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-
.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
(1) Install the ball joint into the control arm and press in using special tools C-4212–F (press), 8698-1
(driver) and 8698-3 (receiver) (Fig. 22).Fig.20LOWERBALLJOINTSEPARATION
1 - STEERING KNUCKLE 2 - SPECIAL TOOL 8677
NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation pro- cess.
Fig.22INSTALLLOWERBALLJOINT
1 - PRESS - C-4212-F 2 - DRIVER - 8698-1
3 - BALL JOINT 4 - LOWER CONTROL ARM 5 - RECEIVER - 8698-3(7) Press the ball joint from the lower control arm tools C-4212–F (PRESS), 8698-2
using (RECEIVER) and 8698-3 (DRIVER) (Fig. 21).
special
Fig.21REMOVALLOWERBALLJOINT
1 - PRESS - C-4212-F 2 - DRIVER - 8698-3
3 - BALL JOINT 4 - RECEIVER - 8698-2INSTALLATION
NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process.
(2) Install the ball joint boot. (3) Stake the ball
flange in four evenly spaced places around the ball joint flange, using a chisel and hammer (LD only).
joint
(4) Replace the snap ring (HD 4X2 only) (5) Remove the support
for the halfshaft and
install into position (If Equipped).
(6) Install the steering knuckle (Refer to 2 - SUS-
PENSION/FRONT/KNUCKLE - INSTALLATION).
(7) Install the tie rod end into the steering knuckle (Refer to 19 - STEERING/LINKAGE/TIE ROD END - INSTALLATION).
(8) Install and tighten the halfshaft nut to 251
N·m (185 ft. lbs.). (If Equipped).
(9) Install the brake caliper and rotor (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS INSTALLATION).
(10) Install the tire and wheel assembly (Refer to 22 - TIRES/WHEELS/WHEELS - STANDARD PRO- CEDURE).
(11) Check the vehicle ride height (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
(12) Perform a wheel alignment (Refer to 2 - SUS- PENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
2 - 20
FRONT - INDEPENDENT FRONT SUSPENSION
DR
LOWER CONTROL ARM
REMOVAL
REMOVAL - 4X4 (LD)
(1) Raise and support the vehicle. (2) Remove the wheel and tire assembly. (3) Remove the upper ball joint nut. Separate ball joint from the steering knuckle with Remover 8677. (4) Remove the front halfshaft, (Refer to 3 - DIF- FERENTIAL & DRIVELINE/HALF SHAFT - REMOVAL).
(5) Remove the torsion bar, (Refer to 2 - SUSPEN-
SION/FRONT/TRACK BAR - REMOVAL).
(6) Remove the shock absorber lower bolt. (7) Remove the stabilizer bar link (Refer to 2 -
SUSPENSION/FRONT/STABILIZER REMOVAL).
LINK
(8) Remove the lower ball joint nut. Separate ball joint from the steering knuckle with Remover 8677. (9) Remove the control arm pivot bolts and suspen-
sion arm from frame rail brackets (Fig. 23).
Fig.23LOWERCONTROLARM
1 - LOWER CONTROL ARM 2 - UPPER CONTROL ARM 3 - FRONT BOLT 4 - NUTS 5 - REAR BOLT
REMOVAL - 4X2
(1) Raise and support the vehicle. (2) Remove the tire and wheel assembly. (3) Support the lower control arm at the outboard side of the lower control arm to support vehicle weight.
(4) Remove the shock (Refer to 2 - SUSPENSION/
FRONT/SHOCK - REMOVAL).
(5) Install Spring Compressor DD-1278 up through the lower suspension arm, coil spring and shock hole
in the frame. The bell-shaped adapter goes against the lower suspension arm. Install the nut on top of the tool at the shock hole.
(6) Tighten the spring compressor nut against bell-
shaped adapter finger tight then loosen 1/2 turn.
NOTE: This will hold the spring in place until the lower suspension arm is separated from the steer- ing knuckle.
(7) Remove the stabilizer link (Refer to 2 - SUS- PENSION/FRONT/STABILIZER LINK - REMOVAL). (8) Remove the lower ball joint nut at the steering
knuckle.
(9) Install Ball Joint Remover tool 8677 on the lower ball joint and separate the ball joint from the knuckle.
NOTE: Do not allow the upper control arm and steering knuckle to rebound downwards they must be supported.
(10) Support the upper control arm and steering
knuckle out of the way.
(11) Remove the lower control arm support. (12) Tighten the spring compressor tool to allow clearance for the lower ball joint to be removed out of the knuckle.
(13) Loosen the tension on the spring compressor tool slowly allowing the lower suspension arm to pivot downward.
(14) Remove the spring compressor tool. (15) Remove coil spring and isolator pad from the
(16) Remove the front and rear pivot bolts (Fig.
vehicle (Fig. 26).
24).
(17) Remove the lower control arm.
Fig.24LOWERCONTROLARM-4X2
1 - FRONT PIVOT BOLT 2 - REAR PIVOT BOLT 3 - LOWER CONTROL ARM
DR LOWER CONTROL ARM (Continued) INSTALLATION
INSTALLATION - 4X4 (LD)
(1) Position the lower control arm at the frame rail brackets. Install the pivot bolts and nuts. Tighten the nuts finger-tight.
CAUTION: The ball joint stud taper must be CLEAN and DRY before installing the knuckle. Clean the stud taper with mineral spirits to remove dirt and grease.
(2) Insert the lower ball
joint into the steering knuckle. Install and tighten the retaining nut to 52
N·m (38 ft. lbs.)(on 1500 series only an additional 90° turn is required).(3) Install the torsion bar, (Refer to 2 - SUSPEN-
SION/FRONT/TRACK BAR - INSTALLATION).
(4) Install shock absorber lower bolt and tighten to
135 N·m (100 ft. lbs.).
(5) Install the front halfshaft, (Refer to 3 - DIF- FERENTIAL & DRIVELINE/HALF SHAFT - INSTALLATION).
(6) Insert the upper ball
joint into the steering knuckle. Install and tighten the retaining nut to 54
N·m (40 ft. lbs.)(on 1500 series only an additional 90° turn is required).(7) Install the stabilizer bar link (Refer to 2 - SUS- PENSION/FRONT/STABILIZER LINK - INSTALLA- TION).
(8) Tighten the lower control arm front pivot nut to 204 N·m (150 ft. lbs.). Tighten rear pivot bolt to 204 N·m (150 ft. lbs.).
(9) Install the wheel and tire assembly,(Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE- DURE).(10) Remove the support and lower the vehicle. (11) Adjust the front suspension height and per- form a wheel alignment (Refer to 2 - SUSPENSION/ WHEEL ALIGNMENT - STANDARD PROCEDURE).
INSTALLATION - 4X2
(1) Install the lower control arm into place on the
vehicle.
bolts finger tight.
(2) Install the front and rear control arm pivot
(3) Install the coil spring into the frame pocket(Re- fer to 2 - SUSPENSION/FRONT/SPRING - INSTAL- LATION).
(4) Install
the Spring Compressor DD-1278 up through the lower suspension arm, coil spring and shock hole in the frame.
(5) Tighten the tool nut
to compress the coil
spring.
(6) Remove the support from the upper control
arm and steering knuckle.
FRONT - INDEPENDENT FRONT SUSPENSION
2 - 21
(7) Position the lower ball joint into the steering
knuckle.
(8) Install the retaining nut on the lower ball joint and tighten to 52 N·m (38 ft. lbs.)(on 1500 series only an additional 90° turn is required) or 135 N·m (100
ft. lbs.)(HD 4X2 only).(9) Support the lower control arm at the outboard side of the lower control arm to support vehicle weight.
(10) Remove the spring compressor tool. (11) Install the shock absorber. (Refer to 2 - SUS-
PENSION/FRONT/SHOCK - INSTALLATION).
(12) Install the stabilizer link (Refer to 2 - SUS- PENSION/FRONT/STABILIZER LINK - INSTALLA- TION).
(13) Remove the lower control arm support. (14) Install the wheel and tire assembly and lower the vehicle. (Refer to 22 - TIRES/WHEELS/WHEELS - STANDARD PROCEDURE).
(15) Lower the vehicle to the floor with vehicle weight and Tighten the front and rear control arm pivot bolts to 204 N·m (150 ft. lbs.)(LD) or 285 N·m (210 ft. lbs.)(HD 4X2 only).
(16) Perform a wheel alignment (Refer to 2 - SUS- PENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
SPRING REMOVAL
(1) Raise and support vehicle. (2) Remove the front wheel and tire assembly. (3) Support the lower control arm at the outboard side of the lower control arm to support vehicle weight. (4) Remove the shock absorber (Refer to 2 - SUS-
PENSION/FRONT/SHOCK - REMOVAL).
(5) Install Spring Compressor DD-1278 up through the lower suspension arm, coil spring and shock hole in the frame. The bell-shaped adapter goes against the lower suspension arm. Install the nut on top of the tool at the shock hole (Fig. 25).
(6) Tighten the spring compressor nut against bell-
shaped adapter finger tight then loosen 1/2 turn.
NOTE: This will hold the spring in place until the lower suspension arm is separated from the steer- ing knuckle.
(7) Remove the stabilizer link (Refer to 2 - SUS- PENSION/FRONT/STABILIZER LINK - REMOVAL). (8) Remove the lower ball joint nut at the steering
(9) Install Ball Joint Remover tool 8677 on the lower ball joint and separate the ball joint from the knuckle.
knuckle.
(10)
FRONT - INDEPENDENT FRONT SUSPENSION
2 - 22
SPRING (Continued)DR
Fig.25SPRINGCOMPRESSORTOOL
Fig.26COILSPRING
1 - SPECIAL TOOL DD-1278
2 - BELL-SHAPED ADAPTERNOTE: Do not allow the upper control arm and steering knuckle to rebound downwards they must be supported.Support the upper control arm and steering knuckle out of the way.
(11) Remove the lower control arm support. (12) Tighten the spring compressor tool to allow clearance for the lower ball joint to be removed out of the knuckle.
NOTE: It may necessary to loosen the control arm pivot bolt to allow downward swing.
(13) Loosen the tension on the spring compressor tool slowly allowing the lower suspension arm to pivot downward.
(14) Remove the spring compressor tool. (15) Remove coil spring and isolator pad from the
vehicle (Fig. 26).
INSTALLATION
(1) Tape the isolator pad to the top of the coil spring. Position the spring in the lower suspension arm well. Be sure that the coil spring is seated in the well.
(2) Install Spring Compressor DD-1278 up through the lower suspension arm, coil spring and shock hole in the frame.
(3) Tighten the tool nut
to compress the coil
spring.
1 - COIL SPRING 2 - STEERING KNUCKLE 3 - OUTER TIE ROD END 4 - LOWER CONTROL ARM 5 - SHOCK
(4) Remove the support from the upper control
arm and steering knuckle.
(5) Position the lower ball joint into the steering
knuckle.
(6) Install the retaining nut on the lower ball joint and tighten to 52 N·m (38 ft. lbs.)(on 1500 series only an additional 90° turn is required) or 135 N·m (100
ft. lbs.)(HD 4X2 only).(7) Remove the spring compressor tool. (8) Support the lower control arm at the outboard side of the lower control arm to support vehicle weight.
(9) Install the shock absorber. (Refer to 2 - SUS-
PENSION/FRONT/SHOCK - INSTALLATION).
(10) Install the stabilizer link (Refer to 2 - SUS- PENSION/FRONT/STABILIZER LINK - INSTALLA- TION).
(11) Remove the lower control arm support. (12) Install the wheel and tire assembly and lower the vehicle. (Refer to 22 - TIRES/WHEELS/WHEELS - STANDARD PROCEDURE).
(13) Lower the vehicle to the floor with vehicle weight and Tighten the front and rear control arm pivot bolts if loosened to 204 N·m (150 ft. lbs.)(LD) or 285 N·m (210 ft. lbs.)(HD 4X2 only).
(14) Perform a wheel alignment (Refer to 2 - SUS- PENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
DR
FRONT - INDEPENDENT FRONT SUSPENSION
2 - 23
SHOCK DIAGNOSIS AND TESTING - SHOCK
A knocking or rattling noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching compo- nents. These noises can usually be stopped by tight- ening the attaching nuts. the noise persists, inspect for damaged and worn bushings, and attach- ing components. Repair as necessary if any of these conditions exist.
If
A squeaking noise from the shock absorber may be caused by the hydraulic valving and may be intermit- tent. This condition is not repairable and the shock absorber must be replaced.
The shock absorbers are not refillable or adjust- able. If a malfunction occurs, the shock absorber must be replaced. To test a shock absorber, hold it in an upright position and force the piston in and out of the cylinder four or five times. The action throughout each stroke should be smooth and even.
The shock absorber bushings do not require any type of lubrication. Do not attempt to stop bushing noise by lubricating them. Grease and mineral oil- base lubricants will deteriorate the bushing.
REMOVAL
REMOVAL - 4X2
(1) Raise and support vehicle. (2) Support the lower control arm outboard end. (3) Remove the upper shock absorber nut, retainer
(4) Remove the lower nuts and remove the shock
and grommet.
absorber.
REMOVAL - 4X4
(1) Raise and support the vehicle. (2) Remove the tire and wheel assembly. (3) Support the lower control arm outboard end. (4) Remove the upper shock nut and with the insu-
lator and retainer (Fig. 27).
(5) Remove the lower shock bolt (Fig. 27). (6) Remove the shock
INSTALLATION
INSTALLATION - 4X2
NOTE: Upper shock nut must be replaced or use Mopar Lock ’N Seal or LoctiteT 242 on existing nut.
Fig.27SHOCK4X4
1 - INSULATOR & RETAINER 2 - NUT 3 - SHOCK ABSORBER 4 - BOLT
(1) Install the lower retainer and grommet on the the shock absorber
shock absorber stud. through the frame bracket hole.
Insert
(2) Install the lower nuts and tighten the nuts to
34 N·m (25 ft. lbs.).
(3) Install the upper grommet, retainer and new nut or use Mopar Lock ’N Seal or Loctitet 242 on existing nut, on the shock absorber stud. Tighten nut to 54 N·m (40 ft. lbs.).
(4) Remove the support from the lower control arm
outboard end.
(5) Lower the vehicle.
INSTALLATION - 4X4
(1) Install the upper part of the shock into the frame bracket with the insulators and retainers (Fig. 27).
(2) Install the nut and Tighten to 54 N·m (40 ft.
lbs.).
(3) Install the lower part of the shock into the lower control arm and Tighten the bolt to 135 N·m (100 ft. lbs.) (Fig. 27).
(4) Remove the support from the lower control arm
outboard end.
(5) Install the tire and wheel assembly (Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE- DURE).(6) Remove the support and lower the vehicle.
2 - 24
FRONT - INDEPENDENT FRONT SUSPENSION
DR
STABILIZER BAR DESCRIPTION
The bar extends across the front underside of the chassis and connects to the frame crossmember. The ends of the bar mount to the lower suspension arm. All mounting points of the stabilizer bar are isolated by bushings (Fig. 28).
(2) Position the stabilizer bar on the frame cross- member brackets and install the bracket and bolts finger-tight (Fig. 29).
NOTE: Check the alignment of the bar to ensure there is no interference with the either frame rail or chassis component. Spacing should be equal on both sides.
(3) Install the stabilizer bar to the stabilizer link
and install the grommets and retainers.
(4) Install
the nuts to the stabilizer link and
tighten to 38 N·m (27 ft. lbs.).
(5) Tighten the brackets to the frame to 61 N·m
(45 ft. lbs.).
STABILIZER LINK
REMOVAL
REMOVAL - 4X4
(1) Raise and support the vehicle. (2) Remove the lower nut (Fig. 29). (3) Remove the upper nut, retainers and grommets
(4) Remove the stabilizer link from the vehicle
(Fig. 29).
(Fig. 29).
REMOVAL - 4X2
(1) Raise and support the vehicle. (2) Remove the lower nut (Fig. 29). (3) Remove the upper nut, retainer and grommets
(4) Remove the stabilizer link from the vehicle
(Fig. 29).
(Fig. 29).
Fig.28STABILIZERBAR
OPERATION
The stabilizer bar is used to minimize vehicle front sway during turns. The bar helps to maintain a flat attitude to the road surface.
REMOVAL
NOTE: To service the stabilizer bar the vehicle should be on a drive on hoist. The vehicle suspen- sion must be at curb height for stabilizer bar instal- lation.
(1) Remove the stabilizer bar link upper nuts and
remove the retainers and grommets (Fig. 29).
(2) Remove the stabilizer bar retainer, bolts and retainers from the frame crossmember (Fig. 29) and remove the bar.
(3) If necessary, remove the bushings from the sta-
bilizer bar.
INSTALLATION
NOTE: To service the stabilizer bar the vehicle must be on a drive on hoist. The vehicle suspension must be at curb height for stabilizer bar installation.
(1) If removed, install the bushings on the stabi-
lizer bar.
Fig.29STABILIZERLINK
1 - STABILIZER LINK 2 - SWAY BAR BRACKET
FRONT - INDEPENDENT FRONT SUSPENSION
2 - 25
(5) Increase the tension on the anchor arm tool until the load is removed from the adjustment bolt and the adjuster nut (Fig. 30).
(6) Turn the adjustment bolt counterclockwise to
remove the bolt and the adjuster nut..
(7) Remove the Special Tool - 8686, allowing the
torsion bar to unload (Fig. 30).
Fig.30LOADING/UNLOADINGTORSIONBAR
1 - SPECIAL TOOL – 8686
2 - CROSSMEMBER(8) Remove torsion bar and anchor. Remove anchor
from torsion bar (Fig. 31).
(9) Remove all foreign material from torsion bar
mounting in anchor and suspension arm.
(10) Inspect adjustment bolt, bearing and swivel
for damage.
DR STABILIZER LINK (Continued) INSTALLATION
INSTALLATION - 4X4
(1) Install the stabilizer link to the vehicle. (2) Install the lower nut and Tighten to 102 N·m
(75 ft. lbs.).
(3) Install the retainers, grommets and upper nut
and Tighten to 38 N·m (27 ft. lbs.).
(4) Remove the support and lower the vehicle.
INSTALLATION - 4X2
(1) Install the stabilizer link to the vehicle (Fig.
(2) Install the lower nut and Tighten to 102 N·m
29).
(75 ft. lbs.).
(3) Install the retainers, grommets and upper nut
and Tighten to 38 N·m (27 ft. lbs.).
(4) Remove the support and lower the vehicle.
TORSION BAR DESCRIPTION
The front of the bar connects to the back side of the lower suspension arm. The rear end of the bar is mounted in a anchor that rests in the frame cross- member.
OPERATION
The torsion bars are used to control ride height and ride quality. The vehicle height is adjusted through an anchor adjustment bolt that increases or decreases the wind up of the torsion bar. Increasing or decreasing the bar angle changes the wind up of the suspension arms.
REMOVAL
CAUTION: The left and right side torsion bars are NOT interchangeable. The bars are identified and stamped R or L, for right or left. The bars do not have a front or rear end and can be installed with either end facing forward.
(1) Raise and support the vehicle with the front
suspension hanging.
(2) Remove the transfer case skid plate (Refer to 13 - FRAME & BUMPERS/FRAME/TRANSFER CASE SKID PLATE - REMOVAL).
NOTE: Count and record the number of turns for installation reference.
(3) Mark the adjustment bolt setting. (4) Install Special Tool - 8686 to the anchor arm
and the cross member (Fig. 30).
Fig.31TORSIONBAR
1 - ANCHOR 2 - SWIVEL 3 - TORSION BAR 4 - LOWER CONTROL ARM
DR
(3) Mount a dial indicator solidly to the frame and
then zero the dial indicator.
(4) Position dial indicator plunger on the topside of
the upper ball joint (Fig. 32).
NOTE: The dial indicator plunger must be perpen- dicular to the machined surface of the ball joint (Fig. 32).
NOTE: Use care not to pry or tear the ball boot, when checking the free play.
joint
(5) Position a pry bar between the steering knuckle and the upper control arm. Pry upwards on the upper control arm (Fig. 32).
(6) If the travel exceeds 0.5 mm (0.020 in.), replace the upper control arm since the upper ball joint is integral to the arm (Refer to 2 - SUSPENSION/ FRONT/UPPER CONTROL ARM - REMOVAL).
(7) If the upper ball joint is within specs reinstall tires (Refer to 22 - TIRES/WHEELS/
the front WHEELS - STANDARD PROCEDURE).
FRONT - INDEPENDENT FRONT SUSPENSION
2 - 26
TORSION BAR (Continued) INSTALLATIONCAUTION: The left and right side torsion bars are NOT interchangeable. The bars are identified and stamped R or L, for right or left. The bars do not have a front or rear end and can be installed with either end facing forward.
(1) Insert torsion bar ends into anchor and suspen-
sion arm.
(2) Position the anchor in the frame crossmember. (3) Install Special Tool - 8686 to the anchor and
the crossmember (Fig. 30).
(4) Increase the tension on the anchor in order to
load the torsion bar.
(5) Install the adjustment bolt and the adjuster
nut.
amount of turns.
member (Fig. 30).
(6) Turn adjustment bolt clockwise the recorded
(7) Remove tool - 8686 from the torsion bar cross-
(8) Install the transfer case skid plate (Refer to 13
- FRAME & BUMPERS/FRAME/TRANSFER CASE SKID PLATE - INSTALLATION).(9) Lower vehicle and adjust the front suspension height (Refer to 2 - SUSPENSION/WHEEL ALIGN- MENT - STANDARD PROCEDURE).
(10) Perform a wheel alignment (Refer to 2 - SUS- PENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
UPPER BALL JOINT DIAGNOSIS AND TESTING - UPPER BALL JOINT
NOTE: If the ball joint is equipped with a lubrication fitting, grease the joint then road test the vehicle before performing test.
(1) Raise the front of the vehicle. Place safety floor stands under both lower control arms as far outboard as possible. Lower the vehicle to allow the stands to support some or all of the vehicle weight.
(2) Remove the front tires.
Fig.32UPPERBALLJOINTPLAY
1 - DIAL INDICATOR 2 - UPPER CONTROL ARM 3 - PRY BAR 4 - KNUCKLE 5 - BALL JOINT BOOT
DR
FRONT - INDEPENDENT FRONT SUSPENSION
2 - 27
UPPER CONTROL ARM REMOVAL
(5) Remove the control arm pivot bolts and remove
control arm (Fig. 34).
(1) Raise and support vehicle. (2) Remove wheel and tire assembly. (3) Remove the nut from upper ball joint. (4) Separate upper ball
joint from the steering
knuckle with Remover 8677 (Fig. 33)
CAUTION: When installing Remover 8677 to sepa- rate the ball joint, be careful not to damage the ball joint seal.
Fig.33UPPERBALLJOINTSEPARATION
1 - UPPER CONTROL ARM 2 - REMOVER 3 - STEERING KNUCKLE
Fig.34UPPERCONTROLARM
1 - REAR PIVOT BOLT 2 - FRONT PIVOT BOLT 3 - UPPER CONTROL ARM
INSTALLATION
(1) Position the control arm into the frame brack- ets. Install bolts and tighten to 132 N·m (97 ft. lbs.)(LD) or 170 N·m (125 ft. lbs.)(HD 4X2 only).
(2) Insert the ball joint in steering knuckle and tighten the upper ball joint nut to 54 N·m (40 ft. lbs.)(on 1500 series only an additional 90° turn is required).
(3) Install the wheel and tire assembly,(Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE- DURE).(4) Remove the support and lower vehicle. (5) Perform a wheel alignment, (Refer to 2 - SUS- PENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).
2 - 28
FRONT - LINK/COIL
FRONT - LINK/COIL
TABLE OF CONTENTS
page
DR
page
FRONT - LINK/COIL SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 28
SPECIAL TOOLS
9 1/4 AA
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
HUB / BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31LOWER BALL JOINT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33UPPER BALL JOINT
REMOVAL - RIGHT
. . . . . . . . . . . . . . . . . . . . 34
INSTALLATION
INSTALLATION - LEFT . . . . . . . . . . . . . . . . . . 34
INSTALLATION - RIGHT . . . . . . . . . . . . . . . . 34
LOWER SUSPENSION ARMREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35SHOCK
DIAGNOSIS AND TESTING - SHOCK . . . . . . . . 35
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35SPRING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36KNUCKLE
STABILIZER BAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
