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CONTENTS
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ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 FRONT SUSPENSION2WD . . . . . . . . . . . . . . . . 6

FRONT SUSPENSION4WD . . . . . . . . . . . . . . . 15 REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . 22

ALIGNMENT
INDEX
page GENERAL INFORMATION WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . 1 SERVICE PROCEDURES PRE-ALIGNMENT INSPECTION . . . . . . . . . . . . . . 1 page SUSPENSION HEIGHT (4WD) . . . . . . . . . . . . . . . 4 WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . 4 SPECIFICATIONS FRONT WHEEL ALIGNMENT SPECIFICATIONS . . 5 TOE is the difference between the leading inside edges and trailing inside edges of the front tires. Uneven wheel toe position causes unstable steering, uneven tire wear and steering wheel off- center. The wheel toe position is the final front wheel alignment adjustment. STEERING AXIS INCLINATION ANGLE is measured in degrees. It is the angle that the steering knuckles are tilted. The inclination angle has a fixed relationship with the camber angle. It will not change except when a spindle or ball stud is damaged or bent. The angle is not adjustable and the damaged component(s) must be replaced to correct mis- alignment. CAUTION: Do not attempt to modify any suspension or steering component by heating and bending.

GENERAL INFORMATION WHEEL ALIGNMENT

Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning is accomplished through suspension and steering linkage adjustments. An alignment is considered essential for efficient steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are caster, camber and toe (Fig. 1). NOTE: Routine inspection of the front suspension and steering components is a good preventative maintenance practice. Inspection also helps to ensure safe operation of the vehicle. CASTER is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle forward provides negative caster. Tilting the top of the knuckle rearward provides positive caster. Positive caster promotes directional stability. This angle enables the front wheels to return to a straight ahead position after turns. CAMBER is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire.

SERVICE PROCEDURES PRE-ALIGNMENT INSPECTION

Before starting wheel alignment, the following inspection and necessary corrections must be completed. Refer to Suspension and Steering System Diagnosis Chart for additional information. (1) Tires with the same recommended air pressure, size, and tread wear. Refer to Group 22, Wheels and Tires for diagnosis information.

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SERVICE PROCEDURES (Continued)

(2) Inspect front wheel bearings for wear or adjustment. (3) Inspect front wheels for excessive radial, lateral runout and unbalance. Refer to Group 22, Wheels and Tires for diagnosis information. (4) Inspect ball studs, linkage pivot points and steering gear for looseness, roughness, binding or a sticking condition. Refer to Group 19, Steering for additional information. (5) Inspect suspension components for wear and noise. Check components for correct torque.

Fig. 1 Wheel Alignment Measurements

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SERVICE PROCEDURES (Continued)
SUSPENSION AND STEERING SYSTEM DIAGNOSIS

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SERVICE PROCEDURES (Continued)

SUSPENSION HEIGHT (4WD)

The front suspension of a new vehicle will settle slightly during the first 2,000 miles/3,200 km of operation. To compensate for this, the front suspension height is slightly higher than the service specification height. A vehicle with less than 2,000 miles/3,200 km, SHOULD NOT be adjusted downward. The torsion bars have not set and can be no more than 0.5 inch (12.7 mm) higher than specifications. (1) Clean the surface areas where the suspension arm height will be measured (Fig. 2).

Fig. 3 Suspension Arm Height Adjustment

WHEEL ALIGNMENT
CAMBER AND CASTER ADJUSTMENT Camber and caster angle adjustments involve changing the position of the upper suspension arm pivot bar (Fig. 4).

Fig. 2 Height Measurement (4WD)

(2) Measure the suspension arm height according to the following instructions: Inner measurementfrom the floor surface to the underside of the pivot bores between the webs (Fig. 2). Outer measurementfrom the floor surface to the underside of the rear edge inboard of the steering stop (Fig. 2). (3) The height of each front suspension arm is adjusted by turning the torsion bar adjustment bolt (Fig. 3). CLOCKWISE to raise the vehicle. COUNTERCLOCKWISE to lower the vehicle. (4) After each adjustment, jounce the vehicle before measuring to determine the effects of the adjustment.

Fig. 4 Caster & Camber Adjustment Location

NOTE: The suspension arm heights at both sides of the vehicle must be measured even if only one side was adjusted. (5) The difference in height between the inner and outer measurement should be 38.00 mm (1.50 in.) plus or minus 6.4 mm (1/4 in.). The side-to-side height difference should not be more than 6.4 mm (0.25 in.). CASTER: Move only the rear position of the pivot bar in or out. This will change the caster angle significantly and camber angle only slightly. To retain the camber while adjusting caster, move the rear pivot bar in or out. Move the forward pivot very slightly in the opposite direction.

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SERVICE PROCEDURES (Continued)
NOTE: For example, to increase a positive caster angle, move the rear position of the pivot bar inward (toward the engine). Move the front of pivot bar outward (away from the engine) slightly until the original camber angle is obtained. CAMBER: Move only the forward position of the pivot bar in or out. This will change the camber angle significantly and caster angle only slightly. The camber angle should be adjusted as close as possible to the service specification. After adjustment is made tighten the pivot bar nuts to 210 Nm (155 ft. lbs.) torque.

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Fig. 5 Toe Adjustment (2WD)

TOE ADJUSTMENT The wheel toe position adjustment should be the final adjustment. (1) Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. (2) Loosen the tie rod adjustment sleeve clamp bolts/nuts.
NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead. (3) Adjust the wheel toe position by turning the tie rod adjustment sleeves as necessary (Fig. 5) and (Fig. 6). (4) Tighten the tie rod adjustment;

Fig. 6 Toe Adjustment (4WD)

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

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FRONT SUSPENSION2WD
INDEX
page DESCRIPTION AND OPERATION 2WDSUSPENSION COMPONENTS . . . . . . . . . 6 DIAGNOSIS AND TESTING LOWER BALL STUD . . . . . . . . . . . . . . . . . . . . . . 6 SHOCK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 7 UPPER BALL STUD . . . . . . . . . . . . . . . . . . . . . . . 7 REMOVAL AND INSTALLATION COIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 LOWER SUSPENSION ARM . . . . . . . . . . . . . . . . 9 SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . 7 STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . 10 STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . . 8 page UPPER SUSPENSION ARM . . . . . . . . . . . . . . . . . 9 WHEEL BEARINGS (2WD) . . . . . . . . . . . . . . . . . 10 WHEEL STUDS . . . . . . . . . . . . . . . . . . . . . . . . . 11 DISASSEMBLY AND ASSEMBLY LOWER BALL STUD . . . . . . . . . . . . . . . . . . . . . . 11 UPPER BALL STUD . . . . . . . . . . . . . . . . . . . . . . 12 CLEANING AND INSPECTION WHEEL BEARING . . . . . . . . . . . . . . . . . . . . . . . 13 SPECIFICATIONS TORQUE CHART2WD . . . . . . . . . . . . . . . . . . . 13 SPECIAL TOOLS FRONT SUSPENSION 2WD . . . . . . . . . . . . . . . . 14 caster and camber adjustment. The lower suspension arms use replaceable pressed in bushings to isolate road noise. The suspension arms are bolted to the frame and pivot through rubber bushings. The suspension arm travel (jounce or rebound) is limited through the use of rubber bumpers. Stabilizer Bar: The stabilizer bar is used to minimize vehicle front sway during turns. The bar helps to maintain a flat attitude to the road surface. The bar extends across the front underside of the chassis and connects to the frame rails. The links are connected to the lower suspension brackets. All mounting points of the stabilizer bar are isolated by rubber bushings. NOTE: All suspension components that use rubber bushings should be tightened with the vehicle at normal height. If springs are not at their normal ride position, vehicle ride comfort could be affected along with premature rubber bushing wear. Rubber bushings must never be lubricated.

DESCRIPTION AND OPERATION 2WDSUSPENSION COMPONENTS

The front suspension is designed to allow each wheel to adapt to different road surfaces independently. The wheels are mounted to hubs that ride on tapered bearings on the steering knuckle spindle. 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 Stabilizer bar Jounce bumpers Shock Absorbers: Ride control is accomplished through the use of dual-action shock absorbers. The shocks dampen the jounce and rebound as the vehicle travels over various road conditions. The top 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 quality and maintain proper ride height. The springs mounted up in a well (pocket) in a bracket that is part of the frame rail. There is a rubber (doughnut) isolator between the top of the spring and bracket. The bottom of the spring seats in the lower suspension arm. Suspension Arms: The upper suspension arms use a cross shaft bolted to the frame rail brackets. The cross shaft isolates road noise by the use of replaceable bushings in the suspension arms. The upper suspension arm cross shaft also allows for

DIAGNOSIS AND TESTING LOWER BALL STUD

(1) Raise the front of the vehicle. Install safety floor stands under both lower suspension arms as far outboard as possible. The upper suspension arms must not contact the rebound bumpers. (2) Install a dial indicator and clamp assembly to the lower suspension arm. (3) Position indicator plunger against knuckle arm and zero indicator.

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DIAGNOSIS AND TESTING (Continued)

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The shock absorber bushings do not require any type of lubrication. Do not attempt to stop bushing noise by lubricating them. Grease and mineral oilbase lubricants will deteriorate the bushing rubber.

REMOVAL AND INSTALLATION SHOCK ABSORBER

REMOVAL (1) Remove the hardware from the shock absorber stud (Fig. 2).

Fig. 1 Front Suspension2WD

(4) Raise and lower the wheel and tire with a pry bar under the center of the tire. Measure the axial movement of the knuckle with respect to the suspension arm. (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) Position a floor jack under the lower suspension arm. Raise the wheel and tire so it lightly contacts the floor (vehicle weight relieved from the tire). (2) Grasp the top of the tire and apply force in and out. Look for any movement at the ball joints between the upper suspension arm and steering knuckle. (3) If any lateral movement is evident, replace the ball joint.

SHOCK DIAGNOSIS
A noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching components. This noise can usually be stopped by tightening the attaching nuts. If the noise persists, inspect for damaged and worn bushings, and attaching components. Repair as necessary if any of these conditions exist. The shock absorbers are not refillable or adjustable. 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.

Fig. 2 Front Shock Absorber2WD

(2) Raise the vehicle, remove the lower bolts and remove the shock absorber.

INSTALLATION (1) Install the lower retainer and grommet on the shock absorber stud. Insert the replacement shock absorber through the frame hole. Install the lower bolts. (2) Tighten the bolts to 23 Nm (17 ft. lbs./200 in. lbs.).

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REMOVAL AND INSTALLATION (Continued)

(3) Install the upper grommet and retainer on the shock absorber stud. Install the bayonet nut and tighten to 41 Nm (30 ft. lbs.).

STEERING KNUCKLE
REMOVAL (1) Raise and support the vehicle. Place a jack under outer end of lower suspension arm. (2) Remove the wheel and tire assembly. (3) Remove disc brake caliper, refer to Group 5 Brakes. (4) Remove tie-rod from steering knuckle arm, refer to Group 19 Steering. (5) Remove ABS sensor wire from lower suspension arm. Remove the rotor dust shield and ABS pick-up from knuckle (Fig. 3).

COIL SPRING
REMOVAL (1) Raise and support the vehicle. (2) Remove the applicable front wheel. (3) Disconnect the stabilizer bar from the lower suspension arm. (4) Remove the shock absorber. (5) Install Spring Compressor DD-1278 up through the lower suspension arm and coil spring. (6) Tighten the tool nut to compress the coil spring. This will retain the spring in place until the lower suspension arm is detached from and lowered for spring removal. (7) Place two jack stands under the lower suspension arm immediately outward from where the bushings are located. Adjust the jack stands against the lower suspension arm. (8) Remove the lower suspension arm mounting bolts from the frame rail. (9) Lower the jack stands and remove the spring 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) 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 and coil spring. (3) Tighten the tool nut to compress the coil spring. (4) Place two jack stands under the lower suspension arm immediately outward from where the bushings are located. (5) Raise the jack stands until the isolator pad/coil spring is correctly seated top and bottom. (6) Install the lower suspension arm bolts and nuts. Tighten the front nut to 176 Nm (130 ft. lbs.) and the rear nut to 108 Nm (80 ft. lbs.). (7) Remove the spring compressor tool and the jack stands. (8) Install the stabilizer bar. (9) Install the shock absorber. (10) Install the wheel and tire assembly.

Fig. 3 Remove ABS Sensor From Knuckle

(6) Remove cotter pins and nuts from upper and lower ball studs. (7) Use Ball Stud Remover C-3564A to free upper and lower ball joints from steering knuckle. (8) Remove tool and steering knuckle assembly. (9) Remove steering arm from steering knuckle (Fig. 4).

INSTALLATION (1) Install steering arm on knuckle. Tighten the nuts to 294 Nm (217 ft. lbs.). (2) Position steering knuckle on upper and lower ball studs and install nuts. Tighten lower nut to 183

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(6) Strike steering knuckle sharply with a hammer to loosen ball stud from knuckle. Do not force ball stud out from knuckle with the tool. (7) Separate ball stud from steering knuckle arm.

Fig. 4 Steering Knuckle

Nm (135 ft. lbs.). Tighten upper nut to 142 Nm (105 ft. lbs.) and install new cotter pins. (3) Install rotor dust shield and ABS sensor on steering knuckle. Tighten bolts to 24 Nm (18 ft. lbs.). (4) Install tie rod to steering knuckle arm, refer to Group 19 Steering. (5) Install ABS sensor wire to lower suspension arm. (6) Install the disc brake caliper, refer to Group 5 Brakes. (7) Install the wheel and tire assembly.

INSTALLATION (1) Loosely attach suspension arm to frame side rail brackets. (2) Follow the procedure outlined in Coil Spring Installation. (3) Position steering knuckle on ball studs. Install ball stud retaining nuts. Tighten lower nut to 183 Nm (135 ft. lbs.). Tighten upper nut to 142 Nm (105 ft. lbs.) and install new cotter pins. (4) Install the rotor and disc brake caliper. Refer to Group 5, Brakes. (5) Lower the vehicle. Tighten suspension arm front nut to 176 Nm (130 ft. lbs.) and rear nut to 108 Nm (80 ft. lbs.).

UPPER SUSPENSION ARM

REMOVAL (1) Raise and support the vehicle. (2) Remove wheel and tire assembly. (3) Remove disc brake caliper, refer to Group 5 Brakes. (4) Remove shock absorber. (5) Install Spring Compressor DD-1278. Use a piece of pipe to fabricate a spacer positioned between the tool and suspension arm. (6) Tighten tool nut against bell-shaped adapter tool finger-tight and loosen 1/2 of-a-turn. (7) Remove cotter pin and nut from upper ball stud. (8) Position Ball Stud Remover C-3564A as shown (Fig. 6). Rotate threaded portion of tool to apply force to the lower ball stud.

LOWER SUSPENSION ARM

REMOVAL (1) Raise and support vehicle. (2) Remove disc brake caliper from steering knuckle and rotor. Refer to Group 5, Brakes. (3) Remove shock absorber. (4) Follow the procedure outlined in Coil Spring Removal. (5) Position Ball Stud Remover C-3564A as shown (Fig. 5). Rotate threaded portion of tool to apply force to the lower ball stud.

Fig. 6 Separate Upper Ball Stud Fig. 5 Separate Ball Stud

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REMOVAL AND INSTALLATION (Continued)

(9) Strike steering knuckle sharply with a hammer to loosen ball stud from knuckle. Do not force ball stud out from knuckle with the tool. (10) Separate upper ball stud from steering knuckle. (11) Remove suspension arm pivot bar nuts and remove suspension arm (Fig. 7). (4) Remove the bolts from the U-shaped retainer. Remove the retainer, and stabilizer bar from the vehicle. (5) If necessary, remove the bushings from the stabilizer bar.

Fig. 8 Stabilizer Bar

INSTALLATION
NOTE: Ensure the stabilizer bushings are prealigned before the bar is installed to the bracket. (1) If removed, install the bushings on the stabilizer bar. (2) Place the stabilizer bar adjacent to the frame side rail brackets. Install the U-shaped retainer and 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 or chassis component. Spacing should be equal on both sides. (3) Install the link bolt, retainers, spacer and insulators at the lower suspension arm on each side. (4) Install the washers and the nuts on the anchor bolts. Tighten the nuts to 23 Nm (17 ft. lbs.) torque. (5) Tighten the U-shaped support bracket bolts to 54 Nm (40 ft. lbs.).

Fig. 7 Upper Suspension Arm

INSTALLATION (1) Position suspension arm pivot bar on adjustment bolts. Install nuts and tighten (temporarily) to 136 Nm (100 ft. lbs.). (2) Position steering knuckle on upper ball stud. Tighten the upper ball stud nut to 142 Nm (105 ft. lbs.) and install a new cotter pin. (3) Remove spring compressor tool. Install the shock absorber. (4) Install the disc brake caliper. Refer to Group 5, Brakes. (5) Install the wheel and tire assembly. (6) Adjust alignment caster and camber. Refer to Front Wheel Alignment in this Group.

STABILIZER BAR
REMOVAL (1) Raise and support the vehicle. (2) Remove the nut and washer from the stabilizer bar link bolt at the lower suspension arm on each side of the vehicle (Fig. 8). (3) Remove the link bolt, retainers, insulators and spacer from each lower suspension arm.

WHEEL BEARINGS (2WD)

REMOVAL (1) Block brake pedal in up position. (2) Raise and support the vehicle. (3) Remove the wheel and tire assembly. (4) Remove disc brake caliper from steering knuckle and rotor. Refer to Group 5, Brakes. (5) Remove the dust cap, cotter pin, and remaining hub components from spindle (Fig. 9).

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Fig. 9 Brake Rotor/Hub and Wheel Bearings

CAUTION: Use care to prevent inner wheel bearing and seal from contacting spindle threads during removal. (6) Carefully slide the hub/rotor from spindle. (7) Remove the seal and inner wheel bearing from the hub/rotor. Remove the inner bearing races from hub/rotor with a pin punch. (7) The adjustment (above) should have 0 to 0.076 mm (0 to 0.003 in.) end play. (8) Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. (9) Install disc brake caliper. Refer to Group 5, Brakes. (10) Install wheel and tire assembly.

INSTALLATION
NOTE: Refer to bearing cleaning and inspection before installation. (1) Install the new bearing cup(s) with an appropriate installation tool. (2) Apply a coating of MOPAR Wheel Bearing Grease (or an equivalent lubricant) to entire inner surface area of hub/rotor. Install inner wheel bearing in the hub/rotor. Install a new bearing seal. (3) Inspect bearing and seal contact surfaces on spindle for burrs or roughness. (4) Remove all rough contact surfaces from spindle. Apply a coating of lubricant. (5) Carefully slide the hub/rotor onto spindle. Install outer wheel bearing, washer and retaining nut. (6) Tighten the nut to 41-54 Nm (30-40 ft. lbs.) to preload bearing while rotating the hub/rotor. Stop hub/rotor and loosen nut to completely release bearing preload torque. Tighten the nut finger-tight and install the nut lock. Install a new cotter pin.

WHEEL STUDS
REMOVAL (1) Remove wheel and tire assembly. (2) Remove disc brake rotor, refer Group 5 Brakes. (3) Place rotor on flat surface and drive studs out of the with a hammer and punch. INSTALLATION (1) Turn the rotor over and place in a vise. (2) Drive new studs into the rotor with hammer and punch. (3) Install rotor, refer to Group 5 Brakes. (4) Install wheel and tire assembly.

DISASSEMBLY AND ASSEMBLY LOWER BALL STUD

REMOVAL (1) Raise and support the vehicle. (2) Remove wheel and tire assembly. (3) Remove disc brake caliper from steering knuckle and rotor. Refer to Group 5 Brakes.

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DISASSEMBLY AND ASSEMBLY (Continued)

(4) Remove shock absorber. (5) Install Spring Compressor DD-1278. Use a piece of pipe to fabricate a spacer positioned between the tool and suspension arm. (6) Tighten tool nut against bell-shaped adapter tool finger-tight and loosen 1/2 of-a-turn. (7) Remove cotter pins and nuts from ball studs. (8) Position Ball Stud Remover C-3564A as shown in (Fig. 5). Rotate threaded portion of tool to apply force to the lower ball stud. (9) Strike steering knuckle sharply with a hammer to loosen ball stud from knuckle. Do not force ball stud out from knuckle with the tool. (10) Remove ball stud seal. Use Remover/Installer C-4212 to press the ball stud from lower suspension arm bore (Fig. 10).

Fig. 11 Lower Ball Stud Installation

UPPER BALL STUD

REMOVAL (1) Place a jack under outer end of lower suspension arm. Raise and support the vehicle. (2) Remove the wheel and tire assembly. (3) Remove cotter pin and nut from upper ball stud. (4) Position Ball Stud Remover C-3564A as shown (Fig. 6). Rotate threaded portion of tool to apply force to the upper ball stud. (5) Strike steering knuckle sharply with a hammer to loosen ball stud from knuckle. Do not force ball stud out from knuckle with the tool. (6) Remove ball stud seal. (7) Use Removal/Installation Tool C-3561 to unthread ball stud from suspension arm. INSTALLATION (1) Thread new ball stud in with Tool C-3561. Tighten ball stud to 170 Nm (125 ft. lbs.). The gap between ball stud Hex and suspension arm bore is 0.25 to 1.25mm (0.01 to 0.05 inch). (2) Install new seal over ball stud. Make sure seal is securely locked in-place. (3) Position steering knuckle on upper ball stud. Tighten the upper ball stud nut to 142 Nm (105 ft. lbs.) and install a new cotter pin. (4) Install the wheel and tire assembly

Fig. 10 Lower Ball Stud Removal

INSTALLATION (1) Press new ball stud in lower suspension arm with Remover/Installer C-4212 (Fig. 11). (2) Position new seal over ball stud. Use a socket to force retaining lip of seal until securely locked inplace. (3) Position steering knuckle on ball studs. Install ball stud retaining nuts. Tighten lower nut to 183 Nm (135 ft. lbs.). Tighten upper nut to 142 Nm (105 ft. lbs.) and install new cotter pins. (4) Remove spring compressor tool and install shock absorber. (5) Install the disc brake caliper, refer to Group 5 Brakes. (6) Install the wheel and tire assembly.

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Fig. 12 Brake Rotor/Hub and Wheel Bearings

CLEANING AND INSPECTION WHEEL BEARING

(1) Thoroughly clean the interior of hub/rotor (Fig. 12). (2) Clean the bearings with solvent and towel dry. (3) After cleaning, apply engine oil to each bearing. (4) Rotate each bearing slowly while applying downward force. Examine the rollers for pitting and roughness, replace bearing if worn or defective. (5) Remove the engine oil from each bearing. Pack each bearing with multi-purpose NLGI, grade 2, EPtype lubricant (or an equivalent lubricant). NOTE: Ensure that lubricant is forced into all the cavities between the bearing cage and rollers.

SPECIFICATIONS TORQUE CHART2WD

DESCRIPTION TORQUE Shock Absorber Upper Nut . . . . . . . . . . . . . . . . .41 Nm (30 ft. lbs.) Lower Bolts. . . . . . . . . . . . . . .23 Nm (200 in. lbs.) Lower Suspension Arm Front Nut . . . . . . . . . . . . . . .176 Nm (130 ft. lbs.) Rear Nut . . . . . . . . . . . . . . . . .108 Nm (80 ft. lbs.) Ball Stud Nut . . . . . . . . . . . .183 Nm (135 ft. lbs.) Upper Suspension Arm Pivot Bar Nuts. . . . . . . . . . . .210 Nm (155 ft. lbs.) Ball Stud Nut . . . . . . . . . . . .142 Nm (105 ft. lbs.) Stabilizer Bar Clamp Bolt . . . . . . . . . . . . . . . .54 Nm (40 ft. lbs.) Link Nut . . . . . . . . . . . . . . . . . .23 Nm (17 ft. lbs.) Support Bracket Bolts . . . . . .30 Nm (22.5 ft. lbs.)

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SPECIAL TOOLS FRONT SUSPENSION 2WD

Compressor, Coil Spring DD-1278

Press, Ball Joint C-4212F

Puller, Knuckle Arm C-3564A

Socket, Ball Joint C-3561

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FRONT SUSPENSION4WD
INDEX
page DESCRIPTION AND OPERATION 4WDSUSPENSION COMPONENTS . DIAGNOSIS AND TESTING LOWER BALL STUD . . . . . . . . . . . . . . SHOCK DIAGNOSIS . . . . . . . . . . . . . . UPPER BALL STUD . . . . . . . . . . . . . . REMOVAL AND INSTALLATION LOWER SUSPENSION ARM . . . . . . . . SHOCK ABSORBER . . . . . . . . . . . . . . STABILIZER BAR . . . . . . . . . . . . . . . . STEERING KNUCKLE . . . . . . . . . . . . TORSION BAR . . . . . . . . . . . . . UPPER SUSPENSION ARM . . . WHEEL HUB/BEARINGS (4WD) WHEEL MOUNTING STUDS . . . DISASSEMBLY AND ASSEMBLY UPPER BALL STUD . . . . . . . . . SPECIFICATIONS TORQUE CHART4WD . . . . . . SPECIAL TOOLS FRONT SUSPENSION 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page . . . . 16 17 20 20

. . . . . . . . 15 . . . . . . . . 16 . . . . . . . . 16 . . . . . . . . 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 16 18 19

. . . . . . . . . . . . . 20 . . . . . . . . . . . . . 21 . . . . . . . . . . . . . 21

DESCRIPTION AND OPERATION 4WDSUSPENSION COMPONENTS

The front suspension is designed to allow each wheel to adapt to different road surfaces independently. The wheels are mounted to hub/bearing design unit. The steering knuckles turn (pivot) on ball studs mounted on the upper and lower suspension arms. The 4WD front suspension is comprised of (Fig. 1); Dual-action shock absorbers Torsion-bar springs Suspension arms Steering knuckles Stabilizer bar Jounce bumpers Shock Absorbers: Ride control is accomplished through the use of dual-action shock absorbers. The shocks dampen the jounce and rebound as the vehicle travels over various road conditions. The top of the shock absorbers are bolted to the frame. The bottom of the shocks are bolted to the lower suspension arm. Torsion Bars: The torsion bars are used to control ride height and ride quality. The bars mounted to the back side of the lower suspension arm. The rearward end of the bar is mounted in a cam pivot that rests in the frame crossmember. The vehicle height is adjusted through the cams with screw jacks that increase the tension (twist) of the torsion bar. Suspension Arms: The upper suspension arms use a cross shaft bolted to the frame rail brackets. The cross shaft isolates road noise by the use of replaceable bushings in the suspension arms. The upper suspension arm cross shaft also allows for caster and camber adjustment. The lower suspension arms use replaceable pressed in bushings to isolate road noise. The suspension arms are bolted to the

Fig. 1 Front Suspension 4WD

frame and pivot through rubber bushings. The suspension arm travel (jounce or rebound) is limited through the use of rubber bumpers. Stabilizer Bar: The stabilizer bar is used to minimize vehicle front sway during turns. The bar helps to maintain a flat attitude to the road surface. The bar extends across the front underside of the chassis

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DESCRIPTION AND OPERATION (Continued)

and connects to the frame rails. The links are connected to the lower suspension brackets. All mounting points of the stabilizer bar are isolated by rubber bushings. All suspension components that use rubber bushings should be tightened with the vehicle at normal height. If the vehicle is not at the normal ride height, vehicle ride comfort could be affected along with premature rubber bushing wear. Rubber bushings must never be lubricated. noise by lubricating them. Grease and mineral oilbase lubricants will deteriorate the bushing rubber.

REMOVAL AND INSTALLATION SHOCK ABSORBER

REMOVAL (1) Remove the hardware from the shock absorber stud (Fig. 2). (2) Raise the vehicle, remove the lower bolts and remove the shock absorber.

DIAGNOSIS AND TESTING LOWER BALL STUD

(1) Raise the front of the vehicle. Install safety floor stands under both lower suspension arms as far outboard as possible. The upper suspension arms must not contact the rebound bumpers. (2) Install a dial indicator and clamp assembly to the lower suspension arm. (3) Position indicator plunger against knuckle arm and zero indicator. (4) Raise and lower the wheel and tire with a pry bar under the center of the tire. Measure the axial movement of the knuckle with respect to the suspension arm. (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) Position a floor jack under the lower suspension arm. Raise the wheel and tire so it lightly contact the floor (vehicle weight relieved from the tire). (2) Grasp the top of the tire and apply force in and out. Look for any movement at the ball joints between the upper suspension arm and steering knuckle. (3) If any lateral movement is evident, replace the ball joint.

Fig. 2 Shock Absorber

INSTALLATION (1) Install the lower retainer and grommet on the shock absorber stud. Insert the replacement shock absorber through the frame hole. Install the lower bolt. (2) Tighten the bolt to 136 Nm (100 ft. lbs.). (3) Install the upper grommet and retainer on the shock absorber stud. Install the bayonet nut and tighten to 41 Nm (30 ft. lbs.).

SHOCK DIAGNOSIS
A noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching components. This noise can usually be stopped by tightening the attaching nuts. If the noise persists, inspect for damaged and worn bushings, and attaching components. Repair as necessary if any of these conditions exist. The shock absorbers are not refillable or adjustable. 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

TORSION BAR
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.

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REMOVAL AND INSTALLATION (Continued)
REMOVAL (1) Remove the suspension arm jounce bumpers before raising vehicle. (2) Raise and support the vehicle with the front suspension hanging. (3) Turn the adjustment bolt counterclockwise to release spring load (Fig. 3). Remove the adjustment bolt from swivel. (4) Remove torsion bar and anchor. Remove anchor from torsion bar. (5) Remove all foreign material from torsion bar mounting in anchor and suspension arm. (6) Inspect adjustment bolt and swivel for damage.

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Fig. 4 Lower Suspension Arm

INSTALLATION (1) Position the lower suspension arm at the frame rail brackets. Install the pivot bolts and nuts. Tighten the nuts finger-tight. (2) Insert the ball stud into steering knuckle. Install and tighten the retaining nut to 142 Nm (115 ft. lbs.) and install a new cotter pin. (3) Install torsion bar. (4) Install shock absorber lower bolt. (5) Install the CV drive shaft. Refer to Group 3 Differential & Drive line. (6) Install the stabilizer bar to the lower suspension arm. (7) Tighten the lower suspension front pivot nut to 108 Nm (80 ft. lbs.). Tighten rear pivot bolt to 176 Nm (130 ft. lbs.). (8) Adjust the front suspension height. Refer to Wheel Alignment in this Group.

Fig. 3 Torsion Bar

INSTALLATION (1) Insert torsion bar ends into anchor and suspension arm. (2) Position anchor and bushing in frame crossmember. Install adjustment bolt through bushing and anchor and into swivel. (3) Turn adjustment bolt clockwise to apply a spring load. (4) Lower vehicle and adjust the front suspension height. Refer to Wheel Alignment in this group. (5) Install suspension arm jounce bumpers.

LOWER SUSPENSION ARM

REMOVAL (1) Remove the CV drive shaft, refer to Group 3 Differential & Driveline. (2) Remove torsion bar. (3) Remove shock absorber lower bolt. (4) Disconnect the stabilizer bar from suspension arm. (5) Remove the cotter pin and nut from lower ball stud. Separate ball stud from steering knuckle with Remover C-3564A. (6) Remove suspension arm pivot bolts and suspension arm from frame rail brackets (Fig. 4).

UPPER SUSPENSION ARM

REMOVAL (1) Remove the CV drive shaft. Refer to Group 3 Differential & Driveline. (2) Turn torsion bar adjustment bolt counter-clockwise to completely remove tension from torsion bar. Count the number of turns for installation reference. (3) Remove brake hose brackets from suspension arm, refer to Group 5 Brakes. (4) Remove shock absorber lower bolt. (5) Remove the cotter pin and nut from lower ball stud.

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REMOVAL AND INSTALLATION (Continued)

(6) Position Ball Stud Remover C-3564A as shown (Fig. 5). Rotate threaded portion of tool to apply force to the upper ball stud.

Fig. 6 Upper Suspension Arm

(8) Tighten upper suspension arm pivot bolts to 210 Nm (155 ft. lbs.). (9) Adjust alignment caster and camber. Refer to Front Wheel Alignment in this Group.

STABILIZER BAR
REMOVAL (1) Raise and support the vehicle. (2) Remove the bolts attaching the stabilizer bar rear support bracket to the frame crossmember bracket (Fig. 7). (3) Remove the bolts attaching the retainer to the lower suspension arm. Remove the retainer and stabilizer bar from the vehicle. (4) If necessary, remove the rear support brackets and the bushings from the stabilizer bar. INSTALLATION (1) If removed, install the bushings and the rear support brackets on the stabilizer bar. (2) Place the stabilizer bar rear support brackets adjacent to the frame crossmember brackets and install the bolts. Tighten the bolts finger-tight. 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) Attach the stabilizer bar to the lower suspension arm with the retainer and bolts. Tighten the bolts to 27 Nm (20 ft. lbs.). (4) Tighten the rear support bracket bolts to 27 Nm (20 ft. lbs.).

Fig. 5 Separate Upper Ball Stud

(7) Strike steering knuckle sharply with a hammer to loosen ball stud from knuckle. Do not force ball stud out from knuckle with the tool. (8) Separate upper ball stud from steering knuckle arm. (9) Remove suspension arm pivot bar bolts and remove suspension arm (Fig. 6).

INSTALLATION (1) Position suspension arm pivot bar on adjustment bolts. Install nuts and tighten (temporarily) to 136 Nm (100 ft. lbs.). (2) Insert ball stud in steering knuckle arm. Install retaining nut. Tighten nut to 142 Nm (105 ft. lbs.) and install a new cotter pin. (3) Install shock absorber lower bolt. (4) Attach brake hose brackets to suspension arm, refer to Group 5 Brakes. (5) Turn torsion bar adjustment bolt clockwise (the amount of turns recorded earlier) to apply tension to torsion bar. (6) Install the CV drive shaft. Refer to CV Drive Shaft Installation in this Group. (7) Install the wheel and tire assembly.

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REMOVAL AND INSTALLATION (Continued)

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Fig. 8 ABS Sensor and Wire Fig. 7 Stabilizer Bar

STEERING KNUCKLE
REMOVAL (1) Remove the CV drive shaft. Refer to CV Drive Shaft Removal in this Group. (2) Turn torsion bar adjustment bolt counter-clockwise to completely remove tension from torsion bar. Count the number of turns for installation reference. (3) Remove shock absorber lower bolt. (4) Disconnect the stabilizer bar from suspension arm. (5) Remove the wheel hub and bearings. (6) Remove tie-rod end stud from steering knuckle arm. Refer to Group 19 Steering. (7) Remove ABS front wheel speed sensor and wire from upper suspension arm if equipped (Fig. 8). (8) Remove the cotter pin and nut from upper and lower ball stud. (9) Use Ball Stud Remover C-3564A to free upper and lower ball joints from steering knuckle. (10) Strike steering knuckle sharply with a hammer to loosen ball stud from knuckle. Do not force ball stud out from knuckle with the tool. (11) Remove steering knuckle from vehicle (Fig. 9). INSTALLATION (1) Position steering knuckle on upper and lower ball studs and install nuts. Tighten lower nut to 156 Nm (115 ft. lbs.). Tighten upper nut to 142 Nm (105 ft. lbs.) and install new cotter pins. (2) Install ABS sensor on steering knuckle and wire on upper suspension arm. Tighten bolts to 24 Nm (18 ft. lbs.).

Fig. 9 Steering Knuckle

(3) Install tie rod to steering knuckle arm, refer to Group 19 Steering. (4) Install wheel hub/bearing. (5) Install shock absorber lower bolt. (6) Install the CV drive shaft. Refer to CV Drive Shaft Installation in this Group. (7) Install the stabilizer bar to suspension arm. (8) Install the wheel and tire assembly. (9) Turn torsion bar adjustment bolt clockwise (the amount of turns recorded earlier) to apply tension to torsion bar.

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REMOVAL AND INSTALLATION (Continued)

(10) Adjust the front suspension height. Refer to Wheel Alignment within this Group. (4) Install disc brake caliper on steering knuckle and rotor. Refer to Group 5 Brakes.

WHEEL HUB/BEARINGS (4WD)

REMOVAL (1) Remove the CV drive shaft, refer to Group 3 Differential & Driveline. (2) Remove disc brake caliper from steering knuckle and rotor, refer to Group 5 Brakes. (3) Remove brake rotor from the hub (Fig. 10).

WHEEL MOUNTING STUDS

REMOVAL (1) Raise and support vehicle. (2) Remove wheel and tire assembly. (3) Remove brake caliper and rotor, refer to Group 5 Brakes for procedure. (4) Remove stud from hub with Remover C-4150A (Fig. 12).

Fig. 10 Rotor, Hub & Knuckle

(4) Remove hub to steering knuckle bolts. Remove hub and bearing unit from the steering knuckle (Fig. 11).

Fig. 12 Wheel Stud Removal

INSTALLATION (1) Install new stud into hub flange. (2) Install three washer onto stud, then install lug nut with the flat side of the nut against the washers. (3) Tighten lug nut until the stud is pulled into the hub flange. Verify that the stud is properly seated into the flange. (4) Remove lug nut and washers. (5) Install the brake rotor and caliper, refer to Group 5 Brakes for procedure. (6) Install wheel and tire assembly, use new lug nut on stud or studs that were replaced. (7) Remove support and lower vehicle.

DISASSEMBLY AND ASSEMBLY UPPER BALL STUD

Fig. 11 Hub/Bearing
INSTALLATION (1) Install the hub on steering knuckle and tighten bolts to 149 Nm (110 ft. lbs.). (2) Install the CV drive shaft, refer to Group 3 Differential & Driveline. (3) Install disc brake rotor on the hub. REMOVAL (1) Place a jack under outer end of lower suspension arm. Raise and support the vehicle. (2) Remove the wheel and tire assembly. (3) Remove cotter pin and nut from upper ball stud.

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DISASSEMBLY AND ASSEMBLY (Continued)
(4) Position Ball Stud Remover C-3564A. Rotate threaded portion of tool to apply force to the upper ball stud. (5) Strike steering knuckle sharply with a hammer to loosen ball stud from knuckle. Do not force ball stud out from knuckle with the tool. (6) Remove ball stud seal. (7) Use Removal/ Installation Tool C-3561 to unthread ball stud from suspension arm.

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SPECIAL TOOLS FRONT SUSPENSION 4WD

INSTALLATION (1) Thread new ball stud in with Tool C-3561. Tighten ball stud to 170 Nm (125 ft. lbs.). The gap between ball stud Hex and suspension arm bore is 0.25 to 1.25mm (0.01 to 0.05 inch). (2) Install new seal over ball stud. Make sure seal securely locked in- place. (3) Position steering knuckle on upper ball stud. Tighten the upper ball stud nut to 142 Nm (105 ft. lbs.) and install a new cotter pin. (4) Install the wheel and tire assembly

Puller, Knuckle Arm C-3564A

SPECIFICATIONS TORQUE CHART4WD

Socket, Ball Joint C-3561
DESCRIPTION TORQUE Shock Absorber Upper Nut . . . . . . . . . . . . . . . . .41 Nm (30 ft. lbs.) Lower Bolt . . . . . . . . . . . . . . .136 Nm (100 ft. lbs.) Lower Suspension Arm Front Bolt . . . . . . . . . . . . . . . .108 Nm (80 ft. lbs.) Rear Bolt . . . . . . . . . . . . . . . .176 Nm (130 ft. lbs.) Ball Stud Nut . . . . . . . . . . . .156 Nm (115 ft. lbs.) Upper Suspension Arm Pivot Bar Bolts . . . . . . . . . . .210 Nm (155 ft. lbs.) Ball Stud Nut . . . . . . . . . . . .142 Nm (105 ft. lbs.) Stabilizer Bar Clamp Bolts. . . . . . . . . . . . . . . .27 Nm (20 ft. lbs.) Retainer Bolts . . . . . . . . . . . . . .27 Nm (20 ft. lbs.) Support Bracket Bolts . . . . . . . .27 Nm (20 ft. lbs.) Wheel Hub/Bearing Bolts. . . .149 Nm (110 ft. lbs.)

Remover C-4170A

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REAR SUSPENSION
INDEX
page GENERAL INFORMATION WEIGHT DISTRIBUTION . . . . . . . . . . . . DESCRIPTION AND OPERATION SUSPENSION COMPONENT . . . . . . . . . DIAGNOSIS AND TESTING SPRING AND SHOCK DIAGNOSIS . . . . . REMOVAL AND INSTALLATION LEAF SPRING AND SHACKLE BUSHING LEAF SPRINGS . . . . . . . . . . . . SHOCK ABSORBER . . . . . . . . . SPRING LEAF REPLACEMENT SPECIFICATIONS TORQUE CHART . . . . . . . . . . . page . . . . . . . . . . . . . 23 . . . . . . . . . . . . . 23 . . . . . . . . . . . . . 24 . . . . . . . . . . . . . 26

. . . . . . 22 . . . . . . 22 . . . . . . 22 . . . . . . 24

GENERAL INFORMATION WEIGHT DISTRIBUTION

A vehicle should always be loaded so the vehicle weight center-line is located immediately forward of the rear axle. Correct vehicle loading 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.

pension. The bar extends across the underside of the body and is attached to the body rails with grommets. Links at the end of the bar are attached to the leaf spring brackets. Jounce Bumpers: The jounce bumpers are used to limit the spring and axle travel. They are bolted to the body rail above the axle. NOTE: Suspension components that use rubber bushings should be tightened with the vehicle at the normal height. Rubber bushings must never be lubricated.

DESCRIPTION AND OPERATION SUSPENSION COMPONENT

The rear suspension is comprised of: Drive Axle Leaf Springs Dual-Action Shock Absorbers Stabilizer Bar Jounce Bumpers Leaf Springs: 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 shackles. The spring and shackles use rubber bushings. The bushing help to isolate road noise. The shackles allow the springs to change their length as the vehicle moves over various road conditions. Shock Absorbers: Ride control is accomplished through the use of dual-action shock absorbers. The shocks dampen the jounce and rebound as the vehicle travels over various road conditions. The top of the shock absorbers are bolted to the body crossmember. The bottom of the shocks are bolted to the axle bracket. Stabilizer Bar: The stabilizer bar is used to minimize vehicle body roll. The spring steel bar helps to control the vehicle body in relationship to the sus-

DIAGNOSIS AND TESTING SPRING AND SHOCK DIAGNOSIS

A noise from a shock absorber may be caused by movement between mounting bushings and metal bracket or attaching components. This noise can usually be stopped by tightening the attaching nuts. If the noise persists, inspect for damaged and worn bushings, and attaching components. Repair as necessary if any of these conditions exist. The shock absorbers are not refillable or adjustable. 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 deteriorate 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,

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DIAGNOSIS AND TESTING (Continued)
SPRING AND SHOCK ABSORBER DIAGNOSIS

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and broken center bolts. Refer to Spring and Shock Absorber Diagnosis chart for additional information.

LEAF SPRINGS
CAUTION: The rear of the vehicle must be lifted only with a jack or hoist. The lift must be placed under the frame rail crossmember located aft of the rear axle. Use care to avoid bending the side rail flange.

REMOVAL AND INSTALLATION SHOCK ABSORBER

REMOVAL (1) Raise and support the vehicle. (2) Remove the shock absorber lower nut and bolt from the axle bracket (Fig. 1) and (Fig. 2). (3) Remove the shock absorber upper nuts and bolts from the frame crossmember bracket. Remove the shock absorber. INSTALLATION (1) Install the shock absorber and upper fasteners on the frame bracket. (2) Install the shock absorber lower eye into the axle bracket. Install the bolt and nut and tighten to 81 Nm (60 ft. lbs.). (3) Tighten the upper bracket nuts to 27 Nm (20 ft. lbs.).

REMOVAL (1) Raise the vehicle at the frame. (2) Use a hydraulic jack to relieve the axle weight. (3) Remove the wheel and tire assemblies. (4) Remove the nuts, the U-bolts and spring bracket from the axle. (5) Remove the nut and bolt that attaches the spring rear eye to the shackle. (6) Remove the nut and bolt from the spring front eye. (7) Remove the spring from the vehicle. INSTALLATION (1) If removed, install the spring shackle on the spring finger tight. (2) Position the spring on the rear axle pad. Make sure the spring center bolt is inserted in the pad

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REMOVAL AND INSTALLATION (Continued)

Fig. 1 2WD Suspension

locating hole. If 2WD, ensure the parking brake cable guide is properly positioned. (3) Align the spring front eye with the bolt hole in the rail front bracket. Install the spring eye bolt and nut. Tighten the spring eye nut finger-tight. (4) Align the spring shackle eye with the bolt hole in the rail rear bracket. Install the bolt and nut. Tighten the spring shackle eye nut finger-tight. (5) Install the spring seat (2WD only), U-bolts, spring bracket, replacement washers and nuts. Tighten the nuts until the washers are compressed against the spring bracket. (6) Remove the support stands from under the frame rails. Lower the vehicle until the springs are supporting the weight of the vehicle. Tighten the U-bolt nuts: 2WD vehicles: 88 Nm (65 ft. lbs.) 4WD vehicles: 149 Nm (110 ft. lbs.) (7) Tighten the spring eye pivot bolt nut and all shackle nuts to 88 Nm (65 ft. lbs.). (8) Install the wheel and tire assemblies. (1) Remove the spring from the vehicle. (2) Remove the spring leaf alignment clips. (3) Clamp the spring in a vise. Remove the nut and center bolt (Fig. 3). (4) Insert a long drift or punch into the center bolt hole and slowly release the vise jaws. (5) Remove the spring from the vise. Replace the defective leaf and insert a long drift or punch into the spring center bolt hole. (6) Position spring between vise jaws and slowly tighten the vise jaws. Keep the spring leaves aligned with the long drift or punch. (7) Remove the drift/punch from the spring center bolt hole and replacement center bolt and nut. (8) Tighten the nut to 20 Nm (15 ft. lbs.). An alternate is to tighten until the center of the spring has no gaps. Use a maximum of 54 Nm (40 ft. lbs.) for this method. (9) Install the alignment clips. (10) Install the spring in the vehicle.

LEAF SPRING AND SHACKLE BUSHING SPRING LEAF REPLACEMENT

NOTE: If a spring has acquired a set (lost significant height), it should be replaced. For front oval bushings bend tabs DOWN before removal. Use an appropriate driver tool and force the original bushing out of the spring eye.

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REMOVAL AND INSTALLATION (Continued)

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Fig. 2 4WD Suspension

Fig. 3 Leaf Spring Disassembly

(1) Assemble tools shown (Fig. 4). Tighten nut at the socket wrench end of the threaded rod until the bushing is forced out. (2) Assemble and align the bushing installation tools. (3) Align the bushing with the spring eye or shackle eye and tighten the nut at the socket wrench end of the threaded rod. Tighten until the bushing is forced into the spring eye.

Fig. 4 Spring Eye Bushing Removal

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REMOVAL AND INSTALLATION (Continued)

NOTE: The bushing must be centered in the spring eye. The ends of the bushing must be flush or slightly recessed within the end surfaces of the spring eye. (4) For front oval bushings bend tabs up after installation.

SPECIFICATIONS TORQUE CHART

DESCRIPTION TORQUE Shock Absorber Lower Bolt. . . . . . . . . . . . . . . . .88 Nm (65 ft. lbs.) Upper Bolt. . . . . . . . . . . . . . . . .27 Nm (20 ft. lbs.) Spring Clamp Nut 2WD . . . . . . . . . . . . . . . . . . . . .88 Nm (65 ft. lbs.) 4WD. . . . . . . . . . . . . . . . . . . .149 Nm (110 ft. lbs.) Spring Spring Eye Nut . . . . . . . . . . . . .88 Nm (65 ft. lbs.) Pivot Bolt Nut . . . . . . . . . . . . . .88 Nm (65 ft. lbs.)