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(1) Install the ball joint into the control arm and press in using special tools C-4212–F (press), 8698-1
(driver) and 8698-3 (receiver) (Fig. 22).Fig.20LOWERBALLJOINTSEPARATION
1 - STEERING KNUCKLE 2 - SPECIAL TOOL 8677
NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation pro- cess.
Fig.22INSTALLLOWERBALLJOINT
1 - PRESS - C-4212-F 2 - DRIVER - 8698-1
3 - BALL JOINT 4 - LOWER CONTROL ARM 5 - RECEIVER - 8698-3(7) Press the ball joint from the lower control arm tools C-4212–F (PRESS), 8698-2
using (RECEIVER) and 8698-3 (DRIVER) (Fig. 21).
special
Fig.21REMOVALLOWERBALLJOINT
1 - PRESS - C-4212-F 2 - DRIVER - 8698-3
3 - BALL JOINT 4 - RECEIVER - 8698-2INSTALLATION
NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process.
(2) Install the ball joint boot. (3) Stake the ball
flange in four evenly spaced places around the ball joint flange, using a chisel and hammer (LD only).
joint
(4) Replace the snap ring (HD 4X2 only) (5) Remove the support
for the halfshaft and
install into position (If Equipped).
(6) Install the steering knuckle (Refer to 2 - SUS-
PENSION/FRONT/KNUCKLE - INSTALLATION).
(7) Install the tie rod end into the steering knuckle (Refer to 19 - STEERING/LINKAGE/TIE ROD END - INSTALLATION).
(8) Install and tighten the halfshaft nut to 251
N·m (185 ft. lbs.). (If Equipped).
(9) Install the brake caliper and rotor (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS INSTALLATION).
(10) Install the tire and wheel assembly (Refer to 22 - TIRES/WHEELS/WHEELS - STANDARD PRO- CEDURE).
(11) Check the vehicle ride height (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
(12) Perform a wheel alignment (Refer to 2 - SUS- PENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
2 - 20
FRONT - INDEPENDENT FRONT SUSPENSION
DR
LOWER CONTROL ARM
REMOVAL
REMOVAL - 4X4 (LD)
(1) Raise and support the vehicle. (2) Remove the wheel and tire assembly. (3) Remove the upper ball joint nut. Separate ball joint from the steering knuckle with Remover 8677. (4) Remove the front halfshaft, (Refer to 3 - DIF- FERENTIAL & DRIVELINE/HALF SHAFT - REMOVAL).
(5) Remove the torsion bar, (Refer to 2 - SUSPEN-
SION/FRONT/TRACK BAR - REMOVAL).
(6) Remove the shock absorber lower bolt. (7) Remove the stabilizer bar link (Refer to 2 -
SUSPENSION/FRONT/STABILIZER REMOVAL).
LINK
(8) Remove the lower ball joint nut. Separate ball joint from the steering knuckle with Remover 8677. (9) Remove the control arm pivot bolts and suspen-
sion arm from frame rail brackets (Fig. 23).
Fig.23LOWERCONTROLARM
1 - LOWER CONTROL ARM 2 - UPPER CONTROL ARM 3 - FRONT BOLT 4 - NUTS 5 - REAR BOLT
REMOVAL - 4X2
(1) Raise and support the vehicle. (2) Remove the tire and wheel assembly. (3) Support the lower control arm at the outboard side of the lower control arm to support vehicle weight.
(4) Remove the shock (Refer to 2 - SUSPENSION/
FRONT/SHOCK - REMOVAL).
(5) Install Spring Compressor DD-1278 up through the lower suspension arm, coil spring and shock hole
in the frame. The bell-shaped adapter goes against the lower suspension arm. Install the nut on top of the tool at the shock hole.
(6) Tighten the spring compressor nut against bell-
shaped adapter finger tight then loosen 1/2 turn.
NOTE: This will hold the spring in place until the lower suspension arm is separated from the steer- ing knuckle.
(7) Remove the stabilizer link (Refer to 2 - SUS- PENSION/FRONT/STABILIZER LINK - REMOVAL). (8) Remove the lower ball joint nut at the steering
knuckle.
(9) Install Ball Joint Remover tool 8677 on the lower ball joint and separate the ball joint from the knuckle.
NOTE: Do not allow the upper control arm and steering knuckle to rebound downwards they must be supported.
(10) Support the upper control arm and steering
knuckle out of the way.
(11) Remove the lower control arm support. (12) Tighten the spring compressor tool to allow clearance for the lower ball joint to be removed out of the knuckle.
(13) Loosen the tension on the spring compressor tool slowly allowing the lower suspension arm to pivot downward.
(14) Remove the spring compressor tool. (15) Remove coil spring and isolator pad from the
(16) Remove the front and rear pivot bolts (Fig.
vehicle (Fig. 26).
24).
(17) Remove the lower control arm.
Fig.24LOWERCONTROLARM-4X2
1 - FRONT PIVOT BOLT 2 - REAR PIVOT BOLT 3 - LOWER CONTROL ARM
DR LOWER CONTROL ARM (Continued) INSTALLATION
INSTALLATION - 4X4 (LD)
(1) Position the lower control arm at the frame rail brackets. Install the pivot bolts and nuts. Tighten the nuts finger-tight.
CAUTION: The ball joint stud taper must be CLEAN and DRY before installing the knuckle. Clean the stud taper with mineral spirits to remove dirt and grease.
(2) Insert the lower ball
joint into the steering knuckle. Install and tighten the retaining nut to 52
N·m (38 ft. lbs.)(on 1500 series only an additional 90° turn is required).(3) Install the torsion bar, (Refer to 2 - SUSPEN-
SION/FRONT/TRACK BAR - INSTALLATION).
(4) Install shock absorber lower bolt and tighten to
135 N·m (100 ft. lbs.).
(5) Install the front halfshaft, (Refer to 3 - DIF- FERENTIAL & DRIVELINE/HALF SHAFT - INSTALLATION).
(6) Insert the upper ball
joint into the steering knuckle. Install and tighten the retaining nut to 54
N·m (40 ft. lbs.)(on 1500 series only an additional 90° turn is required).(7) Install the stabilizer bar link (Refer to 2 - SUS- PENSION/FRONT/STABILIZER LINK - INSTALLA- TION).
(8) Tighten the lower control arm front pivot nut to 204 N·m (150 ft. lbs.). Tighten rear pivot bolt to 204 N·m (150 ft. lbs.).
(9) Install the wheel and tire assembly,(Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE- DURE).(10) Remove the support and lower the vehicle. (11) Adjust the front suspension height and per- form a wheel alignment (Refer to 2 - SUSPENSION/ WHEEL ALIGNMENT - STANDARD PROCEDURE).
INSTALLATION - 4X2
(1) Install the lower control arm into place on the
vehicle.
bolts finger tight.
(2) Install the front and rear control arm pivot
(3) Install the coil spring into the frame pocket(Re- fer to 2 - SUSPENSION/FRONT/SPRING - INSTAL- LATION).
(4) Install
the Spring Compressor DD-1278 up through the lower suspension arm, coil spring and shock hole in the frame.
(5) Tighten the tool nut
to compress the coil
spring.
(6) Remove the support from the upper control
arm and steering knuckle.
FRONT - INDEPENDENT FRONT SUSPENSION
2 - 21
(7) Position the lower ball joint into the steering
knuckle.
(8) Install the retaining nut on the lower ball joint and tighten to 52 N·m (38 ft. lbs.)(on 1500 series only an additional 90° turn is required) or 135 N·m (100
ft. lbs.)(HD 4X2 only).(9) Support the lower control arm at the outboard side of the lower control arm to support vehicle weight.
(10) Remove the spring compressor tool. (11) Install the shock absorber. (Refer to 2 - SUS-
PENSION/FRONT/SHOCK - INSTALLATION).
(12) Install the stabilizer link (Refer to 2 - SUS- PENSION/FRONT/STABILIZER LINK - INSTALLA- TION).
(13) Remove the lower control arm support. (14) Install the wheel and tire assembly and lower the vehicle. (Refer to 22 - TIRES/WHEELS/WHEELS - STANDARD PROCEDURE).
(15) Lower the vehicle to the floor with vehicle weight and Tighten the front and rear control arm pivot bolts to 204 N·m (150 ft. lbs.)(LD) or 285 N·m (210 ft. lbs.)(HD 4X2 only).
(16) Perform a wheel alignment (Refer to 2 - SUS- PENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
SPRING REMOVAL
(1) Raise and support vehicle. (2) Remove the front wheel and tire assembly. (3) Support the lower control arm at the outboard side of the lower control arm to support vehicle weight. (4) Remove the shock absorber (Refer to 2 - SUS-
PENSION/FRONT/SHOCK - REMOVAL).
(5) Install Spring Compressor DD-1278 up through the lower suspension arm, coil spring and shock hole in the frame. The bell-shaped adapter goes against the lower suspension arm. Install the nut on top of the tool at the shock hole (Fig. 25).
(6) Tighten the spring compressor nut against bell-
shaped adapter finger tight then loosen 1/2 turn.
NOTE: This will hold the spring in place until the lower suspension arm is separated from the steer- ing knuckle.
(7) Remove the stabilizer link (Refer to 2 - SUS- PENSION/FRONT/STABILIZER LINK - REMOVAL). (8) Remove the lower ball joint nut at the steering
(9) Install Ball Joint Remover tool 8677 on the lower ball joint and separate the ball joint from the knuckle.
knuckle.
(10)
FRONT - INDEPENDENT FRONT SUSPENSION
2 - 22
SPRING (Continued)DR
Fig.25SPRINGCOMPRESSORTOOL
Fig.26COILSPRING
1 - SPECIAL TOOL DD-1278
2 - BELL-SHAPED ADAPTERNOTE: Do not allow the upper control arm and steering knuckle to rebound downwards they must be supported.Support the upper control arm and steering knuckle out of the way.
(11) Remove the lower control arm support. (12) Tighten the spring compressor tool to allow clearance for the lower ball joint to be removed out of the knuckle.
NOTE: It may necessary to loosen the control arm pivot bolt to allow downward swing.
(13) Loosen the tension on the spring compressor tool slowly allowing the lower suspension arm to pivot downward.
(14) Remove the spring compressor tool. (15) Remove coil spring and isolator pad from the
vehicle (Fig. 26).
INSTALLATION
(1) Tape the isolator pad to the top of the coil spring. Position the spring in the lower suspension arm well. Be sure that the coil spring is seated in the well.
(2) Install Spring Compressor DD-1278 up through the lower suspension arm, coil spring and shock hole in the frame.
(3) Tighten the tool nut
to compress the coil
spring.
1 - COIL SPRING 2 - STEERING KNUCKLE 3 - OUTER TIE ROD END 4 - LOWER CONTROL ARM 5 - SHOCK
(4) Remove the support from the upper control
arm and steering knuckle.
(5) Position the lower ball joint into the steering
knuckle.
(6) Install the retaining nut on the lower ball joint and tighten to 52 N·m (38 ft. lbs.)(on 1500 series only an additional 90° turn is required) or 135 N·m (100
ft. lbs.)(HD 4X2 only).(7) Remove the spring compressor tool. (8) Support the lower control arm at the outboard side of the lower control arm to support vehicle weight.
(9) Install the shock absorber. (Refer to 2 - SUS-
PENSION/FRONT/SHOCK - INSTALLATION).
(10) Install the stabilizer link (Refer to 2 - SUS- PENSION/FRONT/STABILIZER LINK - INSTALLA- TION).
(11) Remove the lower control arm support. (12) Install the wheel and tire assembly and lower the vehicle. (Refer to 22 - TIRES/WHEELS/WHEELS - STANDARD PROCEDURE).
(13) Lower the vehicle to the floor with vehicle weight and Tighten the front and rear control arm pivot bolts if loosened to 204 N·m (150 ft. lbs.)(LD) or 285 N·m (210 ft. lbs.)(HD 4X2 only).
(14) Perform a wheel alignment (Refer to 2 - SUS- PENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
DR
FRONT - INDEPENDENT FRONT SUSPENSION
2 - 23
SHOCK DIAGNOSIS AND TESTING - SHOCK
A knocking or rattling noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching compo- nents. These noises can usually be stopped by tight- ening the attaching nuts. the noise persists, inspect for damaged and worn bushings, and attach- ing components. Repair as necessary if any of these conditions exist.
If
A squeaking noise from the shock absorber may be caused by the hydraulic valving and may be intermit- tent. This condition is not repairable and the shock absorber must be replaced.
The shock absorbers are not refillable or adjust- able. If a malfunction occurs, the shock absorber must be replaced. To test a shock absorber, 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.
The shock absorber bushings do not require any type of lubrication. Do not attempt to stop bushing noise by lubricating them. Grease and mineral oil- base lubricants will deteriorate the bushing.
REMOVAL
REMOVAL - 4X2
(1) Raise and support vehicle. (2) Support the lower control arm outboard end. (3) Remove the upper shock absorber nut, retainer
(4) Remove the lower nuts and remove the shock
and grommet.
absorber.
REMOVAL - 4X4
(1) Raise and support the vehicle. (2) Remove the tire and wheel assembly. (3) Support the lower control arm outboard end. (4) Remove the upper shock nut and with the insu-
lator and retainer (Fig. 27).
(5) Remove the lower shock bolt (Fig. 27). (6) Remove the shock
INSTALLATION
INSTALLATION - 4X2
NOTE: Upper shock nut must be replaced or use Mopar Lock ’N Seal or LoctiteT 242 on existing nut.
Fig.27SHOCK4X4
1 - INSULATOR & RETAINER 2 - NUT 3 - SHOCK ABSORBER 4 - BOLT
(1) Install the lower retainer and grommet on the the shock absorber
shock absorber stud. through the frame bracket hole.
Insert
(2) Install the lower nuts and tighten the nuts to
34 N·m (25 ft. lbs.).
(3) Install the upper grommet, retainer and new nut or use Mopar Lock ’N Seal or Loctitet 242 on existing nut, on the shock absorber stud. Tighten nut to 54 N·m (40 ft. lbs.).
(4) Remove the support from the lower control arm
outboard end.
(5) Lower the vehicle.
INSTALLATION - 4X4
(1) Install the upper part of the shock into the frame bracket with the insulators and retainers (Fig. 27).
(2) Install the nut and Tighten to 54 N·m (40 ft.
lbs.).
(3) Install the lower part of the shock into the lower control arm and Tighten the bolt to 135 N·m (100 ft. lbs.) (Fig. 27).
(4) Remove the support from the lower control arm
outboard end.
(5) Install the tire and wheel assembly (Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE- DURE).(6) Remove the support and lower the vehicle.
2 - 24
FRONT - INDEPENDENT FRONT SUSPENSION
DR
STABILIZER BAR DESCRIPTION
The bar extends across the front underside of the chassis and connects to the frame crossmember. The ends of the bar mount to the lower suspension arm. All mounting points of the stabilizer bar are isolated by bushings (Fig. 28).
(2) Position the stabilizer bar on the frame cross- member brackets and install the bracket and bolts finger-tight (Fig. 29).
NOTE: Check the alignment of the bar to ensure there is no interference with the either frame rail or chassis component. Spacing should be equal on both sides.
(3) Install the stabilizer bar to the stabilizer link
and install the grommets and retainers.
(4) Install
the nuts to the stabilizer link and
tighten to 38 N·m (27 ft. lbs.).
(5) Tighten the brackets to the frame to 61 N·m
(45 ft. lbs.).
STABILIZER LINK
REMOVAL
REMOVAL - 4X4
(1) Raise and support the vehicle. (2) Remove the lower nut (Fig. 29). (3) Remove the upper nut, retainers and grommets
(4) Remove the stabilizer link from the vehicle
(Fig. 29).
(Fig. 29).
REMOVAL - 4X2
(1) Raise and support the vehicle. (2) Remove the lower nut (Fig. 29). (3) Remove the upper nut, retainer and grommets
(4) Remove the stabilizer link from the vehicle
(Fig. 29).
(Fig. 29).
Fig.28STABILIZERBAR
OPERATION
The stabilizer bar is used to minimize vehicle front sway during turns. The bar helps to maintain a flat attitude to the road surface.
REMOVAL
NOTE: To service the stabilizer bar the vehicle should be on a drive on hoist. The vehicle suspen- sion must be at curb height for stabilizer bar instal- lation.
(1) Remove the stabilizer bar link upper nuts and
remove the retainers and grommets (Fig. 29).
(2) Remove the stabilizer bar retainer, bolts and retainers from the frame crossmember (Fig. 29) and remove the bar.
(3) If necessary, remove the bushings from the sta-
bilizer bar.
INSTALLATION
NOTE: To service the stabilizer bar the vehicle must be on a drive on hoist. The vehicle suspension must be at curb height for stabilizer bar installation.
(1) If removed, install the bushings on the stabi-
lizer bar.
Fig.29STABILIZERLINK
1 - STABILIZER LINK 2 - SWAY BAR BRACKET
FRONT - INDEPENDENT FRONT SUSPENSION
2 - 25
(5) Increase the tension on the anchor arm tool until the load is removed from the adjustment bolt and the adjuster nut (Fig. 30).
(6) Turn the adjustment bolt counterclockwise to
remove the bolt and the adjuster nut..
(7) Remove the Special Tool - 8686, allowing the
torsion bar to unload (Fig. 30).
Fig.30LOADING/UNLOADINGTORSIONBAR
1 - SPECIAL TOOL – 8686
2 - CROSSMEMBER(8) Remove torsion bar and anchor. Remove anchor
from torsion bar (Fig. 31).
(9) Remove all foreign material from torsion bar
mounting in anchor and suspension arm.
(10) Inspect adjustment bolt, bearing and swivel
for damage.
DR STABILIZER LINK (Continued) INSTALLATION
INSTALLATION - 4X4
(1) Install the stabilizer link to the vehicle. (2) Install the lower nut and Tighten to 102 N·m
(75 ft. lbs.).
(3) Install the retainers, grommets and upper nut
and Tighten to 38 N·m (27 ft. lbs.).
(4) Remove the support and lower the vehicle.
INSTALLATION - 4X2
(1) Install the stabilizer link to the vehicle (Fig.
(2) Install the lower nut and Tighten to 102 N·m
29).
(75 ft. lbs.).
(3) Install the retainers, grommets and upper nut
and Tighten to 38 N·m (27 ft. lbs.).
(4) Remove the support and lower the vehicle.
TORSION BAR DESCRIPTION
The front of the bar connects to the back side of the lower suspension arm. The rear end of the bar is mounted in a anchor that rests in the frame cross- member.
OPERATION
The torsion bars are used to control ride height and ride quality. The vehicle height is adjusted through an anchor adjustment bolt that increases or decreases the wind up of the torsion bar. Increasing or decreasing the bar angle changes the wind up of the suspension arms.
REMOVAL
CAUTION: The left and right side torsion bars are NOT interchangeable. The bars are identified and stamped R or L, for right or left. The bars do not have a front or rear end and can be installed with either end facing forward.
(1) Raise and support the vehicle with the front
suspension hanging.
(2) Remove the transfer case skid plate (Refer to 13 - FRAME & BUMPERS/FRAME/TRANSFER CASE SKID PLATE - REMOVAL).
NOTE: Count and record the number of turns for installation reference.
(3) Mark the adjustment bolt setting. (4) Install Special Tool - 8686 to the anchor arm
and the cross member (Fig. 30).
Fig.31TORSIONBAR
1 - ANCHOR 2 - SWIVEL 3 - TORSION BAR 4 - LOWER CONTROL ARM
DR
(3) Mount a dial indicator solidly to the frame and
then zero the dial indicator.
(4) Position dial indicator plunger on the topside of
the upper ball joint (Fig. 32).
NOTE: The dial indicator plunger must be perpen- dicular to the machined surface of the ball joint (Fig. 32).
NOTE: Use care not to pry or tear the ball boot, when checking the free play.
joint
(5) Position a pry bar between the steering knuckle and the upper control arm. Pry upwards on the upper control arm (Fig. 32).
(6) If the travel exceeds 0.5 mm (0.020 in.), replace the upper control arm since the upper ball joint is integral to the arm (Refer to 2 - SUSPENSION/ FRONT/UPPER CONTROL ARM - REMOVAL).
(7) If the upper ball joint is within specs reinstall tires (Refer to 22 - TIRES/WHEELS/
the front WHEELS - STANDARD PROCEDURE).
FRONT - INDEPENDENT FRONT SUSPENSION
2 - 26
TORSION BAR (Continued) INSTALLATIONCAUTION: The left and right side torsion bars are NOT interchangeable. The bars are identified and stamped R or L, for right or left. The bars do not have a front or rear end and can be installed with either end facing forward.
(1) Insert torsion bar ends into anchor and suspen-
sion arm.
(2) Position the anchor in the frame crossmember. (3) Install Special Tool - 8686 to the anchor and
the crossmember (Fig. 30).
(4) Increase the tension on the anchor in order to
load the torsion bar.
(5) Install the adjustment bolt and the adjuster
nut.
amount of turns.
member (Fig. 30).
(6) Turn adjustment bolt clockwise the recorded
(7) Remove tool - 8686 from the torsion bar cross-
(8) Install the transfer case skid plate (Refer to 13
- FRAME & BUMPERS/FRAME/TRANSFER CASE SKID PLATE - INSTALLATION).(9) Lower vehicle and adjust the front suspension height (Refer to 2 - SUSPENSION/WHEEL ALIGN- MENT - STANDARD PROCEDURE).
(10) Perform a wheel alignment (Refer to 2 - SUS- PENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
UPPER BALL JOINT DIAGNOSIS AND TESTING - UPPER BALL JOINT
NOTE: If the ball joint is equipped with a lubrication fitting, grease the joint then road test the vehicle before performing test.
(1) Raise the front of the vehicle. Place safety floor stands under both lower control arms as far outboard as possible. Lower the vehicle to allow the stands to support some or all of the vehicle weight.
(2) Remove the front tires.
Fig.32UPPERBALLJOINTPLAY
1 - DIAL INDICATOR 2 - UPPER CONTROL ARM 3 - PRY BAR 4 - KNUCKLE 5 - BALL JOINT BOOT
DR
FRONT - INDEPENDENT FRONT SUSPENSION
2 - 27
UPPER CONTROL ARM REMOVAL
(5) Remove the control arm pivot bolts and remove
control arm (Fig. 34).
(1) Raise and support vehicle. (2) Remove wheel and tire assembly. (3) Remove the nut from upper ball joint. (4) Separate upper ball
joint from the steering
knuckle with Remover 8677 (Fig. 33)
CAUTION: When installing Remover 8677 to sepa- rate the ball joint, be careful not to damage the ball joint seal.
Fig.33UPPERBALLJOINTSEPARATION
1 - UPPER CONTROL ARM 2 - REMOVER 3 - STEERING KNUCKLE
Fig.34UPPERCONTROLARM
1 - REAR PIVOT BOLT 2 - FRONT PIVOT BOLT 3 - UPPER CONTROL ARM
INSTALLATION
(1) Position the control arm into the frame brack- ets. Install bolts and tighten to 132 N·m (97 ft. lbs.)(LD) or 170 N·m (125 ft. lbs.)(HD 4X2 only).
(2) Insert the ball joint in steering knuckle and tighten the upper ball joint nut to 54 N·m (40 ft. lbs.)(on 1500 series only an additional 90° turn is required).
(3) Install the wheel and tire assembly,(Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE- DURE).(4) Remove the support and lower vehicle. (5) Perform a wheel alignment, (Refer to 2 - SUS- PENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
2 - 28
FRONT - LINK/COIL
FRONT - LINK/COIL
TABLE OF CONTENTS
page
DR
page
FRONT - LINK/COIL SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 28
SPECIAL TOOLS
9 1/4 AA
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
HUB / BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31LOWER BALL JOINT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33UPPER BALL JOINT
REMOVAL - RIGHT
. . . . . . . . . . . . . . . . . . . . 34
INSTALLATION
INSTALLATION - LEFT . . . . . . . . . . . . . . . . . . 34
INSTALLATION - RIGHT . . . . . . . . . . . . . . . . 34
LOWER SUSPENSION ARMREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35SHOCK
DIAGNOSIS AND TESTING - SHOCK . . . . . . . . 35
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35SPRING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36KNUCKLE
STABILIZER BAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37UPPER SUSPENSION ARM
REMOVAL
REMOVAL - LEFT
. . . . . . . . . . . . . . . . . . . . . 34
FRONT - LINK/COIL
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION Shock Absorber
Upper Nut
Shock Absorber
Lower Bolt
Lower Suspension Arm
Frame Nuts
Lower Suspension Arm
Axle Nut
Upper Suspension Arm
Frame Nuts
Upper Suspension Arm
Axle Nut
Stabilizer Bar Frame Bolt
Stabilizer Link
Lower Control Arm Nut
N·m 54
121
217
217
149
149
61
102
Ft. Lbs.
In. Lbs.
40
89
160
160
110
110
45
75
—
—
—
—
—
—
—
—
DR FRONT - LINK/COIL (Continued)
FRONT - LINK/COIL
2 - 29
DESCRIPTION Stabilizer Link
Stabilizer Bar Nut
Hub/Bearing
Bolts
Axle Nut
Tie Rod End
Nut
N·m 38
202
Ft. Lbs.
27
149
179 Beginning Torque, Then Rotate 5 to 10 Times With a
132 Beginning Torque, Then Rotate 5 to 10 Times With a
Final Torque of 356
Final Torque of 263
75
55
In. Lbs.
—
—
—
—
NOTE: Suspension components with rubber/ure- thane bushings should be tightened with the vehi- cle at normal ride height. It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. If springs are not at their normal ride position, vehicle ride comfort could be affected and premature bushing wear may occur.
SPECIAL TOOLS
9 1/4 AA
REMOVER/INSTALLERBALLJOINT-8445
PullerC-3894–A
Remover,WheelStudC-4150A
RECEIVERCUP-6761
BALLJOINTPRESS-C-4212F
BALLJOINTRECIEVER/INSTALLERKIT-8975
2 - 30
FRONT - LINK/COIL
HUB / BEARING REMOVAL
(1) Raise and support the vehicle. (2) Remove the wheel and tire assembly. (3) Remove the hub extension mounting nuts and remove the extension from the rotor if equipped (Fig. 1).
DR
(7) Back off the hub/bearing mounting bolts 1/4
inch each (Fig. 3). Then tap the bolts with a hammer to loosen the hub/bearing from the steering knuckle. (8) Remove the hub/bearing mounting bolts andremove the hub/bearing.
Fig.3Hub/BearingMountingBolts
1 - SOCKET AND EXTENSION 2 - ROTOR AND HUB 3 - STEERING KNUCKLE
(9) Remove the rotor assembly (Fig. 4), brake
shield and spacer from the steering knuckle.
to 5 -
Fig.1HubExtension
1 - HUB EXTENSION 2 - HUB
(4) Remove the brake caliper,
(Refer
BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - REMOVAL).
(5) Remove the cotter pin and the hub nut from
the axle shaft (Fig. 2).
Fig.2HubNutCotterPin
1 - HUB NUT 2 - COTTER PIN
(6) Disconnect the ABS wheel speed sensor wire from under the hood. Remove the sensor wire from the frame and steering knuckle if equipped.
Fig.4RotorHub/BearingAssembly
1 - ROTOR AND HUB 2 - UNIT BEARING ASSEMBLY 3 - SEAL
(10) Press out the wheel studs/hub extension studs
and separate the rotor from the hub (Fig. 5).
(11) Remove the wheel speed sensor (Fig. 6) from
the hub bearing if equipped.
DR HUB / BEARING (Continued)
FRONT - LINK/COIL
2 - 31
Fig.5ROTORANDHUB/BEARING
1 - HUB BEARING 2 - ROTOR
Fig.6WheelSpeedSensor
1 - HUB BEARING 2 - WHEEL SPEED SENSOR
INSTALLATION
(1) Install the wheel speed sensor in the hub bear-
ing if equipped.
(2) Position the rotor on the hub/bearing. (3) Press the wheel studs/hub extension studs through the back side of the rotor and through the hub bearing flange (Fig. 7).
(4) Apply a liberal quantity of anti-seize compound
to the splines of the front drive shaft.
(5) Insert the two rearmost, top and bottom rotor hub bolts in the steering knuckle. Insert the bolts through the back side of the knuckle so they extend out the front face as shown.
(6) Position the hub spacer (Fig. 8) and brake
shield (Fig. 9) on bolts just installed in knuckle.
Fig.7Rotor,Hub/BearingAndStud
1 - HUB BEARING 2 - ROTOR 3 - STUD
NOTE: If the vehicle is equipped with a wheel speed sensor the brake shield must be positioned on the hub bearing (Fig. 10).
Fig.8HubSpacer
1 - ROTOR HUB BOLTS 2 - HUB SPACER (POSITION FLAT TO REAR) 3 - APPLY ANTI-SEIZE COMPOUND TO SPLINES
(7) Align the rotor hub with the drive shaft and
start the shaft into the rotor hub splines.
NOTE: Position wheel speed sensor wire at the top of the knuckle if equipped.
FRONT - LINK/COIL
2 - 32
HUB / BEARING (Continued)DR
(9) Install the remaining bolts. Tighten the hub/
bearing bolts to 202 N·m (149 ft. lbs.
(10) Install the washer and axle nut and tighten a
beginning torque of 179 N·m (132 ft. lbs.).
(11) Rotate the axle 5 to 10 times to seat the hub
(12) Tighten to a final torque of 356 N·m (263 ft.
bearing.
lbs.).
(13) Align the axle nut to the next forward cotter pin hole and install a new cotter pin in the axle nut. to 5 -
the brake caliper,
(14) Install
(Refer
BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - INSTALLATION).
(15) Install the sensor wire to the steering knuckle and frame and if equipped. Connect the wheel speed sensor wire under the hood.
(16) Install the wheel and tire assemblies, (Refer to 22 - TIRES/WHEELS/WHEELS - STANDARD PROCEDURE).
(17) Remove the support and lower the vehicle. (18) Apply the brakes several times to seat the brake shoes and caliper piston. Do not move the vehi- cle until a firm brake pedal is obtained.
LOWER BALL JOINT REMOVAL
(1) Remove lower snap ring from the lower ball
joint (Fig. 11).
Fig.9BrakeShield
1 - BRAKE SHIELD 2 - HUB BEARING BOLTS 3 - STEERING KNUCKLE
Fig.10BrakeShieldWithWheelSpeedSensor
1 - WHEEL SPEED SENSOR 2 - HUB BEARING 3 - SHIELD
(8) Align the bolt holes in the hub bearing flange with the bolts installed in the knuckle. Then thread the bolts into the bearing flange far enough to hold the assembly in place.
Fig.11LOWERSNAPRING
(2) Position special tool 8975–2 (RECEIVER) and 8975–4 (DRIVER) with tool C4212–F as shown to remove lower ball stud (Fig. 12).
DR LOWER BALL JOINT (Continued)
FRONT - LINK/COIL
2 - 33
UPPER BALL JOINT REMOVAL
(1) Position special tool 6761 (RECEIVER) and shown to
8445–3 (DRIVER) with C-4212–F as remove upper ball stud (Fig. 14).
Fig.12LOWERBALLJOINTREMOVAL
1 - SPECIAL TOOL C4212-F 2 - SPECIAL TOOL 8975-2
3 - KNUCKLE 4 - SPECIAL TOOL 8975-4INSTALLATION
(1) Position special
tool 8975–1 (DRIVER) and 8975–3 (RECEIVER) with C4212–F as shown to install lower ball stud (Fig. 13).
Fig.14UPPERBALLJOINTREMOVAL
1 - SPECIAL TOOL C4212-F 2 - SPECIAL TOOL 6761
3 - KNUCKLE 4 - SPECIAL TOOL 8445-3INSTALLATION
(1) Position special
tool 8445–2 (DRIVER) and 8975–5 (RECEIVER) with C-42121–F as shown to install upper ball stud (Fig. 15).
Fig.13LOWERBALLJOINTINSTALLATION
1 - SPECIAL TOOL C4212-F 2 - SPECIAL TOOL 8975-1
3 - BALL JOINT 4 - KNUCKLE 5 - SPECIAL TOOL 8975-3Fig.15UPPERBALLJOINTINSTALLATION
1 - SPECIAL TOOL C4212-F 2 - SPECIAL TOOL 8445-2
3 - BALL JOINT 4 - KNUCKLE 5 - SPECIAL TOOL 8975-52 - 34
FRONT - LINK/COIL
DR
KNUCKLE REMOVAL
(1) Remove the hub bearing (Refer to 2 - SUSPEN-
SION/FRONT/HUB / BEARING - REMOVAL).
(2) Remove tie-rod or drag link end from the steer-
ing knuckle arm.
(3) Remove the ABS sensor wire and bracket from
knuckle. Refer to Brakes, for proper procedures.
(4) Remove the cotter pin from the upper ball stud
nut. Remove the upper and lower ball stud nuts.
(5) Strike the steering knuckle with a brass ham-
(6) Remove knuckle from axle tube yokes.
mer to loosen.
INSTALLATION
(1) Position the steering knuckle on the ball studs. (2) Install and tighten lower ball stud nut to 47
N·m (35 ft. lbs.) torque. Do not install cotter pin at this time.(3) Install and tighten upper ball stud nut to 94
N·m (70 ft. lbs.) torque. Advance nut to next slot to line up hole and install new cotter pin.(4) Retorque lower ball stud nut to 190–217 N·m (140–160 ft. lbs.) torque. Advance nut to next slot to line up hole and install new cotter pin.
(5) Install the hub bearing (Refer to 2 - SUSPEN- SION/FRONT/HUB / BEARING - INSTALLATION). (6) Install tie-rod or drag link end onto the steer-
ing knuckle arm.
(7) Install the ABS sensor wire and bracket to the
knuckle. Refer to Brakes, for proper procedure.
UPPER SUSPENSION ARM
REMOVAL
REMOVAL - LEFT
Fig.16Link/CoilSuspension
1 - STABILIZER BAR 2 - SHOCK ABSORBER 3 - COIL SPRING 4 - UPPER SUSPENSION ARM 5 - LOWER SUSPENSION ARM 6 - TRACK BAR
(7) Remove the nut and bolt at the frame rail and
remove the upper suspension arm.
(8) Remove the upper suspension arm nut and bolt
at the axle bracket.
(9) Remove the suspension arm from the vehicle.
INSTALLATION
INSTALLATION - LEFT
(1) Position the upper suspension arm at the axle
and frame rail.
(2) Install the bolts and finger tighten the nuts. (3) Remove the supports and lower the vehicle. (4) Tighten nut at the axle bracket to 163 N·m (120 ft. lbs.). Tighten nut at frame bracket to 163
N·m (120 ft. lbs.).(1) Raise and support the vehicle. (2) Remove the upper suspension arm nut and bolt
INSTALLATION - RIGHT
at the axle bracket (Fig. 16).
(1) Position the upper suspension arm at the axle
(3) Remove the nut and bolt at the frame rail and
and frame rail.
remove the upper suspension arm.
REMOVAL - RIGHT
(1) Raise and support the vehicle. (2) Disconnect the exhaust system at the mani-
(3) Disconnect the rubber exhaust mounts at the
folds.
muffler.
(4) Support the transmission. (5) Remove the transmission cross member. (6) Lower the exhaust system down in order to
gain access to the removal of the upper bolt.
(2) Install the bolts, then finger tighten the nuts. (3) Reconnect the rubber exhaust mounts at the
muffler.
(4) Reconnect the exhaust at the manifolds. (5) Install the transmission crossmember. (6) Remove the supports and lower the vehicle. (7) Tighten nut at the axle bracket to 163 N·m (120 ft. lbs.). Tighten nut at frame bracket to 163
N·m (120 ft. lbs.).DR
FRONT - LINK/COIL
2 - 35
LOWER SUSPENSION ARM REMOVAL
(1) Raise and support the vehicle. (2) Paint or scribe alignment marks on the cam adjusters and suspension arm for installation refer- ence (Fig. 17).
Fig.17AdjustmentCam
1 - ADJUSTMENT CAM 2 - AXLE BRACKET 3 - BRACKET REINFORCEMENT 4 - LOWER SUSPENSION ARM
(3) Remove the lower suspension arm nut, cam
and cam bolt from the axle.
(4) Remove the nut and bolt from the frame rail bracket and remove the lower suspension arm (Fig. 17).
INSTALLATION
bracket and frame rail bracket.
(2) Install the rear bolt and finger tighten the nut. (3) Install the cam bolt, cam and nut in the axle
and align the reference marks.
(4) Remove support and lower the vehicle. (5) Tighten cam nut at the axle bracket to 217
lbs.). Tighten rear nut at the frameN·m (160 ft. bracket to 217 N·m (160 ft. lbs.).
SHOCK DIAGNOSIS AND TESTING - SHOCK
A knocking or rattling noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching compo- nents. These noises can usually be stopped by tight- ening the attaching nuts. the noise persists, inspect for damaged and worn bushings, and attach- ing components. Repair as necessary if any of these conditions exist.
If
A squeaking noise from the shock absorber may be caused by the hydraulic valving and may be intermit- tent. This condition is not repairable and the shock absorber must be replaced.
The shock absorbers are not refillable or adjust- able. If a malfunction occurs, the shock absorber must be replaced. To test a shock absorber, 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.
The shock absorber bushings do not require any type of lubrication. Do not attempt to stop bushing noise by lubricating them. Grease and mineral oil- base lubricants will deteriorate the bushing.
REMOVAL
(1) Remove the nut, retainer and grommet from
the upper stud in the engine compartment.
(2) Remove three nuts from the upper shock
bracket (Fig. 18).
(3) Remove the lower bolt from the axle bracket (Fig. 19). Remove the shock absorber from engine compartment.
INSTALLATION
(1) Position the lower retainer and grommet on the upper stud. Insert the shock absorber through the spring from engine compartment.
(2) Install the lower bolt and tighten to 135 N·m
(100 ft. lbs.).
Tighten nuts to 75 N·m (55 ft. lbs.).
(4) Install upper grommet and retainer. Install
upper shock nut and tighten to 47 N·m (35 ft. lbs).
(1) Position the lower suspension arm at the axle
(3) Install the upper shock bracket and three nuts.
FRONT - LINK/COIL
2 - 36
SHOCK (Continued)DR
SPRING REMOVAL
(1) Raise and support
the vehicle. Position a
hydraulic jack under the axle to support it.
(2) Paint or scribe alignment marks on lower sus- pension arm cam adjusters and axle bracket for installation reference.
(3) Remove the upper suspension arm and loosen
lower suspension arm bolts.
(4) Mark and disconnect the front propeller shaft
from the axle 4x4 models.
(5) Disconnect the track bar from the frame rail
bracket.
(6) Disconnect the drag link from pitman arm. (7) Disconnect the stabilizer bar link and shock
absorber from the axle.
(8) Lower the axle until the spring is free from the
upper mount. Remove the coil spring.
INSTALLATION
(1) Position the coil spring on the axle pad. (2) Raise the axle into position until the spring
seats in the upper mount.
(3) Connect the stabilizer bar links and shock absorbers to the axle bracket. Connect the track bar to the frame rail bracket.
(4) Install the upper suspension arm. (5) Install the front propeller shaft to the axle 4x4
model.
(6) Install drag link to pitman arm and tighten
nut to specifications. Install new cotter pin.
to specifications:
(7) Remove the supports and lower the vehicle. (8) Tighten the following suspension components † Link to stabilizer bar nut. † Lower shock bolt. † Track bar bolt at axle shaft tube bracket. † Upper suspension arm nut at axle bracket. † Upper suspension nut at frame bracket. † Align lower suspension arm reference marks and † Lower suspension nut at frame bracket.
tighten cam nut.
Fig.18ShockAbsorberandBracket
1 - GROMMET 2 - RETAINER 3 - BRACKET 4 - RETAINER 5 - SHOCK 6 - GROMMET
Fig.19ShockAbsorberAxleMount
1 - SHOCK 2 - SPRING 3 - FLAG NUT 4 - SHOCK BOLT
DR
FRONT - LINK/COIL
2 - 37
STABILIZER BAR REMOVAL
(1) Raise and support the vehicle. (2) Hold the stabilizer link shafts with a wrench
and remove the link nuts at the stabilizer bar.
(3) Remove the retainers and grommets from the
stabilizer bar links.
axle brackets.
(4) Remove the stabilizer bar link nuts from the
(5) Remove the links from the axle brackets with
Puller C-3894-A (Fig. 20).
(6) Remove the stabilizer bar clamps from the
frame rails and remove the stabilizer bar.
INSTALLATION
(1) Position the stabilizer bar on the frame rail and install the clamps and bolts. Ensure the bar is centered with equal spacing on both sides.
(2) Tighten the clamp bolts to 61 N·m (45 ft. lbs.). (3) Install links to the axle bracket and tighten
nut to 47 N·m (35 ft. lbs.).
(4) Install links, retainers, grommets and nuts to the stabilizer bar. Hold the link shaft with a wrench and tighten the nuts to 37 N·m (27 ft. lbs.).
(5) Remove the supports and lower the vehicle.
Fig.20StabilizerLink
1 - PULLER 2 - LINK
2 - 38
REAR
REAR
TABLE OF CONTENTS
page
DR
page
REAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 38
DIAGNOSIS AND TESTING - SPRING ANDSHOCK
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 39
BUSHINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40
SHOCK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40SPRING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 41
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41JOUNCE BUMPER
SPRING TIP INSERTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42AUXILIARY SPRING BUMPERS (3500)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
REAR DESCRIPTION
The rear suspension is comprised of: † Shock Absorbers † Jounce Bumpers † Stabilizer Bar (optional) † Leaf Springs † Auxiliary Leaf Spring (3500 series) † Auxiliary Spring Bumpers (3500 series) † Drive Axle
CAUTION: A vehicle should always be loaded so the vehicle weight center-line is located immedi- ately forward of the rear axle. Correct vehicle load- ing provides proper front tire-to-road contact. This results in maximum vehicle handling stability and safety. Incorrect vehicle weight distribution can cause excessive tire tread wear, spring fatigue or failure, and erratic steering.
CAUTION: Suspension components with rubber/ure- thane bushings (except stabilizer bar) should be tightened with the vehicle at normal ride height. It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. If springs are not at their normal ride position, vehicle ride comfort could be affected and premature bush- ing wear may occur.
DIAGNOSIS AND TESTING - SPRING AND SHOCK
A knocking or rattling noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching compo- nents. These noises can usually be stopped by tight- ening the attaching nuts. the noise persists, inspect for damaged and worn bushings, and attach- ing components. Repair as necessary if any of these conditions exist.
If
A squeaking noise from the shock absorber may be caused by the hydraulic valving and may be intermit- tent. This condition is not repairable and the shock absorber must be replaced.
The shock absorbers are not refillable or adjust- able. If a malfunction occurs, the shock absorber must be replaced. To test a shock absorber, 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.
The spring eye and shock absorber bushings do not require any type of lubrication. Do not attempt to stop spring bushing noise by lubricating them. Grease and mineral oil-base lubricants will deterio- rate the bushing rubber.
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 clips, and broken center bolts. Refer to Spring and Shock Absorber Diagnosis chart for additional information.
DR REAR (Continued)
REAR
2 - 39
SPRING AND SHOCK ABSORBER
CONDITION
POSSIBLE CAUSES
CORRECTION
SPRING SAGS
1. Broken leaf.
2. Spring fatigue.
1. Replace spring.
2. Replace spring.
SPRING NOISE
1. Loose spring clamp bolts.
1. Tighten to specification.
2. Worn bushings. 3. Worn or missing spring tip inserts.
2. Replace bushings. 3. Replace spring tip inserts.
1. Loose mounting fastener. 2. Worn bushings. 3. Leaking shock.
1. Tighten to specification. 2. Replace shock. 3. Replace shock.
TORQUE SPECIFICATIONS
N·m 135
135
149
163
163
40
41
Ft. Lbs.
In. Lbs.
100
100
110
120
120
30
30
INSTALLATION
—
—
—
—
—
—
—
SHOCK NOISE
SPECIFICATIONS
TORQUE CHART
DESCRIPTION Shock Absorber
Lower Nut
Shock Absorber
Upper Nut
Spring Clamp U-Bolts
Nuts Spring
Front & Rear Bolt & Nut
Spring
Spring Rear Shackle Nuts
Jounce Bumper
Bolts
Auxialiary Spring Bumpers
BUSHINGS REMOVAL
(1) Remove the spring from the vehicle. (2) Make small relief cuts in the flared up end of the bushing metal being careful not to cut the spring. Use a punch to bend the flared bushing metal down for push out.
(3) Position the spring eye in a press. (4) Press the bushing out with an appropriate size
driver.
(1) Press new bushing into the spring eye with an appropriate size driver. The bushing should be cen- tered in the spring eye.
(2) Stake the outermetal of the bushing in a mini-
mum of six points to retain the bushing.
(3) Install the spring on the vehicle.
2 - 40
REAR
JOUNCE BUMPER REMOVAL
DR
(1) Remove the two bolts securing the jounce
bumper to the bracket (Fig. 1).
(2) Remove the jounce bumper.
Fig.1JOUNCEBUMPER
1 - MOUNTING BOLTS 2 - JOUNCE BUMPER
INSTALLATION
Fig.2AUXILIARYSPRINGBUMPER(3500)
1 - NUTS 2 - AUXILIARY SPRING BUMPERS
SHOCK REMOVAL
(1) Raise vehicle and support the axle. (2) Remove the upper shock bolt and nut (Fig. 3). (3) Remove the lower shock bolt and nut. (4) Remove the rear shock absorber from the vehicle.
(1) Install the jounce bumper. (2) Install
the two bolts
securing the jounce bumper to the bracket. Tighten the bolts to 40 N·m (30 ft. lbs.).
AUXILIARY SPRING BUMPERS (3500) REMOVAL
(1) Remove the nut securing the auxiliary spring
bumper to the bracket (Fig. 2).
(2) Remove the auxiliary spring bumper.
INSTALLATION
(1) Install the auxiliary spring bumper. (2) Install the nut securing the auxiliary spring bumper to the bracket (Fig. 2). Tighten the nut to 61
N·m (45 ft. lbs.).Fig.3SHOCKABSORBER
1 - NUT 2 - AXLE 3 - SHOCK ABSORBER
INSTALLATION
(1) Position the shock absorber in the brackets. (2) Install the bolts through the brackets and the shock. Install the flag nut on the top bolt and nut on lower bolt.
(3) Tighten the upper and lower bolt/nuts Tighten
to 135 N.m (100 ft. lbs.)
(4) Remove the support and lower the vehicle.
DR
SPRING DESCRIPTION
The rear suspension system uses a multi-leaf springs and a solid drive axle. The forward end of the springs are mounted to the body rail hangers through rubber bushings. The rearward end of the springs are attached to the body by the use of shack- les. The spring and shackles use rubber bushings.
OPERATION
The springs control ride quality and maintain vehi- cle ride height. The shackles allow the springs to change their length as the vehicle moves over various road conditions.
REMOVAL
(1) Raise and support the vehicle. (2) Support the axle with a suitable holding fix-
ture.
(3) Remove the nuts, spring clamp bolts and the
plate that attach the spring to the axle (Fig. 4).
(4) Remove the nuts and bolts from the spring
front and rear shackle (Fig. 4).
(5) Remove the spring from the vehicle.
REAR
2 - 41
INSTALLATION
(1) Position spring on axle shaft tube so spring center bolt is inserted into the locating hole in the axle tube.
(2) Align the front of the spring with the bolt hole in
the front bracket. Install the eye pivot bolt and nut.
(3) Align the rear of the spring into the shackle
and install the bolt and nut.
(4) Tighten the spring front and rear eye pivot bolt
snug do not torque.
retaining nuts.
(5) Install the spring clamp bolts, plate and the
(6) Remove the holding fixture for the rear axle. (7) Remove the supports and lower the vehicle so
that the weight is being supported by the tires.
(8) Tighten the spring clamp retaining nuts to 149
N·m (110 ft. lbs.).
(9) Tighten the spring front and rear pivot bolt
nuts to 163 N·m (120 ft. lbs.).
SPRING TIP INSERTS REMOVAL
(1) Raise and support the vehicle. (2) Remove both rear tireand wheel assemblies (3) Position a large C-Clamp adjacent to the spring clinch clip and clamp the leaves of the spring together
CAUTION: When working on the front leaf spring clinch clamps finish the front before starting on the rear to prevent personal injury.
(4) Use an appropriate pry bar to bend open the spring clinch clip (Fig. 5). If necessary, remove the existing spring clinch clip isolators.
Fig.4REARSPRING
1 - LEAF SPRING 2 - PLATE 3 - NUTS 4 - FRONT NUT & BOLT 5 - SPRING CLAMP BOLTS 6 - SHACKLES
Fig.5C-CLAMPANDPRYBAR
1 - REAR LEAF SPRING CLINCH CLAMP 2 - PRY BAR 3 - C-CLAMP
REAR
2 - 42
SPRING TIP INSERTS (Continued)DR
(5) Use the pry bar to spread apart the leaf (Fig. 6). The clearance between the leaves should be enough to remove the old liner (if necessary) and install the replacement liner.
NOTE: THE SPRING TIP LINER IS PROPERLY INSTALLED WHEN THE RETAINING PIN IS POINT- ING TOWARD THE PAVEMENT AND THE WEAR PAD IS CONTACTING THE LEAF SPRING.
Fig.6SPRINGSEPARATION
Fig.8CLINCHCLIP
1 - REAR LEAF SPRING 2 - PRY BAR
1 - C-CLAMP 2 - SPRING CLINCH CLAMP
(6) If necessary, remove the old spring tip liner
(Fig. 7).
Fig.7SPRINGTIPLINERREMOVAL
1 - SPRING TIP LINER 2 - RUBBER MALLET
INSTALLATION
(1) With the prybar still
inserted between the
leaves, install a new spring tip liner onto the leaf.
(2) Firmly seat the spring tip liner onto the leaf. A C-Clamp can be used to compress the adjacent leaves together (Fig. 8) which will seat the liner retaining pin into the hole.
(3) Apply a small amount of lubricant oil onto the
tip liner wear pad.
(4) Install all the spring tip liners. (5) Place one spring clinch clip isolator onto the outboard side of the spring clinch clip (Fig. 9) and one isolator on the inboard side of the spring clinch clip.
Fig.9CLINCHCLIPISOLATOR
1 - SPRING CLINCH CLIP ISOLATOR 2 - C-CLAMP
DR SPRING TIP INSERTS (Continued)
(6) Using large adjustable pliers, close the spring clinch clip until the isolator contacts the leaf spring (Fig. 10).
CAUTION: DO NOT USE A HAMMER TO CLOSE THE SPRING CLINCH CLIP. DAMAGE TO THE ISOLATOR MAY RESULT.
REAR
2 - 43
(7) Use an appropriate pry bar to bend open the spring clinch clip. If necessary, remove the existing spring clinch clip isolators.
(8) Repeat procedure for the other side of the vehi-
cle.
(9) Iinstall the tire wheel assemblies. (10) Lower the vehicle.
Fig.10CLINCHCLIPREASSEMBLY
1 - SPRING CLINCH CLIP 2 - ADJUSTABLE PLIERS 3 - C-CLAMP
DR
DIFFERENTIAL & DRIVELINE
3 - 1
DIFFERENTIAL & DRIVELINE
TABLE OF CONTENTS
page
page
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . 1
HALF SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
FRONT AXLE - C205F
