Login- Download PDF Manual
-
DR
LUBRICATION & MAINTENANCE
0 - 13
JUMP STARTING STANDARD PROCEDURE - JUMP STARTING
WARNING: REVIEW ALL SAFETY PRECAUTIONS AND WARNINGS IN THE BATTERY SYSTEM SEC- TION OF THE SERVICE MANUAL. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BATTERY - STAN- DARD PROCEDURE) † DO NOT JUMP START A FROZEN BATTERY, PERSONAL INJURY CAN RESULT. † IF EQUIPPED, DO NOT JUMP START WHEN MAINTENANCE FREE BATTERY INDICATOR DOT IS YELLOW OR BRIGHT COLOR. † DO NOT JUMP START A VEHICLE WHEN THE BATTERY FLUID IS BELOW THE TOP OF LEAD PLATES. † DO NOT ALLOW JUMPER CABLE CLAMPS TO TOUCH EACH OTHER WHEN CONNECTED TO A BOOSTER SOURCE. † DO NOT USE OPEN FLAME NEAR BATTERY. † REMOVE METALLIC JEWELRY WORN ON HANDS OR WRISTS TO AVOID INJURY BY ACCI- DENTAL ARCING OF BATTERY CURRENT. † WHEN USING A HIGH OUTPUT BOOSTING DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO EXCEED 16 VOLTS. REFER TO INSTRUCTIONS PROVIDED WITH DEVICE BEING USED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
CAUTION: When using another vehicle as a booster, do not allow vehicles to touch. Electrical systems can be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE:
inspect engine compartment for:
(1) Raise hood on disabled vehicle and visually † Battery cable clamp condition, clean if necessary. † Frozen battery. † Yellow or bright color test indicator, if equipped. † Low battery fluid level. † Generator drive belt condition and tension. † Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis- abled vehicle is severe, damage to booster vehicle charging system can result.
(2) When using another vehicle as a booster source, park the booster vehicle within cable reach. Turn off all accessories, set the parking brake, place the automatic transmission in PARK or the manual transmission in NEUTRAL and turn the ignition OFF.
(3) On disabled vehicle, place gear selector in park or neutral and set park brake. Turn off all accesso- ries.
(4) Connect jumper cables to booster battery. RED clamp to positive terminal (+). BLACK clamp to neg- ative terminal (-). DO NOT allow clamps at opposite end of cables to touch, electrical arc will result. Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable clamp to positive (+) terminal. Connect BLACK jumper cable clamp to engine ground as close to the ground cable attaching point as possible.
(6) Start the engine in the vehicle which has the booster battery, let the engine idle a few minutes, then start the engine in the vehicle with the dis- charged battery.
CAUTION: Do not crank starter motor on disabled vehicle for more than 15 seconds, starter will over- heat and could fail.
(7) Allow battery in disabled vehicle to charge to at least 12.4 volts (75% charge) before attempting to start engine. If engine does not start within 15 sec- onds, stop cranking engine and allow starter to cool (15 min.), before cranking again.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
ground on disabled vehicle.
† Disconnect BLACK cable clamp from engine † When using a Booster vehicle, disconnect BLACK cable clamp from battery negative terminal. Disconnect RED cable clamp from battery positive terminal. † Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle.
0 - 14
LUBRICATION & MAINTENANCE
DR
HOISTING STANDARD PROCEDURE - HOISTING
Refer to the Owner’s Manual for emergency vehicle
lifting procedures.
WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHI- CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO- NENT IS REMOVED FROM A VEHICLE, THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE. PROPERLY SUPPORT (Fig. 5) OR SECURE VEHICLE TO HOIST- ING DEVICE WHEN THESE CONDITIONS EXIST.
† A drive shaft. † The engine or transmission oil pan. † The fuel tank. † A front suspension arm.
NOTE: Use the correct frame rail only (Fig. 7) and (Fig. 8).
lifting locations
HOIST
A vehicle can be lifted with: † A single-post, frame-contact hoist. † A twin-post, chassis hoist. † A ramp-type, drive-on hoist.
NOTE: When a frame-contact type hoist is used, verify that the lifting pads are positioned properly (Fig. 6). The forward lifting pads should be posi- tioned against the forward flange of the transmis- sion crossmember brackets at the bottom of the frame rail (Fig. 7). The real lifting pads should be wedged between the forward flange of the leaf spring bracket and the frame rail (Fig. 8). Safety stands should be placed under the frame rails at the front and rear ends (Fig. 5).
Fig.5SafetyStands
1 - SAFETY STANDS
FLOOR JACK
When properly positioned, a floor jack can be used to lift a vehicle (Fig. 6). Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails (Fig. 5).
CAUTION: Do not lift vehicle with a floor jack posi- tioned under: † An axle tube. † A body side sill. † A steering linkage component.
Fig.6VehicleLiftingLocations
DR HOISTING (Continued)
LUBRICATION & MAINTENANCE
0 - 15
Fig.7FRONTLIFTPADLOCATION
1 - BODY MOUNT BRACKET 2 - FRONT LIFT PAD 3 - TRANSMISSION CROSSMEMBER BRACKET 4 - FRAME RAIL
Fig.9TowVehiclesWithApprovedEquipment
1 - SLING TYPE 2 - WHEEL LIFT 3 - FLAT BED
SAFETY PRECAUTIONS
CAUTION: The following safety precautions must be observed when towing a vehicle:
being towed.
disabled vehicle’s fuel tank.
while it is lifted by the towing device.
pendent of the lifting and towing equipment.
† Secure loose and protruding parts. † Always use a safety chain system that is inde- † Do not allow towing equipment to contact the † Do not allow anyone under the disabled vehicle † Do not allow passengers to ride in a vehicle † Always observe state and local laws regarding † Do not tow a vehicle in a manner that could jeopardize the safety of the operator, pedestrians or other motorists. † Do not attach tow chains, T-hooks, J-hooks, or a tow sling to a bumper, steering linkage, drive shafts or a non-reinforced frame hole. † Do not tow a heavily loaded vehicle. Damage to the cab, cargo box or frame may result. Use a flatbed device to transport a loaded vehicle.
towing regulations.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels removed, install lug nuts to retain brake drums or rotors.
Fig.8REARLIFTPADLOCATION
1 - FRAME RAIL 2 - REAR LIFT PAD 3 - LEAF SPRING MOUNTING BRACKET 4 - BOX MOUNTING BRACKET
TOWING STANDARD PROCEDURE - TOWING
A vehicle equipped with SAE approved sling-type towing equipment can be used to tow all vehicles. When towing a 4WD vehicle using a wheel-lift towing device, use tow dollies under the opposite end of the vehicle. A vehicle with flat-bed device can also be used to transport a disabled vehicle (Fig. 9).
A wooden crossbeam may be required for proper connection when using the sling-type, front-end tow- ing method.
LUBRICATION & MAINTENANCE
0 - 16
TOWING (Continued)A towed vehicle should be raised until lifted wheels are a minimum 100 mm (4 in) from the ground. Be sure there is adequate ground clearance at the oppo- site end of the vehicle, especially when towing over rough terrain or steep rises in the road. If necessary, remove the wheels from the lifted end of the vehicle and lower the vehicle closer to the ground, to increase the ground clearance at the opposite end of the vehicle. Install lug nuts on wheel attaching studs to retain brake drums or rotors.
RAMP ANGLE
If a vehicle with flat-bed towing equipment is used, the approach ramp angle should not exceed 15
degrees.TOWING WHEN KEYS ARE NOT AVAILABLE
When the vehicle is locked and keys are not avail- able, use a flat bed hauler. A Wheel-lift or Sling-type device can be used on 4WD vehicles provided all the wheels are lifted off the ground using tow dol- lies.
DR
FOUR-WHEEL-DRIVE VEHICLE TOWING
Chrysler Corporation recommends that a vehicle be transported on a flat-bed device. A Wheel-lift or Sling-type device can be used provided all the wheels are lifted off the ground using tow dol- lies.
WARNING: WHEN TOWING A DISABLED VEHICLE AND THE DRIVE WHEELS ARE SECURED IN A WHEEL LIFT OR TOW DOLLIES, ENSURE THE TRANSMISSION IS IN THE PARK POSITION (AUTO- MATIC TRANSMISSION) OR A FORWARD DRIVE GEAR (MANUAL TRANSMISSION).
CAUTION: Many vehicles are equipped with air dams, spoilers, and/or ground effect panels. To avoid component damage, a wheel-lift towing vehi- cle or a flat-bed hauling vehicle is recommended.
DR
SUSPENSION
2 - 1
SUSPENSION
TABLE OF CONTENTS
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . 1
FRONT - INDEPENDENT FRONT SUSPENSION . . 8FRONT - LINK/COIL REAR
. . . . . . . . . . . . . . . . . . . . . . 28
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38page
page
WHEEL ALIGNMENT
TABLE OF CONTENTS
page
page
WHEEL ALIGNMENT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - PRE-ALIGNMENTINSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
STANDARD PROCEDURE
STANDARD PROCEDURE - HEIGHT
STANDARD PROCEDURE - TOE
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 4
STANDARD PROCEDURE - CAMBER,
CASTER AND TOE ADJUSTMENT . . . . . . . . . . 4
STANDARD PROCEDURE - ALIGNMENT
LINK/COIL SUSPENSION. . . . . . . . . . . . . . . . . 5
SPECIFICATIONS
MEASUREMENT - 4WD (LD) . . . . . . . . . . . . . . 3
ALIGNMENT
. . . . . . . . . . . . . . . . . . . . . . . . . . 6
STANDARD PROCEDURE - HEIGHT
SPECIAL TOOLS
ADJUSTMENT - 4WD (LD) . . . . . . . . . . . . . . . . 3
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . 7
STANDARD PROCEDURE - CAMBER AND
CASTER ADJUSTMENT . . . . . . . . . . . . . . . . . . 4
WHEEL ALIGNMENT DESCRIPTION
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.
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 stabil- ity and to minimize tire wear. The most important measurements of an alignment are caster, camber and toe (Fig. 1).
CAUTION: Never attempt to modify suspension or steering components by heating or bending.
Fig.1WheelAlignmentMeasurements
1 - FRONT OF VEHICLE 2 - STEERING AXIS INCLINATION 3 - PIVOT POINT 4 - TOE-IN
2 - 2 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) OPERATION † CASTER is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle forward provides less positive caster. Tilting the top of the knuckle rearward provides more posi- tive caster. Positive caster promotes directional sta- bility. This angle enables the front wheels to return to a straight ahead position after turns (Fig. 1) † 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 (Fig. 1) † TOE is the difference between the leading inside edges and trailing inside edges of the front tires. Wheel toe position out of specification cause’s unsta- ble steering, uneven tire wear and steering wheel off- center. The wheel toe position is the final front wheel alignment adjustment (Fig. 1) † THRUST ANGLE is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust angle can cause off-center steering and exces-
DR
sive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust angle (Fig. 1)
DIAGNOSIS AND TESTING - PRE-ALIGNMENT INSPECTION
Before starting wheel alignment,
the following inspection and necessary corrections must be com- pleted. Refer to Suspension and Steering System Diagnosis Chart below for additional information.
(1) Inspect tires for size, air pressure and tread
(2) Inspect front wheel bearings for wear. (3) Inspect front wheels for excessive radial or lat-
eral runout and balance. (4) Inspect ball studs,
steering gear for looseness, roughness or binding.
(5) Inspect suspension components for wear and
linkage pivot points and
(6) On 4x4 vehicles check suspension height (LD
wear.
noise.
only).
(7) Road test the vehicle.
SUSPENSION AND STEERING SYSTEM DIAGNOSIS
CONDITION
POSSIBLE CAUSES
CORRECTION
FRONT END NOISE
1. Loose or worn wheel bearing.
1. Replace wheel bearing.
EXCESSIVE PLAY IN STEERING
2. Loose or worn steering or suspension components. 3. Loose or worn steering or suspension components.
2. Tighten or replace components as necessary. 3. Tighten or replace components as necessary.
1. Loose or worn wheel bearing.
1. Replace wheel bearing.
2. Loose or worn steering or suspension components. 3. Loose or worn steering gear.
2. Tighten or replace components as necessary. 3. Replace steering gear.
FRONT WHEELS SHIMMY
1. Loose or worn wheel bearing.
1. Replace wheel bearing.
2. Loose or worn steering or suspension components. 3. Tires worn or out of balance. 4. Alignment.
2. Tighten or replace components as necessary. 3. Replace or balance tires. 4. Align vehicle to specifications.
VEHICLE INSTABILITY
1. Loose or worn wheel bearing.
1. Replace wheel bearing.
2. Loose or worn steering or suspension components. 3. Tire pressure. 4. Alignment.
2. Tighten or replace components as necessary. 3. Adjust tire pressure. 4. Align vehicle to specifications.
DR WHEEL ALIGNMENT (Continued)
WHEEL ALIGNMENT
2 - 3
CONDITION
POSSIBLE CAUSES
CORRECTION
EXCESSIVE STEERING EFFORT
VEHICLE PULLS TO ONE SIDE
1. Loose or worn steering gear.
1. Replace steering gear.
2. Column coupler binding. 3. Tire pressure. 4. Alignment.
1. Tire pressure. 2. Tire. 3. Alignment. 4. Loose or worn steering or suspension components. 5. Radial tire lead. 6. Brake pull. 7. Weak or broken spring. 8. Ride height (LD) 4WD only.
2. Replace coupler. 3. Adjust tire pressure. 4. Align vehicle to specifications.
1. Adjust tire pressure. 2. Criss-Cross Front Tires. 3. Align vehicle to specifications. 4. Tighten or replace components as necessary. 5. Rotate or replace tire as necessary. 6. Repair brake as necessary. 7. Replace spring. 8. Measure and adjust ride height. (LD only)
STANDARD PROCEDURE
STANDARD PROCEDURE - HEIGHT MEASUREMENT - 4WD (LD)
The vehicle suspension height MUST be measured and adjusted before performing wheel alignment pro- cedure. Also when front suspension components have been replaced. This measure must be performed with the vehicle supporting it’s own weight and taken on both sides of the vehicle.
(1) Inspect tires and set to correct pressure. (2) Jounce the front of the vehicle. (3) Measure and record the height from the ground at the centerline of the rear lower control arm bolt front tip (Fig. 2).
(4) Measure and record the height from the ground at the front spindle centerline (Static Load Radius) (Fig. 2).
(5) Subtract the first measurement from the sec- ond measurement. The difference between the two measurement should be 58 mm (2.3 inches) ± 3 mm (0.12 inches).
(6) If value is greater than 61 mm (2.4 inches), tighten the torsion bar bolt until the specification is achieved (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
(7) If value is less than 55 mm (2.1 inches), loosen the torsion bar bolt until the specification is achieve- d,(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
(8) Repeat the previous steps until the ride height
is within specifications.
Fig.2HEIGHTMESUREMENT
1 - HEIGHT FROM THE GROUND AT THE FRONT SPINDLE CENTERLINE (STATIC LOAD RADIUS) 2 - CENTERLINE OF THE REAR LOWER CONTROL ARM BOLT FRONT TIP 3 - GROUND LINE
STANDARD PROCEDURE - HEIGHT ADJUSTMENT - 4WD (LD)
The vehicle suspension height MUST be measured and adjusted before performing wheel alignment pro- cedure (Refer to 2 - SUSPENSION/WHEEL ALIGN- MENT - STANDARD PROCEDURE). Also when front suspension components have been replaced. This measurement must be performed with the vehi- cle supporting it’s own weight and taken on both sides of the vehicle.
2 - 4 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued)
To adjust the vehicle height turn the torsion bar adjustment bolt CLOCKWISE to raise the vehicle and COUNTER CLOCKWISE to lower the vehicle.
CAUTION: ALWAYS raise the vehicle to the correct suspension height, NEVER lower the vehicle to obtain the correct suspension height. If the vehicle suspension height is too high, lower the vehicle below the height specification. Then raise the vehi- cle to the correct suspension height specification. This will insure the vehicle maintains the proper suspension height.
NOTE: If a height adjustment has been made, per- form height measurement again on both sides of the vehicle.
STANDARD PROCEDURE - CAMBER AND CASTER ADJUSTMENT
NOTE: 4X4 (LD) SUSPENSION HEIGHT MEASURE- MENT MUST BE PERFORMED BEFORE AN ALIGN- MENT.
NOTE: When the upper control arm pivot bolts are loosened the upper control arm will normally go inwards toward the frame automatically with the weight of the vehicle.
Camber and caster angle adjustments involve changing the position of the upper control arm incon- junction with the slotted holes in the frame brackets, Install special tool 8876 between the top of the upper control arm bracket and the upper control arm (on 1500 series 4X2 & 4X4). Install special tool 8876
between the bottom of the upper control arm bracket pressing the tool against the frame and the upper control arm (on 2500/3500 series 4X2) in order to move the upper control arm outwards for proper adjustment with the vehicle at normal ride height (Fig. 3).STANDARD PROCEDURE - TOE ADJUSTMENT
4X4 SUSPENSION HEIGHT MESUREMENT MUST BE PERFORMED BEFORE AN ALIGN- MENT.
The wheel toe position adjustment is 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 jam nuts.
DR
Fig.3CASTER&CAMBERADJUSTMENT
1 - FRONT PIVOT BOLT 2 - REAR PIVOT BOLT 3 - SLOTTED HOLES FOR ADJUSTMENT OF CASTER & CAMBER 4 - UPPER CONTROL ARM
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
inner tie rod as necessary (Fig. 4).
(4) Tighten the tie rod jam nut to 75 N·m (55 ft.
lbs.).
(5) Verify the specifications (6) Turn off engine.
STANDARD PROCEDURE - CAMBER, CASTER AND TOE ADJUSTMENT
NOTE: 4X4 (LD) SUSPENSION HEIGHT MEASURE- MENT MUST BE PERFORMED BEFORE AN ALIGN- MENT.
Camber and caster angle adjustments involve changing the position of the upper control arm with the slots in the frame brackets using special tool 8876 to move the upper control arm outwards for proper adjustment. (Fig. 3)
NOTE: When the upper control arm pivot bolts are loosened the upper control arm will normally go inwards toward the frame automatically with the weight of the vehicle.
CASTER
Moving the front or rear position of the upper con- trol arm in or out, will change the caster angle and camber angle significantly. To maintain the camber
DR WHEEL ALIGNMENT (Continued)
angle while adjusting caster, move one pivot bolt of the upper control arm in or out. Then move the other pivot bolt of the upper control arm in the opposite direction. Install special tool 8876 between the top of the upper control arm bracket and the upper control arm (on 1500 series 4X2 & 4X4). Install special tool 8876 between the bottom of the upper control arm bracket pressing the tool against the frame and the upper control arm (on 2500/3500 series 4X2) in order to move the upper control arm outwards for proper adjustment with the vehicle at normal ride height (Fig. 3).
To increase positive caster angle, move the rear position of the upper control arm inward (toward the engine). Move the front of the upper control arm out- ward (away from the engine) slightly until the origi- nal camber angle is obtained using special tool 8876
to move the upper control arm for proper adjustment. (Fig. 3)CAMBER
Move both pivot bolts of the upper control arm together in or out. This will change the camber angle significantly and little effect on the caster angle using special tool 8876 to move the upper control arm for proper adjustment. (Fig. 3)
After adjustment is made tighten the upper control
arm nuts to proper torque specification.
TOE ADJUSTMENT
The wheel toe position adjustment is 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 jam nuts.
WHEEL ALIGNMENT
2 - 5
Fig.4TIERODEND
1 - JAM NUT 2 - TIE ROD - INNER 3 - TIE ROD END - OUTER
the down position. Set the front end alignment to specifications while the vehicle is in its NOR- MALLY LOADED CONDITION.
CAMBER: The wheel camber angle is preset and
is not adjustable.
CASTER: Check the caster of the front axle for correct angle. Be sure the axle is not bent or twisted. Road test the vehicle and make left and right turn. Observe the steering wheel return-to-center position. Low caster will cause poor steering wheel returnabil- ity.
Caster can be adjusted by rotating the cams on the
lower suspension arm (Fig. 5).
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
inner tie rod as necessary (Fig. 4).
(4) Tighten the tie rod jam nut to 75 N·m (55 ft.
lbs.).
(5) Verify the specifications (6) Turn off engine.
STANDARD PROCEDURE - ALIGNMENT LINK/COIL SUSPENSION
Before each alignment reading the vehicle should be jounced (rear first, then front). Grasp each bumper at the center and jounce the vehicle up and down several times. Always release the bumper in
Fig.5ALIGNMENTADJUSTMENTCAM
1 - BRACKET REINFORCEMENT 2 - ADJUSTING BOLT 3 - ADJUSTMENT CAM
TOE POSITION: The wheel toe position adjust-
ment should be the final adjustment.
2 - 6 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued)
(1) Start the engine and turn wheels both ways before straightening the wheels. Center and Secure the steering wheel and turn off engine.
(2) Loosen the adjustment sleeve clamp bolts. (3) Adjust the right wheel toe position with the drag link. Turn the sleeve until the right wheel is at the correct TOE-IN position. Position clamp bolts to their original position and tighten to specifications. Make sure the toe setting does not change dur- ing clamp tightening.
(4) Adjust left wheel toe position with tie rod at left knuckle. Turn the sleeve until the left wheel is at the correct TOE-IN position. Position clamp bolts to their original position and tighten to specifications. Make sure the toe setting does not change dur- ing clamp tightening.
(5) Verify the right toe setting and a straight steer-
ing wheel.
(6) Road test the vehicle.
SPECIFICATIONS
ALIGNMENT
NOTE: All alignment specifications are in degrees.
SPECIFICATIONS
DESCRIP-
TION
VEHICLE
1500
WHEEL BASE
4X2
4X2
4X2
120.5
in
140.5
in
160.5
in
VEHICLE
1500
WHEEL BASE
4X4
4X4
4X4
120.5
in
140.5
in
160.5
in
SPECIFICATION
CASTER
(3.0° Max, +.75° Target)
4.0°
4.2°
4.4°
CASTER
(3.0° Max, +.75° Target)
4.2°
4.4°
4.6°
CAMBER (± .50°)
TOTAL TOE-IN (± .10°)
.0°
.0°
.0°
.10°
.10°
.10°
CAMBER (±.50°)
TOTAL TOE-IN (±.10°)
.0°
.0°
.0°
.10°
.10°
.10°
DR
SPECIFICATION
—
.40°
.50°
0.06°
DESCRIP-
TION
MAX RT/LT
DIF-
FERENCE
4X2
1500MAX RT/LT
—
.40°
.60°
0.06°
DIF-
FERENCE
4X4
1500VEHICLE
4X2
2500 & 3500
4X2
2500&3500
4X2
2500&3500
MAX RT/LTDIF-
FERENCE
4X2
2500&3500
VEHICLE4X4
2500&3500
4X4
2500&3500
4X4
2500&3500
MAX RT/LTDIF-
FERENCE
4X4
2500&3500
DESCRIP-TION
WHEEL BASE
140
160
—
CASTER (3.25° Max, +.75° Target)
4.0°
4.3°
CAMBER (±.50°)
0.0°
0.0°
±0.4°
±0.6°
WHEEL BASE
140
160
—
CASTER
CAMBER
(.25° ±.5°)
(4.0° Min, +.75° Target)
4.5°
.25°
4.7°
.25°
±.5°
±.5°
TOTAL TOE-IN (0.20° ±.10°)
.10° ± .05° .10° ± .05°
0.1°
TOTAL TOE-IN (0.20° ±.10°)
.10° ± .05° .10° ± .05° 0.1°
REAR SPECIFICATION
CAMBER
(-.10° ± 0.35°)
TOTAL TOE-IN (0.30° ± 0.35°)
THRUST ANGLE 0° ± 0.4°
4X2
4X4
1500THRUST ANGLE -0.2° ± 0.2°
4X2
4X42500&3500
DR WHEEL ALIGNMENT (Continued) SPECIAL TOOLS
WHEEL ALIGNMENT
WHEEL ALIGNMENT
2 - 7
8876-CAMBER/CASTERADJUSTMENTTOOL
2 - 8
FRONT - INDEPENDENT FRONT SUSPENSION
FRONT - INDEPENDENT FRONT SUSPENSION
TABLE OF CONTENTS
page
DR
page
FRONT - INDEPENDENT FRONT SUSPENSION
LOWER CONTROL ARM
DESCRIPTION
DESCRIPTION DESCRIPTION SPECIFICATIONS
. . . . . . . . . . . . . . . . . . . . . . . . 9
. . . . . . . . . . . . . . . . . . . . . . . . 9REMOVAL - 4X4 (LD) REMOVAL - 4X2
. . . . . . . . . . . . . . . . . . . 20
. . . . . . . . . . . . . . . . . . . . . . 20INSTALLATION
REMOVAL
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 10
SPECIAL TOOLS
. . . . . . . . . . . . . . . 21
INSTALLATION - 4X4 (LD) INSTALLATION - 4X2 . . . . . . . . . . . . . . . . . . . 21FRONT SUSPENSION . . . . . . . . . . . . . . . . . . 11
SPRING
BUSHINGS REMOVAL
REMOVAL - LOWER CONTROL ARM
BUSHINGS - 4WD (LD) . . . . . . . . . . . . . . . . . 12
REMOVAL - TORSION BAR
CROSSMEMBER BUSHING . . . . . . . . . . . . . . 12
REMOVAL - LOWER CONTROL ARM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22SHOCK
DIAGNOSIS AND TESTING - SHOCK . . . . . . . . 23
REMOVALREMOVAL - 4X2
REMOVAL - 4X4. . . . . . . . . . . . . . . . . . . . . . 23
. . . . . . . . . . . . . . . . . . . . . . 23BUSHINGS - 2WD (LD) . . . . . . . . . . . . . . . . . 12
INSTALLATION
INSTALLATION
INSTALLATION - LOWER CONTROL ARM
INSTALLATION - 4X2 . . . . . . . . . . . . . . . . . . . 23
INSTALLATION - 4X4 . . . . . . . . . . . . . . . . . . . 23BUSHINGS - 4WD (LD) . . . . . . . . . . . . . . . . . 13
STABILIZER BAR
INSTALLATION - TORSION BAR CROSS
MEMBER BUSHING . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION - LOWER CONTROL ARM
BUSHINGS - 2WD (LD) . . . . . . . . . . . . . . . . . 14
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24HUB / BEARING
REMOVAL
STABILIZER LINK
REMOVAL
REMOVAL - 4X4
REMOVAL - 4X2. . . . . . . . . . . . . . . . . . . . . . 15
. . . . . . . . . . . . . . . . . . . . . . 16REMOVAL - 4X4
REMOVAL - 4X2. . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . 24INSTALLATION
INSTALLATION
INSTALLATION - 4X4 . . . . . . . . . . . . . . . . . . . 16
INSTALLATION - 4X2 . . . . . . . . . . . . . . . . . . . 17INSTALLATION - 4X4 . . . . . . . . . . . . . . . . . . . 25
INSTALLATION - 4X2 . . . . . . . . . . . . . . . . . . . 25KNUCKLE
TORSION BAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26LOWER BALL JOINT
DIAGNOSIS AND TESTING - LOWER BALL
JOINT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19UPPER BALL JOINT
DIAGNOSIS AND TESTING - UPPER BALL
JOINT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
UPPER CONTROL ARM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27DR
FRONT - INDEPENDENT FRONT SUSPENSION
2 - 9
FRONT - INDEPENDENT FRONT SUSPENSION
DESCRIPTION
DESCRIPTION
The front suspension is designed to allow each wheel to adapt to different road surfaces indepen- dently. The wheels are mounted to hub/bearings units bolted to the steering knuckle. The double-row hub bearings are sealed and lubricated for life. The steering knuckles turn (pivot) on ball joints. The front suspension is comprised of (Fig. 1) (Fig. 2): † Shock absorbers † Torsion bar - 4X4 (LD only) † Coil Spring - 4X2
† Control arms † Steering knuckles † Stabilizer bar † Stabilizer link † Tie Rod Ends † Hub/Bearing † Rack & Pinion † Ball JointsFig.1FRONTSUSPENSION-4X2
1 - STABILIZER BAR 2 - UPPER CONTROL ARM 3 - STEERING KNUCKLE 4 - ROTOR 5 - CALIPER ADAPTER 6 - OUTER TIE ROD END 7 - STABILIZER LINK 8 - LOWER CONTROL ARM 9 - RACK & PINION 10 - COIL SPRING 11 - SHOCK ABSORBER
Fig.2FRONTSUSPENSION-4X4(LDONLY)
1 - STABILIZER BAR 2 - UPPER CONTROL ARM 3 - STEERING KNUCKLE 4 - ROTOR 5 - OUTER TIE ROD END 6 - SHOCK ABSORBER 7 - STABILIZER LINK 8 - LOWER CONTROL ARM 9 - INNER TIE ROD 10 - RACK & PINION
NOTE: Components attached with a nut must be torqued to specification.
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.
DESCRIPTION
The upper control arm bolts on frame brackets. The frame brackets have slotted holes which allow the arms to be adjusted for caster and camber.
The lower control arms bolt to the lower frame
brackets and pivots through bushings.
The control arms have lube for life ball studs. The control arm travel (jounce) is limited through the use of rubber/urethane bumpers. Rebound travel is lim- ited by the shock absorber.
FRONT - INDEPENDENT FRONT SUSPENSION
2 - 10
FRONT - INDEPENDENT FRONT SUSPENSION (Continued) SPECIFICATIONSTORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION Shock Absorber
Upper Nut
4X4
Shock Absorber
Lower Bolt
4X4
Shock Absorber
Upper Nut
4X2
Shock Absorber
Lower Bolt
4X2
Lower Suspension Arm
Frame Nuts
Lower Suspension Arm
Frame Nuts
Lower Suspension Arm
Ball Joint Nut
1500 series only
Lower Suspension Arm
Ball Joint Nut (HD 4X2 only
Upper Suspension Arm
Frame Nuts
(LD)
Upper Suspension Arm
Frame Nuts (HD 4X2 only)
Upper Suspension Arm
Ball Joint Nut
1500 series only
Stabilizer Bar Frame Bolt
Stabilizer Link
Lower Control Arm Nut
Stabilizer Link
Stabilizer Bar Nut
Hub/Bearing
Bolts (LD)
Hub/Bearing
Bolts
(HD 4X2)
Tie Rod End
Nut
N·m 54
135
54
34
204
285
52
Ft. Lbs.
40
100
40
25
150
210
38
Then an additional 90°
Then an additional 90°
135
132
170
54
100
97
125
40
Then an additional 90°
Then an additional 90°
61
102
38
163
176
61
45
75
27
120
130
45
Then an additional 90°
Then an additional 90°
DR
In. Lbs.
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
DR FRONT - INDEPENDENT FRONT SUSPENSION (Continued) SPECIAL TOOLS
FRONT - INDEPENDENT FRONT SUSPENSION
2 - 11
FRONT SUSPENSION
TORSIONBARBUSHINGREMOVAL/INSTALL-8835
PULLER-8677
4WDBUSHINGREMOVAL/INSTALLKIT-8682
TORSIONBARLOADER/UNLOADER-8686
RECEIVER/DRIVERBALLJOINT-8698
BALLJOINTPRESS-C-4212F
2WD-LOWERCONTROLARMBUSHING
REMOVAL/INSTALL-8836
2 - 12
FRONT - INDEPENDENT FRONT SUSPENSION
DR
BUSHINGS
REMOVAL
REMOVAL - LOWER CONTROL ARM BUSHINGS - 4WD (LD)
(1) Remove the lower control arm (Refer to 2 - SUSPENSION/FRONT/LOWER CONTROL ARM - REMOVAL).
(2) Secure the control arm in a vise.
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.
FRAME MOUNTED BUSHING
(1) Install the bushing tool 8682-3 (receiver) and 8682-4 (driver) with the threaded rod and the two bearings as shown for the replacement of the frame bushing (Fig. 3)
Fig.3FRAMEBUSHINGREMOVAL
1 - THREADED ROD 2 - BEARINGS 3 - 8682-3 (RECEIVER) 4 - FRAME 5 - 8682-4 (DRIVER) 6 - NUT 7 - BUSHING
CONTROL ARM BUSHING
(1) Install bushing remover tools 8682-2 (adapter), 8682-3 (receiver) and 8682-4 (driver) with the threaded rod and the two bearings as shown (Fig. 4)
Fig.4CONTROLARMBUSHINGREMOVAL
1 - 8682-4 (DRIVER) 2 - BUSHING 3 - LOWER CONTROL ARM 4 - 8682-2 (ADAPTER) 5 - 8682-3 (RECEIVER) 6 - BEARING 7 - THREADED ROD
REMOVAL - TORSION BAR CROSSMEMBER BUSHING
(1) Remove the torsion bar cross member (Refer to 13 - FRAME & BUMPERS/FRAME/REAR CROSS- MEMBER - REMOVAL).
(2) Secure the cross member in a vise.
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.
(3) Install special tools 8838 threaded rod, 8835-1, 8835-4 and 8835-3 as shown in the graphic below (Fig. 5).
(4) Press out the bushing.
REMOVAL - LOWER CONTROL ARM BUSHINGS - 2WD (LD)
NOTE: HD 4X2 bushings are not servicable.
(1) Remove the lower control arm (Refer to 2 - SUSPENSION/FRONT/LOWER CONTROL ARM - REMOVAL).
(2) Secure the control arm in a vise.
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.
DR BUSHINGS (Continued)
FRONT - INDEPENDENT FRONT SUSPENSION
2 - 13
Fig.5TORSIONBARCROSSMEMBERBUSHING-
REMOVAL
Fig.7SMALLLOWERCONTROLARMBUSHING-
REMOVAL
1 - 8838
2 - 8835-1
3 - 8835-4
4 - 8835-3LARGE BUSHING
(1) Install bushing remover tools 8836-2 (receiver), 8836-4 (spacer) and 8836-5 (driver) with the threaded rod 8839 and the bearing as shown (Fig. 6) for replacement of the large bushing.
1 - 8839 (THREADED ROD) 2 - 8836-6 (DRIVER) 3 - 8836-3 (SPACER) 4 - 8836-2 (RECEIVER)
INSTALLATION
INSTALLATION - LOWER CONTROL ARM BUSHINGS - 4WD (LD)
NOTE: Be careful to properly orient the bushing voids in the correct position to within ± 10°. The correct position places the long narrow void out- board of the bushing and the short wide void inboard of the bushing (Fig. 8).
Fig.6LARGELOWERCONTROLARMBUSHING-
REMOVAL
1 - 8836-4 (SPACER) 2 - 8836-5 (DRIVER) 3 - 8839 (THREADED ROD) 4 - 8836-2 (RECEIVER)
SMALL BUSHING
(1) Install the bushing tool 8836-6 (driver), 8836-3
(spacer) and 8836-2 (receiver) with the threaded rod 8839 and the bearing as shown for the replacement of the small bushing (Fig. 7)Fig.8REARLOWERCONTROLARMBUSHING
1 - SHORT - WIDE VOID 2 - INWARD TOWARD VEHICLE 3 - LONG - THIN VOID
DR
FRONT - INDEPENDENT FRONT SUSPENSION
2 - 14
BUSHINGS (Continued) FRAME MOUNTED BUSHINGNOTE: 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.
(1) Install the new bushing into the frame using special tools 8682-3 (receiver), 8682-1 (driver) with the two bearings and the threaded rod (Fig. 9)mak- ing sure to properly orient the bushing as shown (Fig. 8).
Fig.10CONTROLARMBUSHINGINSTALL
1 - THREADED ROD 2 - BEARINGS 3 - 8682-1 (DRIVER) 4 - BUSHING 5 - CONTROL ARM 6 - 8682-5 (RECEIVER) 7 - NUT
INSTALLATION - TORSION BAR CROSS MEMBER BUSHING
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.
(1) Install the new bushing into the cross member using special tools 8835-2, 8835-4 and 8835-3 with the bearing and the threaded rod 8838 (Fig. 11) mak- ing sure to properly orient the bushing.
(2) Remove the cross member from the vise. (3) Install the torsion bar cross member (Refer to 13 - FRAME & BUMPERS/FRAME/REAR CROSS- MEMBER - INSTALLATION).
(4) Reset the vehicle ride height (Refer to 2 - SUS- PENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
(5) Perform a wheel alignment (Refer to 2 - SUS- PENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
INSTALLATION - LOWER CONTROL ARM BUSHINGS - 2WD (LD)
NOTE: HD 4X2 bushings are not servicable.
Fig.9FRAMEBUSHINGINSTALL
1 - THREADED ROD 2 - BEARINGS 3 - 8682-3 (RECEIVER) 4 - BUSHING 5 - 8682-1 (DRIVER)
CONTROL ARM BUSHING
(1) Install the new lower control arm bushings into the lower control arm using tools 8682-1 (driver), 8682-5 (receiver) and the two bearings with the threaded rod (Fig. 10) making sure to properly orient the bushing in the control (Fig. 8).
(1) Remove the control arm from the vise. (2) Install the lower control arm (Refer to 2 - SUS- CONTROL ARM -
PENSION/FRONT/LOWER INSTALLATION).
(3) Reset the vehicle ride height (Refer to 2 - SUS- PENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
(4) Perform a wheel alignment (Refer to 2 - SUS- PENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
DR BUSHINGS (Continued)
FRONT - INDEPENDENT FRONT SUSPENSION
2 - 15
SMALL BUSHING
(1) Install the small bushings into the lower con- trol arm using tools 8836-7 (driver), 8836-2 (receiver), 8836–3 (spacer) and the bearing with the threaded rod (8839) (Fig. 13).
Fig.11TORSIONBARCROSSMEMBERBUSHING-
INSTALLATION
1 - 8835-2
2 - 8835-4
3 - 8835-3
4 - 8838LARGE BUSHING
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.
(1) Install the new bushing into the lower control arm using special tools 8836-2 (receiver), 8836-1
(driver), 8836-4 (spacer) with the bearing and the threaded rod (8839) (Fig. 12).Fig.12LARGELOWERCONTROLARMBUSHING-
INSTALL
1 - 8836-1 (DRIVER) 2 - 8839 (THREADED ROD) 3 - 8836-2 (RECEIVER) 4 - 8836-4 (SPACER)
Fig.13SMALLLOWERCONTROLARMBUSHING-
INSTALL
1 - 8836-2 (RECEIVER) 2 - 8839 (THREADED ROD) 3 - 8836-3 (SPACER) 4 - 8836-7 (DRIVER)
(1) Remove the control arm from the vise. (2) Install the lower control arm (Refer to 2 - SUS- CONTROL ARM -
PENSION/FRONT/LOWER INSTALLATION).
(3) Reset the vehicle ride height (Refer to 2 - SUS- PENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
(4) Perform a wheel alignment (Refer to 2 - SUS- PENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
HUB / BEARING
REMOVAL
REMOVAL - 4X4
(1) Raise and support the vehicle. (2) Remove the wheel and tire assembly. (3) Remove the brake caliper and rotor (Refer to 5
- BRAKES/HYDRAULIC/MECHANICAL/ROTORS - REMOVAL).(4) Remove
equipped, FRONT WHEEL SPEED SENSOR - REMOVAL).
the ABS wheel
if to 5 - BRAKES/ELECTRICAL/
speed sensor
(Refer
(5) Remove the halfshaft nut.
FRONT - INDEPENDENT FRONT SUSPENSION
2 - 16
HUB / BEARING (Continued)NOTE: Do not strike the knuckle with a hammer to remove the tie rod end or the ball joint. Damage to the steering knuckle will occur.
DR
(6) Remove the tie rod end nut and separate the
tie rod from the knuckle using special tool 8677.
(7) Remove the upper ball joint nut and separate the upper ball joint from the knuckle using special tool 8677.
(8) Pull down on the steering knuckle to separate
the halfshaft from the hub/bearing.
Fig.15HUB/BEARING4X2
1 - HUB/BEARING 2 - DUST SHIELD 3 - STEERING KNUCKLE 4 - WHEEL SPEED SENSOR WIRE 5 - HUB/BEARING MOUNTING NUT
INSTALLATION
INSTALLATION - 4X4
(1) Install the brake dust shield (Fig. 16). (2) Install
steering knuckle and tighten the bolts to 163 N·m (120 ft. lbs.) (Fig. 16).
the hub/bearing into
the
Fig.14HALFSHAFT/HUB/BEARING
1 - HUB/BEARING MOUNTING NUTS 2 - HALF SHAFT
(9) Remove the three hub/bearing mounting bolts
from the steering knuckle (Fig. 14).
(10) Slide the hub/bearing out of
the steering
knuckle (Fig. 14).
(11) Remove the brake dust shield.
REMOVAL - 4X2
(1) Raise and support the vehicle. (2) Remove the wheel and tire assembly. (3) Remove the brake caliper and rotor (Refer to 5
- BRAKES/HYDRAULIC/MECHANICAL/ROTORS - REMOVAL).(4) Remove
the ABS wheel
if equipped, to 5 - BRAKES/ELECTRICAL/ FRONT WHEEL SPEED SENSOR - REMOVAL) (Fig. 15)
speed sensor
(Refer
(5) Remove the three hub/bearing mounting bolts
from the steering knuckle (Fig. 15).
(6) Slide the hub/bearing out of
the steering
knuckle (Fig. 15).
(7) Remove the brake dust shield (Fig. 15).
Fig.16HUB/BEARING4X4
1 - HUB/BEARING 2 - DUST SHIELD 3 - STEERING KNUCKLE 4- WHEEL SPEED SENSOR WIRE 5 - HUB/BEARING MOUNTING NUT
(3) Install the brake rotor and caliper (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS INSTALLATION).
DR HUB / BEARING (Continued)
FRONT - INDEPENDENT FRONT SUSPENSION
2 - 17
(4) Install the ABS wheel speed sensor if equipped - BRAKES/ELECTRICAL/FRONT
(Refer WHEEL SPEED SENSOR - INSTALLATION).
to
(5) Install the upper ball joint nut to the steering knuckle and tighten to 54 N·m (40 ft. lbs.) (on 1500
series only an additional 90° turn).(6) Install the tie rod end nut to the steering knuckle and tighten to 61 N·m (45 ft. lbs.) then an additional 90°.
(7) Install the halfshaft nut and tighten to 251
N·m (185 ft. lbs.).
(8) Install the wheel and tire assembly (Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE- DURE).(9) Remove the support and lower vehicle.
INSTALLATION - 4X2
(1) Install the brake dust shield (Fig. 15). (2) Install
steering knuckle and tighten the bolts to 163 N·m (120 ft. lbs.) (Fig. 15).
the hub/bearing into
the
(3) Install the brake rotor and caliper (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS INSTALLATION).
(4) Install the ABS wheel speed sensor if equipped - BRAKES/ELECTRICAL/FRONT (Refer WHEEL SPEED SENSOR - INSTALLATION) (Fig. 15).
to
(5) Install the wheel and tire assembly (Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE- DURE).(6) Remove the support and lower vehicle.
KNUCKLE DESCRIPTION
The knuckle is a single casting with legs machined for the upper and lower ball joints. The knuckle also has machined mounting locations for the front brake calipers and hub bearing.
OPERATION
The steering knuckle pivot between the upper and joint. Steering linkage attached to the
lower ball knuckle allows the vehicle to be steered.
REMOVAL
(1) Raise and support the vehicle. (2) Remove the wheel and tire assembly. (3) Remove the brake caliper, rotor (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS REMOVAL), shield and ABS wheel speed sensor if equipped (Refer to 5 - BRAKES/ELECTRICAL/ FRONT WHEEL SPEED SENSOR - REMOVAL).
(4) Remove the front halfshaft nut (if equipped).
(5) Remove the tie rod end nut. Separate the tie
rod from the knuckle with Remover 8677.
CAUTION: When installing Remover 8677 to sepa- rate the ball joint, be careful not to damage the ball joint seal.
(6) Remove the upper ball joint nut. Separate the ball joint from the knuckle with Remover 8677 (Fig. 17)
Fig.17STEERINGKNUCKLE
1 - STEERING KNUCKLE 2 - SHOCK 3 - HALFSHAFT 4 - DISC BRAKE CALIPER 5 - HUB/BEARING
(7) Remove the lower ball joint nut. Separate the ball joint from the knuckle with Remover 8677 (Fig. 18) and remove the knuckle.
Fig.18LOWERBALLJOINTSEPARATION
1 - STEERING KNUCKLE 2 - SPECIAL TOOL 8677
FRONT - INDEPENDENT FRONT SUSPENSION
2 - 18
KNUCKLE (Continued)DR
(8) Remove the hub/bearing from the steering knuckle (Refer to 2 - SUSPENSION/FRONT/HUB / BEARING - REMOVAL).
INSTALLATION
CAUTION: The ball joint stud tapers must be CLEAN and DRY before installing the knuckle. Clean the stud tapers with mineral spirits to remove dirt and grease.
NOTE: When installing hub/bearing with ABS brakes, position the speed sensor opening towards the front of the vehicle.
(1) Install the hub/bearing to the steering knuckle and tighten the bolts to 163 N·m (120 ft. lbs.)(LD) or 176 N·m (130 ft. lbs.)(HD 4X2) (Fig. 19).
(2) Install the knuckle onto the upper and lower
ball joints (Fig. 19).
(8) Install the ABS wheel speed sensor if equipped (Refer to 5 - BRAKES/ELECTRICAL/FRONT WHEEL SPEED SENSOR - INSTALLATION) and brake shield, rotor and caliper (Refer to 5 - BRAKES/HYDRAULIC/ MECHANICAL/ROTORS - INSTALLATION).
(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) Perform a wheel alignment (Refer to 2 - SUS- PENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
LOWER BALL JOINT DIAGNOSIS AND TESTING - LOWER 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) Mount a dial indicator solidly to the topside of the lower control arm and then zero the dial indicator. (3) Position the indicator plunger against the bot-
tom surface of the steering knuckle.
NOTE: The dial indicator plunger must be perpen- dicular to the machined surface of the steering knuckle.
Fig.19STEERINGKNUCKLE
1 - STEERING KNUCKLE 2 - LOWER CONTROL ARM 3 - LOWER BALL JOINT NUT
(3) Install the upper and lower ball
joint nuts. Tighten the upper ball joint nut to 54 N·m (40 ft. lbs.) (on 1500 series only an additional 90° turn is required) and the lower ball joint nut to 52 N·m (38
ft. lbs.)(on 1500 series only an additional 90° turn is required)(LD) or 135 N·m (100 ft. lbs.)(HD 4X2).(4) Remove the hydraulic jack from the lower sus-
pension arm.
61 N·m (45 ft. lbs.).
(if equipped).
(5) Install the tie rod end and tighten the nut to
(6) Install the front halfshaft into the hub/bearing
(7) Install the the halfshaft nut and tighten to 251
N·m (185 ft. lbs.) (if equipped).
(4) Position a pry bar under the tire assembly. Pry
upwards on the tire assembly.
(5) If the travel exceeds 0.5 mm (0.020 in.), replace joint (Refer to 2 - SUSPENSION/
the lower ball FRONT/LOWER BALL JOINT - REMOVAL).
REMOVAL
(1) Remove the tire and wheel assembly. (2) Remove the brake caliper and rotor (Refer to 5
- BRAKES/HYDRAULIC/MECHANICAL/ROTORS - REMOVAL).(3) Disconnect
the tie rod from the steering knuckle (Refer to 19 - STEERING/LINKAGE/TIE ROD END - REMOVAL).
(4) Remove the steering knuckle (Fig. 20)(Refer to 2 - SUSPENSION/FRONT/KNUCKLE - REMOVAL). (5) Move the halfshaft to the side and support the
halfshaft out of the way (If Equipped).
(6) Remove the snap ring, from the lower control
arm (HD 4X2 only)
DR LOWER BALL JOINT (Continued)
FRONT - INDEPENDENT FRONT SUSPENSION
2 - 19
