r sprin gs

Suspension arms Steering knuckles

St a bi l i z e r ba r

J ounce bumpers




shock absorbers are bolted to the frame. The bottom

of the shocks are bolted to the lower suspension arm.

Torsion Bars: The t orsion bar s a re used t o controlride height and ride quali ty. The bars mounted to the

back side of the lower suspension arm. The rearward

e n d o f t h e b a r i s m o u n t e d i n a c a m p i v o t t h a t r e s t si n t h e f r a m e cr os sm em b er. Th e v eh i cl e h ei gh t i s

a d ju st ed t h r ou gh t h e ca m s w i t h s cr ew ja ck s t h a t

increase the tension (twist) of the torsion bar.

Suspension Arms: Th e u p pe r s u s pe n si on a r m su s e a cr os s s h a f t b ol t ed t o t h e f r a m e r a i l b r a ck et s .

Th e cr os s s h a f t i sol a t es r oa d n oi se b y t h e u s e o f

r e pl a ce a bl e bu s h i n g s i n t h e s u s pe n si on a r m s . Th e

u pp er s u sp en s ion a r m cr os s s h a f t a l s o a l low s f or

caster and camber adjustment. The lower suspension

a r m s u s e r e p l a c e a bl e p r e s s e d i n bu s h i n g s t o i s o l a t e

r oa d n oi s e. Th e s u s pe n si on a r m s a r e bol t e d t o t h e

f r a m e a n d p iv ot t h r o ug h r u bbe r bu s h in g s . Th e s u s -

p en s i on a r m t r a v e l (jou n ce or r e bou n d ) i s l i mi t e d

through the use of rubber bumpers.

Stabilizer Bar: The stabil izer bar is used to min-imize vehicle front sway during turns. The bar helps

t o m a i n t a i n a f la t a t t i t u d e t o t h e r oa d s u rf a ce . Th e

bar extends across the front underside of the chassis

Fig. 1 Front Suspension 4WD


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a n d con n e ct s t o t h e f r a m e r a i ls . Th e l i n k s a r e c on -

nected to the lower suspension brackets. All mount-

ing points of the stabil izer bar are isolated by rubber

bushings.

All suspension components tha t use rubber bush-

i n g s s h o u l d be t i g h t e n e d w i t h t h e v e h i c l e a t n o r m a l

height. If the vehicle is not at the normal ride height,vehicle ride comfort could be a ffected along with pre-

m a t u r e r u bbe r bu s h i n g w e a r . R u bbe r bu s h i n g s m u s t

never be lubricated.


LOWER BALL STUD(1) R a i s e t h e f r on t of t h e v eh i cl e. I n s t a l l s a f et y

floor stands under both lower suspension arms as far

ou t boa r d a s p os s ibl e. Th e u p pe r s u s pe n si on a r m s

must not contact the rebound bumpers.

(2 ) I n s t a l l a d i a l i n d i c a t o r a n d c l a m p a s s e m bl y t othe lower suspension arm.

(3) Position indicator plunger against knuckle arm

and zero indicator.

(4) R a i s e a n d l ow e r t h e w h e el a n d t i r e w i t h a p ry

b a r u n d e r t h e c e n t e r o f t h e t i r e . M e a s u r e t h e a x i a l

movement of the knuckle with respect to the suspen-

s i o n a r m .

(5) If the travel of the suspension arm is 1.27 mm

(0.050 inch) or more, replace the lower control arm.

UPPER BALL STUD(1) P os i t ion a f loor ja c k u n d er t h e l ow e r s u s pe n -

s i o n a r m . R a i s e t h e w h e e l a n d t i r e s o i t l i g h t l y c o n -tact the floor (vehicle weight relieved from the t ire).

(2) G r a s p t h e t o p of t h e t i r e a n d a p p ly f o r ce i n a n d

ou t . L ook f or a n y m ov em en t at the ball jointsb et w e en t h e u pp er s u sp en s ion a r m a n d s t eer i ng

knuckle.

(3) If any lateral movement is evident, replace the

ball joint.

SHOCK DIAGNOSISA n oi s e f r om a s h ock a bs or ber m a y be c a u s ed by

m ov em en t b et w e en m ou n t in g b u sh i ng s a n d m et a l

br a c ke t s or a t t a c h i n g com p on e n t s . Th i s n oi s e c a n

u s u a l l y be s t o p p e d by t i g h t e n i n g t h e a t t a c h i n g n u t s .I f t h e n o i s e p e r s i s t s , i n s p e c t f o r d a m a g e d a n d w o r n









Th e s h ock a bs or ber bu s h in g s d o n o t r e q u ir e a n y

t y p e o f l u br ica t i on . Do n o t a t t e m pt t o s t o p bu s h i n g

n oi se b y l ub r ica t i n g t h e m. G r e a s e a n d m i ne ra l oi l-

base lubricants wil l deteriorate the bushing rubber.


SHOCK ABSORBER

REMOVAL

(1) Remove the hardware from the shock absorber

stud (Fig. 2).

(2) R a i s e t h e v eh i cl e, r e mov e t h e l ow e r bol t s a n d

remove the shock absorber.

INSTALLATION

(1 ) I n s t a l l t h e l o w e r r e t a i n e r a n d g r o m m e t o n t h e

s h ock a bs or ber s t u d . I n s e rt t h e r e pl a c em e n t s h ock

a b s or b er t h r ou g h t h e f r a m e h ol e. I n s t a l l t h e l ow e r

bolt.

(2) Tighten th e bolt to 136 Nm (100 ft. lbs.).

(3 ) I n s t a l l t h e u p p e r g r o m m e t a n d r e t a i n e r o n t h e

s hock a b sor ber s t ud . I n st a l l t h e b a y on et n u t a n d

tighten to 41 Nm (30 ft . lbs.).

TORSION BAR

CAUTION: The left and right side torsion bars are

NOT interchangeable. The bars are identified andstamped R or L, for right or left. The bars do nothave a front or rear end and can be installed witheither end facing forward.

Fig. 2 Shock Absorber


DESCRIPTION AND OPERATION (Continued)

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REMOVAL

(1) R e m ov e t h e s u s pe n si on a r m jou n ce bu m pe r s

before raising vehicle.

(2) R a i s e a n d s u pp or t t h e v eh i cl e w i t h t h e f r on t

suspension han ging.

(3) Turn the adjustment bolt counterclockwise to

release spring load (Fig. 3). Remove the adjustmentbolt from swivel .

(4) Remove torsion bar and anchor. Remove anchor

from torsion bar.

(5) R e m ov e a l l f or e ig n m a t e r i a l f r om t o r si on ba r

m ou n t i n g i n a n c h or a n d s u s pe n si on a r m .

(6) Inspect adjustment bolt and swivel for damage.

INSTALLATION

(1) Insert torsion bar ends into anchor and suspen-

s i o n a r m .

(2) P o s it i on a n c h or a n d bu s h in g i n f r a m e cr os s -

m em b er. I n s t a l l a d ju s t me nt b ol t t h r ou g h b u sh i ng

a n d a n c h o r a n d i n t o s w i v e l .

(3) Tu r n a d ju s t me nt b ol t cl ock w i se t o a p pl y a

spring load.

(4) Lower vehicle a nd adjust the front suspension

height. Refer to Wheel Alignment in this group.

(5) Instal l suspension arm jounce bumpers.

LOWER SUSPENSION ARM

REMOVAL

(1) R em ov e t h e C V d r iv e s h a f t , r ef er t o G r o up 3

Differentia l & Driveline.

(2) Remove torsion bar.

(3) Remove shock absorber lower bolt.

(4) Disconnect the sta bil izer ba r from suspension

a r m .

(5) Remove the cotter pin and nut from lower ball

s t u d . Se p a r a t e ba l l s t u d f r o m s t e e r i n g k n u c k l e w i t h

Rem over C-3564A.

(6) R e m ov e s u s pe n si on a r m p iv ot bol t s a n d s u s -

pension arm from frame rai l brackets (Fig. 4).

INSTALLATION

(1) Position the lower suspension arm at the frame

r a il b ra ck et s. I n st a ll t h e piv ot b olt s a n d n ut s.

Tighten the nuts finger-tight.

(2) I n s er t t h e b a l l s t u d i n t o s t eer i ng k n uck le .

Instal l and t ighten the retaining nut to 142 Nm (115

f t . l bs .) a n d i n s t a l l a n e w c o t t e r p i n .

(3) Instal l torsion bar.

(4) Instal l shock absorber lower bolt .

(5) I n s t a l l t h e C V d r i v e s h a f t . R ef er t o G r ou p 3

Differential & Drive l ine.

(6 ) I n s t a l l t h e s t a bi l i z e r ba r t o t h e l o w e r s u s p e n -

s i o n a r m .

(7) Tighten th e low er suspension front pivot n ut to

108 Nm (80 ft . lbs.). Tighten rear pivot bolt to 176

Nm (130 ft. lbs.).

(8) Ad ju s t t h e f r on t s u s pe n si on h e ig h t . R e fe r t o

Wheel Alignment in this Group.

UPPER SUSPENSION ARM

REMOVAL

(1 ) R e m o v e t h e C V d r i v e s h a f t . R e f e r t o Gr o u p 3


(2) Turn torsion ba r a djustment bolt count er-clock-

wise to completely remove t ension from torsion bar.

Count the number of turns for instal lation reference.

(3) Remove brake hose bra ckets from suspension

a r m , r e f e r t o Gr o u p 5 B r a k e s .

(4) Remove shock absorber lower bolt.

(5) Remove the cotter pin and nut from lower ball

s t u d .

Fig. 3 Torsion Bar

Fig. 4 Lower Suspension Arm



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t o t h e u p p e r ba l l s t u d .



(8) Separate upper ball stud from steering knuckle

a r m .

(9) R em ov e s u s pe n si on a r m p iv ot ba r bol t s a n d

remove suspension arm (Fig. 6).

INSTALLATION

(1) P os i t ion s u s pe n si on a r m p iv ot ba r on a d ju st -

m e n t bo l t s . I n s t a l l n u t s a n d t i g h t e n (t e m p o r a r i l y ) t o

136 Nm (100 ft. lbs.).

(2) I n ser t b a ll s t ud i n s t eer in g k nu ck le a r m .Instal l retaining nut. Tighten nut to 142 Nm (105 ft .



(4) Attach brake hose brackets to suspension arm,

r e f e r t o Gr o u p 5 B r a k e s .

(5) Turn torsion ba r a djustment bolt clockwise (th e

amount of turns recorded earl ier) to apply tension to

torsion bar.

( 6 ) I n s t a l l t h e C V d r i v e s h a f t . R e f e r t o C V D r i v e

Sh a f t I n s t a l l a t i o n i n t h i s Gr o u p .


(8) Ti g h t en u p pe r s u s pe n si on a r m p iv ot bol t s t o

210 Nm (155 ft. lbs.).

(9) Ad ju s t a l i g n m en t ca s t e r a n d ca m be r. R e fe r t o

Front Wheel Alignment in this Group.

STABILIZER BAR

REMOVAL


(2) R e m ov e t h e bol t s a t t a c h in g t h e s t a bi l iz er ba r

r ea r s uppor t b ra ck et t o t h e f ra m e cr os sm em ber

bracket (Fig. 7).

(3 ) R e m o v e t h e bo l t s a t t a c h i n g t h e r e t a i n e r t o t h e

l o w e r s u s p e n s i o n a r m . R e m o v e t h e r e t a i n e r a n d s t a -

bil izer bar from the vehicle.

(4) If necessary, remove the rear support brackets

a n d t h e bu s h i n g s f r o m t h e s t a bi l i z e r ba r .

INSTALLATION

(1 ) I f r e m o v e d , i n s t a l l t h e bu s h i n g s a n d t h e r e a r

support brackets on the stabil izer bar.

(2) P l a c e t h e s t a bi l iz er ba r r e a r s u pp or t br a c ke t s

a d ja c en t t o t h e f r a m e cr os sm em b er b r a ck et s a n d

i n st a l l t h e b ol t s. Ti gh t en t h e b ol t s f in g er -t i gh t .

Check the alignment of the bar to ensure thereis no interference with the either frame rail orchassis component. Spacing should be equal onboth sides.

(3 ) A t t a c h t h e s t a bi l i z e r ba r t o t h e l o w e r s u s p e n -

s ion a r m w i t h t h e r e t a i n er a n d b ol t s. Ti gh t en t h e

bolts to 27 Nm (20 ft. lbs.).

(4) Ti g h t en t h e r e a r s u pp or t br a c ke t bol t s t o 27

Nm (20 ft. lbs.).

Fig. 5 Separate Upper Ball Stud

Fig. 6 Upper Suspension Arm



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STEERING KNUCKLE

REMOVAL

(1) R e m ov e t h e C V d r i v e s h a f t . R e fe r t o C V Dr i v e

Sh a f t R e m o v a l i n t h i s Gr o u p .

(2) Turn torsion ba r a djustment bolt counter-clock-

wise to completely remove t ension from torsion bar.

Count the number of turns for instal lation reference.

(3) Remove shock absorber lower bolt.(4) Disconnect the sta bil izer ba r from suspension

a r m .

(5) R e m ov e t h e w h e e l h u b a n d bea r i n g s .

(6) Remove tie-rod end stud from steering knuckle

a r m . R e fe r t o G r ou p 1 9 St e er i n g .

(7) Remove AB S front wh eel speed sensor an d wire

from upper suspension arm if equipped (Fig. 8).

(8) Remove the cotter pin and nut from upper and

l o w e r ba l l s t u d .

(9) Use Ball Stud Remover C-3564A to free upper

and lower ball joints from steering knuckle.

(10) S t r i k e s t e er i n g k n u ck l e s h a r p l y w i t h a h a m -

mer to loosen ball stud from knuckle. Do not forceball stud out from knuckle with the tool.

(11) Remove steering knuckle from vehicle (Fig. 9).

INSTALLATION

(1) Position steering knuckle on upper an d lower

ba l l s t u d s a n d i n s t a l l n u t s . Ti g h t en l ow e r n u t t o 1 56



(2) I n s t a l l AB S s en s or on s t eer i ng k n uck le a n d

w i r e on u p pe r s u s pe n si on a r m . Ti g h t en bol t s t o 24

Nm (18 ft. lbs.).

(3) Instal l t ie rod to steering knuckle arm, refer to

Group 19 Steering.

(4) In sta ll w heel hub/bearin g.


( 6 ) I n s t a l l t h e C V d r i v e s h a f t . R e f e r t o C V D r i v e

Sh a f t I n s t a l l a t i o n i n t h i s Gr o u p .

(7) I n s t a l l t h e s t a bi l iz er ba r t o s u s p en s i on a r m .

(8) I n s t a l l t h e w h e e l a n d t i r e a s s em bly.

(9) Turn torsion ba r a djustment bolt clockwise (the

amount of turns recorded earl ier) to apply tension to

torsion bar.

Fig. 7 Stabilizer BarFig. 8 ABS Sensor and Wire

Fig. 9 Steering Knuckle



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(10) Adjust the front suspension height. Refer to

Wheel Alignment within this Group.

WHEEL HUB/BEARINGS (4WD)

REMOVAL

(1) R em ov e t h e C V d r iv e s h a f t , r ef er t o G r o up 3


(2) R em ov e d is c b ra k e ca l ip er f rom s t eer in g

knuckle and rotor, refer to Group 5 Brakes.

(3) Remove brake rotor from the hub (Fig. 10).

(4) Remove hub to steering knuckle bolts. Remove

hub and bearing unit from the steering knuckle (Fig.

11).

INSTALLATION

(1) Instal l the hub on steering knuckle and t ighten

bolts to 149 Nm (110 ft. lbs.).

(2) Instal l the CV drive shaft , refer to Group 3 Dif-

ferentia l & Driveline.

(3) I n s t a l l d i sc br a k e r ot o r o n t h e h u b.

(4) I n s t a l l d i s c br a k e ca l i p er on s t e er i n g k n u ck l e

a n d r o t o r . R e f e r t o Gr o u p 5 B r a k e s .

WHEEL MOUNTING STUDS

REMOVAL

(1) Raise and support vehicle.


(3) Remove brake caliper and rotor, refer to Group

5 Brakes for procedure.

(4) Remove stud from hub with Remover C-4150A

(Fig. 12).

INSTALLATION

(1 ) I n s t a l l n e w s t u d i n t o h u b f l a n g e .

(2) I n s t a l l t h r e e w a s h e r o n t o s t u d , t h e n i n s t a l l l u gn u t w i t h t h e f l a t s i d e o f t h e n u t a g a i n s t t h e w a s h e r s .

(3) Ti gh t en l ug n u t u n t il t h e s t u d i s p ul le d i n t o

t h e h u b f la n g e. Ver if y t h a t t h e s t ud i s pr op er ly

s e a t e d i n t o t h e f l a n g e .

(4 ) R e m o v e l u g n u t a n d w a s h e r s .

(5) I n st a l l t h e b r a k e r ot or a n d ca l i pe r, r ef er t o

Group 5 Brakes for procedure.

(6) I n s t a l l w h e el a n d t i r e a s sem b ly, u s e n e w l ug

n u t o n s t u d o r s t u d s t h a t w e r e r e p l a c e d .

(7) Remove support and lower vehicle.


UPPER BALL STUD

REMOVAL

(1) P l a ce a ja c k u n d e r ou t e r e n d o f l ow e r s u s pe n -

sion arm. Raise and support the vehicle.


(3) R em ov e cot t e r p in a n d n u t f r om u pp er b a l l

s t u d .

Fig. 10 Rotor, Hub & Knuckle

Fig. 11 Hub/Bearing

Fig. 12 Wheel Stud Removal



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(4) P os i t ion B a l l St u d R e m ov er C -3564A. R ot a t e

t h r e a d e d p o r t i o n o f t o o l t o a p p l y f o r c e t o t h e u p p e r

ba l l s t u d .



(6) Remove ball stud seal .(7) U s e R em ov a l / I n s t a l la t i on Tool C -3561 t o

u n t h r e a d ba l l s t u d f r o m s u s p e n s i o n a r m .

INSTALLATION

(1) Th r e a d n e w ba l l s t u d i n w i t h Tool C -3561.

Tighten ball stud to 170 Nm (125 ft . lbs.). The gap

b et w e en b a l l s t u d H e x a n d s us pen s ion a r m b or e i s

0.25 to 1.25mm (0.01 to 0.05 inch).

(2) I n s t a l l n e w s ea l ov er ba l l s t u d . M a k e s u r e s e a l

securely locked in- place.

(3) P os i t ion s t e er i n g k n u ck l e o n u p pe r ba l l s t u d .


l bs .) a n d i n s t a l l a n e w c o t t e r p i n .(4 ) I n s t a l l t h e w h e e l a n d t i r e a s s e m bl y

SPECIFICATIONS

TORQUE CHART 4WD

DESCRIPTION TORQUE

Shock Absorber

Upper Nut . . . . . . . . . . . . . . . . .41 Nm (30 ft . lbs.)

Lower B olt . . . . . . . . . . . . . . .136 Nm (100 ft . lbs.)

Lower Suspension Arm

Front Bolt . . . . . . . . . . . . . . . .108 Nm (80 ft . lbs.)Rear B olt . . . . . . . . . . . . . . . .176 Nm (130 ft . lbs.)


Upper Suspension Arm

P ivot B ar B olts . . . . . . . . . . .210 Nm (155 ft . lbs.)



Clamp Bolts. . . . . . . . . . . . . . . .27 Nm (20 ft . lbs.)

Retainer B olts . . . . . . . . . . . . . .27 Nm (20 ft . lbs.)

Support B ra cket B olts . . . . . . . .27 Nm (20 ft . lbs.)

Wheel H ub/B earin g B olts. . . .149 Nm (110 ft. lbs.)

SPECIAL TOOLS

FRONT SUSPENSION 4WD

Puller, Knuckle Arm C-3564A

Socket, Ball Joint C-3561

Remover C-4170A


DISASSEMBLY AND ASSEMBLY (Continued)

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REAR SUSPENSION

INDEX

page page

GENERAL INFORMATION

WEIGHT DISTRIBUTION . . . . . . . . . . . . . . . . . . 22DESCRIPTION AND OPERATION

SUSPENSION COMPONENT . . . . . . . . . . . . . . . 22DIAGNOSIS AND TESTING

SPRING AND SHOCK DIAGNOSIS . . . . . . . . . . . 22REMOVAL AND INSTALLATION

LEAF SPRING AND SHACKLE BUSHING . . . . . . 24

LEAF SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . 23

SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . 23SPRING LEAF REPLACEMENT . . . . . . . . . . . . . 24

SPECIFICATIONSTORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 26

GENERAL INFORMATION

WEIGHT DISTRIBUTIONA v eh i cl e s h o u ld a l w a y s be l o a d e d s o t h e v eh i cl eweight center-line is locat ed immediately forwa rd of

the rear axle. Correct vehicle loading provides proper

front t ire-to-road contact . This results in maximum

vehicle ha ndling sta bil ity an d sa fety. In correct vehi-

cle weight distribution can cause excessive t ire tread

w e a r , s p r i n g f a t i g u e or f a i l u r e, a n d e r r a t i c s t e er i n g .


SUSPENSION COMPONENTThe rear suspension is comprised of:

Drive Axle

L e a f Sp r i n g s

Dual-Action Shock Absorbers


J ounce Bumpers

Leaf Springs: The rear suspension system uses amulti-leaf springs and a solid drive axle. The forward

end of the springs are mounted to the body rai l hang-

e r s t h r o u g h r u bbe r bu s h i n gs . Th e r e a r w a r d e n d o f

t h e s p r i n g s a r e a t t a c h e d t o t h e b o d y b y t h e u s e o f

shackles. The spring and shackles use rubber bush-

i n g s. Th e bu s h in g h e lp t o i s ol a t e r oa d n oi s e. Th e

s h a c k l e s a l l o w t h e s p r i n g s t o c h a n g e t h e i r l e n g t h a sthe vehicle moves over various r oad conditions.




shock absorbers are bolted to the body crossmember.

Th e b ot t om of t h e s hock s a r e b ol ted t o t h e a x le

bracket.

Stabilizer Bar: The stabil izer bar is used to min-imize vehicle body roll . The spring steel bar helps to

con t r o l t h e v eh i cl e bo d y i n r e la t i on s h i p t o t h e s u s -

pension. The bar extends across the underside of the

b od y a n d i s a t t a ch ed t o t h e b od y r a i ls w i t h g rom -

m e t s . L i n k s a t t h e e n d o f t h e ba r a r e a t t a c h e d t o t h e

leaf spring brackets.

J ounce Bumpers: The jounce bumpers are usedto l imit the spring and axle travel . They are bolted to

t h e bo d y r a i l a bo v e t h e a x l e .

NOTE: Suspension components that use rubber

bushings should be tightened with the vehicle atthe normal height. Rubber bushings must never belubricated.


SPRING AND SHOCK DIAGNOSISA n oi s e f r om a s h ock a bs or ber m a y be c a u s ed by

m ov em en t b et w e en m ou n t in g b us h in g s a n d m et a l

bracket or at ta ching components. This n oise can usu-

a l l y b e s t o p p e d b y t i g h t e n i n g t h e a t t a c h i n g n u t s . I f

t h e n oi se p er s is t s, i n sp ect f or d a m a g ed a n d w o rn









The spring eye a nd shock a bsorber bushings do not

r eq u ir e a n y t y p e of l ub r ica t i on . D o n ot a t t e m pt t o

s t op s pr in g b us hi ng n oi se b y l ub ri ca t i ng t h em .

G r e a s e a n d m i n er a l oi l -ba s e l u br i ca n t s w i l l d e t er i o-

r a t e t h e bu s h i n g r u bbe r.

If the vehicle is used for severe, off-road operation,

the springs should be examined periodically. Check

for broken and shifted leafs, loose and missing cl ips,


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a n d br o k e n c e n t e r bo l t s . R e f e r t o Sp r i n g a n d Sh o c k

Absorber Diagnosis chart for additional information.


SHOCK ABSORBER

REMOVAL


(2) Remove the shock absorber lower nut and bolt

from the axle bracket (Fig. 1) and (Fig. 2).

(3) R em ov e t h e s h ock a b s or b er u pp er n u t s a n d

bolts from the frame crossmember bracket. Remove

the shock absorber.

INSTALLATION

(1) Instal l the shock absorber and upper fasteners

o n t h e f r a m e br a c k e t .

(2) I n s t a l l t h e s h ock a bs or ber l ow e r e y e i n t o t h e

a x l e b ra c ke t . I n s t a l l t h e b ol t a n d n u t a n d t i gh t e n t o

81 Nm (60 ft. lbs.).

(3) Tighten the upper bracket nuts to 27 Nm (20

ft. lbs.).

LEAF SPRINGS

CAUTION: The rear of the vehicle must be liftedonly with a jack or hoist. The lift must be placed

under the frame rail crossmember located aft of therear axle. Use care to avoid bending the side railflange.

REMOVAL

(1 ) R a i s e t h e v e h i c l e a t t h e f r a m e .

(2) Use a hydraulic jack to relieve the axle weight.

(3) Remove the wheel and t ire assemblies.

(4) R em ov e t h e n u ts , t h e U -b ol t s a n d s pr in g

bracket from the axle.

(5) Rem ov e t h e n u t a n d b ol t t h a t a t t a ch es t h es p r i n g r e a r e y e t o t h e s h a c k l e .

(6) Remove the nut and bolt from the spring front

eye.

(7) Remove the spring from the vehicle.

INSTALLATION

(1) I f r e m ov ed , i n s t a l l t h e s p ri n g s h a c kl e o n t h e

spring finger t ight.

(2) P o s it i on t h e s p r i n g o n t h e r e a r a x l e p a d . M a k e

s u re t h e s pr in g ce nt e r b ol t i s i n s er t ed i n t h e p a d

SPRING AND SHOCK ABSORBER DIAGNOSIS


DIAGNOSIS AND TESTING (Continued)

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locating hole. If 2WD, ensure the pa rking bra ke cable

guide is properly positioned.

(3) Align the spring front eye with the bolt hole int h e r a i l f r on t br a c ke t . I n s t a l l t h e s p r i n g e y e bol t a n d

nut. Tighten t he spring eye nut finger-tight.

(4) Align the spring shackle eye with the bolt hole

i n t h e r a i l r ea r b ra ck et . I n st a l l t h e b ol t a n d n ut .

Tighten the spring sha ckle eye nut finger-tight.

(5) I n s t a l l t h e s pr i n g s ea t (2WD on l y ), U -bol t s ,

s pr in g b ra ck et , r epl a cem en t w a s h er s a n d n ut s .

Ti g h t en t h e n u t s u n t i l t h e w a s h e r s a r e com p r es s ed

a g a i n s t t h e s p r i n g br a c k e t .

(6) R em ov e t h e s u pp or t s t a n d s f r om u n d er t h e

f r a m e r a i l s . L o w e r t h e v e h i c l e u n t i l t h e s p r i n g s a r e

s u pp or t i n g t h e w e ig h t of t h e v eh i cl e. Ti gh t en t h e

U-bolt nuts: 2WD vehicles: 88 Nm (65 ft. lbs.)

4WD vehicles: 149 Nm (110 ft. lbs.)

(7) Ti g h t en t h e s p ri n g e y e p iv ot bol t n u t a n d a l l

shackle nuts to 88 Nm (65 ft . lbs.).

(8) I n s t a l l t h e w h e el a n d t i r e a s s em bl ie s.

SPRING LEAF REPLACEMENT

NOTE: If a spring has acquired a set (lost signifi-

cant height), it should be replaced.

(1) Remove the spring from the vehicle.

(2) Remove the spring leaf al ignment cl ips.

(3) C l a m p t h e s pr i ng i n a v is e. R em ov e t h e n u tand center bolt (Fig. 3).

(4) Insert a long drift or punch into the center bolt

h ol e a n d s l ow l y r e le a s e t h e v i se ja w s .

(5 ) R e m o v e t h e s p r i n g f r o m t h e v i s e . R e p l a c e t h e

d ef ect i v e l ea f a n d i n s er t a l on g d r i ft or p u n ch i n t o

the spring center bolt hole.

(6) P os i t ion s pr i n g bet w e e n v i se ja w s a n d s l ow l y

tighten the vise jaws. Keep the spring leaves al igned

w i t h t h e l o n g d r i f t o r p u n c h .

(7) Remove th e dr ift/punch from the spring center

bolt hole and replacement center bolt and nut.

(8) Ti gh t en t h e n u t t o 20 N m (15 f t . l bs .). An

a l t e r n a t e i s t o t i g h t e n u n t i l t h e c e n t e r o f t h e s p r i n gh a s n o g a p s . U s e a m a x i m u m o f 5 4 N m (4 0 f t . l bs .)

for this method.

(9) Instal l the al ignment cl ips.

(10) Instal l the spring in the vehicle.

LEAF SPRING AND SHACKLE BUSHINGFo r f r o n t ov a l bu sh i n g s be n d t a bs DO WN bef or e

removal . Use an appropriate driver tool and force the

original bushing out of the spring eye.

Fig. 1 2WD Suspension



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(1) Assemble tools shown (Fig. 4). Tighten nut at

t h e s o c k e t w r e n c h e n d o f t h e t h r e a d e d r o d u n t i l t h e

bushing is forced out.

(2) As sem b le a n d a l i gn t h e b u sh i ng i n st a l l a t i on

tools.

(3) Al ig n t h e b us hi ng w i t h t h e s pr in g ey e or

s h a c kl e e y e a n d t i g h t e n t h e n u t a t t h e s o ck et w r e n ch

end of the t hreaded rod. Tighten unt i l the bushing is

forced into the spring eye.

Fig. 2 4WD Suspension

Fig. 3 Leaf Spring Disassembly

Fig. 4 Spring Eye Bushing Removal



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NOTE: The bushing must be centered in the springeye. The ends of the bushing must be flush orslightly recessed within the end surfaces of thespring eye.

(4) F or f ron t ov a l b us hi ng s b en d t a b s u p a f t er

instal lation.

SPECIFICATIONS

TORQUE CHART

DESCRIPTION TORQUE

Sh ock Absorber

Lower Bolt . . . . . . . . . . . . . . . . .88 Nm (65 ft . lbs.)Upper Bolt . . . . . . . . . . . . . . . . .27 Nm (20 ft . lbs.)

Sp r i n g C l a m p Nu t

2WD . . . . . . . . . . . . . . . . . . . . .88 Nm (65 ft . lbs.)

4WD . . . . . . . . . . . . . . . . . . . .149 Nm (110 ft . lbs.)

Spring

Spring E ye Nut . . . . . . . . . . . . .88 Nm (65 ft . lbs.)

P ivot B olt Nut . . . . . . . . . . . . . .88 Nm (65 ft . lbs.)



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