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INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37UPPER SUSPENSION ARM
REMOVAL
REMOVAL - LEFT
. . . . . . . . . . . . . . . . . . . . . 34
FRONT - LINK/COIL
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION Shock Absorber
Upper Nut
Shock Absorber
Lower Bolt
Lower Suspension Arm
Frame Nuts
Lower Suspension Arm
Axle Nut
Upper Suspension Arm
Frame Nuts
Upper Suspension Arm
Axle Nut
Stabilizer Bar Frame Bolt
Stabilizer Link
Lower Control Arm Nut
N·m 54
121
217
217
149
149
61
102
Ft. Lbs.
In. Lbs.
40
89
160
160
110
110
45
75
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DR FRONT - LINK/COIL (Continued)
FRONT - LINK/COIL
2 - 29
DESCRIPTION Stabilizer Link
Stabilizer Bar Nut
Hub/Bearing
Bolts
Axle Nut
Tie Rod End
Nut
N·m 38
202
Ft. Lbs.
27
149
179 Beginning Torque, Then Rotate 5 to 10 Times With a
132 Beginning Torque, Then Rotate 5 to 10 Times With a
Final Torque of 356
Final Torque of 263
75
55
In. Lbs.
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NOTE: Suspension components with rubber/ure- thane bushings should be tightened with the vehi- cle at normal ride height. It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. If springs are not at their normal ride position, vehicle ride comfort could be affected and premature bushing wear may occur.
SPECIAL TOOLS
9 1/4 AA
REMOVER/INSTALLERBALLJOINT-8445
PullerC-3894–A
Remover,WheelStudC-4150A
RECEIVERCUP-6761
BALLJOINTPRESS-C-4212F
BALLJOINTRECIEVER/INSTALLERKIT-8975
2 - 30
FRONT - LINK/COIL
HUB / BEARING REMOVAL
(1) Raise and support the vehicle. (2) Remove the wheel and tire assembly. (3) Remove the hub extension mounting nuts and remove the extension from the rotor if equipped (Fig. 1).
DR
(7) Back off the hub/bearing mounting bolts 1/4
inch each (Fig. 3). Then tap the bolts with a hammer to loosen the hub/bearing from the steering knuckle. (8) Remove the hub/bearing mounting bolts andremove the hub/bearing.
Fig.3Hub/BearingMountingBolts
1 - SOCKET AND EXTENSION 2 - ROTOR AND HUB 3 - STEERING KNUCKLE
(9) Remove the rotor assembly (Fig. 4), brake
shield and spacer from the steering knuckle.
to 5 -
Fig.1HubExtension
1 - HUB EXTENSION 2 - HUB
(4) Remove the brake caliper,
(Refer
BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - REMOVAL).
(5) Remove the cotter pin and the hub nut from
the axle shaft (Fig. 2).
Fig.2HubNutCotterPin
1 - HUB NUT 2 - COTTER PIN
(6) Disconnect the ABS wheel speed sensor wire from under the hood. Remove the sensor wire from the frame and steering knuckle if equipped.
Fig.4RotorHub/BearingAssembly
1 - ROTOR AND HUB 2 - UNIT BEARING ASSEMBLY 3 - SEAL
(10) Press out the wheel studs/hub extension studs
and separate the rotor from the hub (Fig. 5).
(11) Remove the wheel speed sensor (Fig. 6) from
the hub bearing if equipped.
DR HUB / BEARING (Continued)
FRONT - LINK/COIL
2 - 31
Fig.5ROTORANDHUB/BEARING
1 - HUB BEARING 2 - ROTOR
Fig.6WheelSpeedSensor
1 - HUB BEARING 2 - WHEEL SPEED SENSOR
INSTALLATION
(1) Install the wheel speed sensor in the hub bear-
ing if equipped.
(2) Position the rotor on the hub/bearing. (3) Press the wheel studs/hub extension studs through the back side of the rotor and through the hub bearing flange (Fig. 7).
(4) Apply a liberal quantity of anti-seize compound
to the splines of the front drive shaft.
(5) Insert the two rearmost, top and bottom rotor hub bolts in the steering knuckle. Insert the bolts through the back side of the knuckle so they extend out the front face as shown.
(6) Position the hub spacer (Fig. 8) and brake
shield (Fig. 9) on bolts just installed in knuckle.
Fig.7Rotor,Hub/BearingAndStud
1 - HUB BEARING 2 - ROTOR 3 - STUD
NOTE: If the vehicle is equipped with a wheel speed sensor the brake shield must be positioned on the hub bearing (Fig. 10).
Fig.8HubSpacer
1 - ROTOR HUB BOLTS 2 - HUB SPACER (POSITION FLAT TO REAR) 3 - APPLY ANTI-SEIZE COMPOUND TO SPLINES
(7) Align the rotor hub with the drive shaft and
start the shaft into the rotor hub splines.
NOTE: Position wheel speed sensor wire at the top of the knuckle if equipped.
FRONT - LINK/COIL
2 - 32
HUB / BEARING (Continued)DR
(9) Install the remaining bolts. Tighten the hub/
bearing bolts to 202 N·m (149 ft. lbs.
(10) Install the washer and axle nut and tighten a
beginning torque of 179 N·m (132 ft. lbs.).
(11) Rotate the axle 5 to 10 times to seat the hub
(12) Tighten to a final torque of 356 N·m (263 ft.
bearing.
lbs.).
(13) Align the axle nut to the next forward cotter pin hole and install a new cotter pin in the axle nut. to 5 -
the brake caliper,
(14) Install
(Refer
BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - INSTALLATION).
(15) Install the sensor wire to the steering knuckle and frame and if equipped. Connect the wheel speed sensor wire under the hood.
(16) Install the wheel and tire assemblies, (Refer to 22 - TIRES/WHEELS/WHEELS - STANDARD PROCEDURE).
(17) Remove the support and lower the vehicle. (18) Apply the brakes several times to seat the brake shoes and caliper piston. Do not move the vehi- cle until a firm brake pedal is obtained.
LOWER BALL JOINT REMOVAL
(1) Remove lower snap ring from the lower ball
joint (Fig. 11).
Fig.9BrakeShield
1 - BRAKE SHIELD 2 - HUB BEARING BOLTS 3 - STEERING KNUCKLE
Fig.10BrakeShieldWithWheelSpeedSensor
1 - WHEEL SPEED SENSOR 2 - HUB BEARING 3 - SHIELD
(8) Align the bolt holes in the hub bearing flange with the bolts installed in the knuckle. Then thread the bolts into the bearing flange far enough to hold the assembly in place.
Fig.11LOWERSNAPRING
(2) Position special tool 8975–2 (RECEIVER) and 8975–4 (DRIVER) with tool C4212–F as shown to remove lower ball stud (Fig. 12).
DR LOWER BALL JOINT (Continued)
FRONT - LINK/COIL
2 - 33
UPPER BALL JOINT REMOVAL
(1) Position special tool 6761 (RECEIVER) and shown to
8445–3 (DRIVER) with C-4212–F as remove upper ball stud (Fig. 14).
Fig.12LOWERBALLJOINTREMOVAL
1 - SPECIAL TOOL C4212-F 2 - SPECIAL TOOL 8975-2
3 - KNUCKLE 4 - SPECIAL TOOL 8975-4INSTALLATION
(1) Position special
tool 8975–1 (DRIVER) and 8975–3 (RECEIVER) with C4212–F as shown to install lower ball stud (Fig. 13).
Fig.14UPPERBALLJOINTREMOVAL
1 - SPECIAL TOOL C4212-F 2 - SPECIAL TOOL 6761
3 - KNUCKLE 4 - SPECIAL TOOL 8445-3INSTALLATION
(1) Position special
tool 8445–2 (DRIVER) and 8975–5 (RECEIVER) with C-42121–F as shown to install upper ball stud (Fig. 15).
Fig.13LOWERBALLJOINTINSTALLATION
1 - SPECIAL TOOL C4212-F 2 - SPECIAL TOOL 8975-1
3 - BALL JOINT 4 - KNUCKLE 5 - SPECIAL TOOL 8975-3Fig.15UPPERBALLJOINTINSTALLATION
1 - SPECIAL TOOL C4212-F 2 - SPECIAL TOOL 8445-2
3 - BALL JOINT 4 - KNUCKLE 5 - SPECIAL TOOL 8975-52 - 34
FRONT - LINK/COIL
DR
KNUCKLE REMOVAL
(1) Remove the hub bearing (Refer to 2 - SUSPEN-
SION/FRONT/HUB / BEARING - REMOVAL).
(2) Remove tie-rod or drag link end from the steer-
ing knuckle arm.
(3) Remove the ABS sensor wire and bracket from
knuckle. Refer to Brakes, for proper procedures.
(4) Remove the cotter pin from the upper ball stud
nut. Remove the upper and lower ball stud nuts.
(5) Strike the steering knuckle with a brass ham-
(6) Remove knuckle from axle tube yokes.
mer to loosen.
INSTALLATION
(1) Position the steering knuckle on the ball studs. (2) Install and tighten lower ball stud nut to 47
N·m (35 ft. lbs.) torque. Do not install cotter pin at this time.(3) Install and tighten upper ball stud nut to 94
N·m (70 ft. lbs.) torque. Advance nut to next slot to line up hole and install new cotter pin.(4) Retorque lower ball stud nut to 190–217 N·m (140–160 ft. lbs.) torque. Advance nut to next slot to line up hole and install new cotter pin.
(5) Install the hub bearing (Refer to 2 - SUSPEN- SION/FRONT/HUB / BEARING - INSTALLATION). (6) Install tie-rod or drag link end onto the steer-
ing knuckle arm.
(7) Install the ABS sensor wire and bracket to the
knuckle. Refer to Brakes, for proper procedure.
UPPER SUSPENSION ARM
REMOVAL
REMOVAL - LEFT
Fig.16Link/CoilSuspension
1 - STABILIZER BAR 2 - SHOCK ABSORBER 3 - COIL SPRING 4 - UPPER SUSPENSION ARM 5 - LOWER SUSPENSION ARM 6 - TRACK BAR
(7) Remove the nut and bolt at the frame rail and
remove the upper suspension arm.
(8) Remove the upper suspension arm nut and bolt
at the axle bracket.
(9) Remove the suspension arm from the vehicle.
INSTALLATION
INSTALLATION - LEFT
(1) Position the upper suspension arm at the axle
and frame rail.
(2) Install the bolts and finger tighten the nuts. (3) Remove the supports and lower the vehicle. (4) Tighten nut at the axle bracket to 163 N·m (120 ft. lbs.). Tighten nut at frame bracket to 163
N·m (120 ft. lbs.).(1) Raise and support the vehicle. (2) Remove the upper suspension arm nut and bolt
INSTALLATION - RIGHT
at the axle bracket (Fig. 16).
(1) Position the upper suspension arm at the axle
(3) Remove the nut and bolt at the frame rail and
and frame rail.
remove the upper suspension arm.
REMOVAL - RIGHT
(1) Raise and support the vehicle. (2) Disconnect the exhaust system at the mani-
(3) Disconnect the rubber exhaust mounts at the
folds.
muffler.
(4) Support the transmission. (5) Remove the transmission cross member. (6) Lower the exhaust system down in order to
gain access to the removal of the upper bolt.
(2) Install the bolts, then finger tighten the nuts. (3) Reconnect the rubber exhaust mounts at the
muffler.
(4) Reconnect the exhaust at the manifolds. (5) Install the transmission crossmember. (6) Remove the supports and lower the vehicle. (7) Tighten nut at the axle bracket to 163 N·m (120 ft. lbs.). Tighten nut at frame bracket to 163
N·m (120 ft. lbs.).DR
FRONT - LINK/COIL
2 - 35
LOWER SUSPENSION ARM REMOVAL
(1) Raise and support the vehicle. (2) Paint or scribe alignment marks on the cam adjusters and suspension arm for installation refer- ence (Fig. 17).
Fig.17AdjustmentCam
1 - ADJUSTMENT CAM 2 - AXLE BRACKET 3 - BRACKET REINFORCEMENT 4 - LOWER SUSPENSION ARM
(3) Remove the lower suspension arm nut, cam
and cam bolt from the axle.
(4) Remove the nut and bolt from the frame rail bracket and remove the lower suspension arm (Fig. 17).
INSTALLATION
bracket and frame rail bracket.
(2) Install the rear bolt and finger tighten the nut. (3) Install the cam bolt, cam and nut in the axle
and align the reference marks.
(4) Remove support and lower the vehicle. (5) Tighten cam nut at the axle bracket to 217
lbs.). Tighten rear nut at the frameN·m (160 ft. bracket to 217 N·m (160 ft. lbs.).
SHOCK DIAGNOSIS AND TESTING - SHOCK
A knocking or rattling noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching compo- nents. These noises can usually be stopped by tight- ening the attaching nuts. the noise persists, inspect for damaged and worn bushings, and attach- ing components. Repair as necessary if any of these conditions exist.
If
A squeaking noise from the shock absorber may be caused by the hydraulic valving and may be intermit- tent. This condition is not repairable and the shock absorber must be replaced.
The shock absorbers are not refillable or adjust- able. If a malfunction occurs, the shock absorber must be replaced. To test a shock absorber, hold it in an upright position and force the piston in and out of the cylinder four or five times. The action throughout each stroke should be smooth and even.
The shock absorber bushings do not require any type of lubrication. Do not attempt to stop bushing noise by lubricating them. Grease and mineral oil- base lubricants will deteriorate the bushing.
REMOVAL
(1) Remove the nut, retainer and grommet from
the upper stud in the engine compartment.
(2) Remove three nuts from the upper shock
bracket (Fig. 18).
(3) Remove the lower bolt from the axle bracket (Fig. 19). Remove the shock absorber from engine compartment.
INSTALLATION
(1) Position the lower retainer and grommet on the upper stud. Insert the shock absorber through the spring from engine compartment.
(2) Install the lower bolt and tighten to 135 N·m
(100 ft. lbs.).
Tighten nuts to 75 N·m (55 ft. lbs.).
(4) Install upper grommet and retainer. Install
upper shock nut and tighten to 47 N·m (35 ft. lbs).
(1) Position the lower suspension arm at the axle
(3) Install the upper shock bracket and three nuts.
FRONT - LINK/COIL
2 - 36
SHOCK (Continued)DR
SPRING REMOVAL
(1) Raise and support
the vehicle. Position a
hydraulic jack under the axle to support it.
(2) Paint or scribe alignment marks on lower sus- pension arm cam adjusters and axle bracket for installation reference.
(3) Remove the upper suspension arm and loosen
lower suspension arm bolts.
(4) Mark and disconnect the front propeller shaft
from the axle 4x4 models.
(5) Disconnect the track bar from the frame rail
bracket.
(6) Disconnect the drag link from pitman arm. (7) Disconnect the stabilizer bar link and shock
absorber from the axle.
(8) Lower the axle until the spring is free from the
upper mount. Remove the coil spring.
INSTALLATION
(1) Position the coil spring on the axle pad. (2) Raise the axle into position until the spring
seats in the upper mount.
(3) Connect the stabilizer bar links and shock absorbers to the axle bracket. Connect the track bar to the frame rail bracket.
(4) Install the upper suspension arm. (5) Install the front propeller shaft to the axle 4x4
model.
(6) Install drag link to pitman arm and tighten
nut to specifications. Install new cotter pin.
to specifications:
(7) Remove the supports and lower the vehicle. (8) Tighten the following suspension components † Link to stabilizer bar nut. † Lower shock bolt. † Track bar bolt at axle shaft tube bracket. † Upper suspension arm nut at axle bracket. † Upper suspension nut at frame bracket. † Align lower suspension arm reference marks and † Lower suspension nut at frame bracket.
tighten cam nut.
Fig.18ShockAbsorberandBracket
1 - GROMMET 2 - RETAINER 3 - BRACKET 4 - RETAINER 5 - SHOCK 6 - GROMMET
Fig.19ShockAbsorberAxleMount
1 - SHOCK 2 - SPRING 3 - FLAG NUT 4 - SHOCK BOLT
DR
FRONT - LINK/COIL
2 - 37
STABILIZER BAR REMOVAL
(1) Raise and support the vehicle. (2) Hold the stabilizer link shafts with a wrench
and remove the link nuts at the stabilizer bar.
(3) Remove the retainers and grommets from the
stabilizer bar links.
axle brackets.
(4) Remove the stabilizer bar link nuts from the
(5) Remove the links from the axle brackets with
Puller C-3894-A (Fig. 20).
(6) Remove the stabilizer bar clamps from the
frame rails and remove the stabilizer bar.
INSTALLATION
(1) Position the stabilizer bar on the frame rail and install the clamps and bolts. Ensure the bar is centered with equal spacing on both sides.
(2) Tighten the clamp bolts to 61 N·m (45 ft. lbs.). (3) Install links to the axle bracket and tighten
nut to 47 N·m (35 ft. lbs.).
(4) Install links, retainers, grommets and nuts to the stabilizer bar. Hold the link shaft with a wrench and tighten the nuts to 37 N·m (27 ft. lbs.).
(5) Remove the supports and lower the vehicle.
Fig.20StabilizerLink
1 - PULLER 2 - LINK
2 - 38
REAR
REAR
TABLE OF CONTENTS
page
DR
page
REAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 38
DIAGNOSIS AND TESTING - SPRING ANDSHOCK
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 39
BUSHINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40
SHOCK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40SPRING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 41
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41JOUNCE BUMPER
SPRING TIP INSERTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42AUXILIARY SPRING BUMPERS (3500)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
REAR DESCRIPTION
The rear suspension is comprised of: † Shock Absorbers † Jounce Bumpers † Stabilizer Bar (optional) † Leaf Springs † Auxiliary Leaf Spring (3500 series) † Auxiliary Spring Bumpers (3500 series) † Drive Axle
CAUTION: A vehicle should always be loaded so the vehicle weight center-line is located immedi- ately forward of the rear axle. Correct vehicle load- ing provides proper front tire-to-road contact. This results in maximum vehicle handling stability and safety. Incorrect vehicle weight distribution can cause excessive tire tread wear, spring fatigue or failure, and erratic steering.
CAUTION: Suspension components with rubber/ure- thane bushings (except stabilizer bar) should be tightened with the vehicle at normal ride height. It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. If springs are not at their normal ride position, vehicle ride comfort could be affected and premature bush- ing wear may occur.
DIAGNOSIS AND TESTING - SPRING AND SHOCK
A knocking or rattling noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching compo- nents. These noises can usually be stopped by tight- ening the attaching nuts. the noise persists, inspect for damaged and worn bushings, and attach- ing components. Repair as necessary if any of these conditions exist.
If
A squeaking noise from the shock absorber may be caused by the hydraulic valving and may be intermit- tent. This condition is not repairable and the shock absorber must be replaced.
The shock absorbers are not refillable or adjust- able. If a malfunction occurs, the shock absorber must be replaced. To test a shock absorber, hold it in an upright position and force the piston in and out of the cylinder four or five times. The action throughout each stroke should be smooth and even.
The spring eye and shock absorber bushings do not require any type of lubrication. Do not attempt to stop spring bushing noise by lubricating them. Grease and mineral oil-base lubricants will deterio- rate the bushing rubber.
If the vehicle is used for severe, off-road operation, the springs should be examined periodically. Check for broken and shifted leafs, loose and missing clips, and broken center bolts. Refer to Spring and Shock Absorber Diagnosis chart for additional information.
DR REAR (Continued)
REAR
2 - 39
SPRING AND SHOCK ABSORBER
CONDITION
POSSIBLE CAUSES
CORRECTION
SPRING SAGS
1. Broken leaf.
2. Spring fatigue.
1. Replace spring.
2. Replace spring.
SPRING NOISE
1. Loose spring clamp bolts.
1. Tighten to specification.
2. Worn bushings. 3. Worn or missing spring tip inserts.
2. Replace bushings. 3. Replace spring tip inserts.
1. Loose mounting fastener. 2. Worn bushings. 3. Leaking shock.
1. Tighten to specification. 2. Replace shock. 3. Replace shock.
TORQUE SPECIFICATIONS
N·m 135
135
149
163
163
40
41
Ft. Lbs.
In. Lbs.
100
100
110
120
120
30
30
INSTALLATION
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—
SHOCK NOISE
SPECIFICATIONS
TORQUE CHART
DESCRIPTION Shock Absorber
Lower Nut
Shock Absorber
Upper Nut
Spring Clamp U-Bolts
Nuts Spring
Front & Rear Bolt & Nut
Spring
Spring Rear Shackle Nuts
Jounce Bumper
Bolts
Auxialiary Spring Bumpers
BUSHINGS REMOVAL
(1) Remove the spring from the vehicle. (2) Make small relief cuts in the flared up end of the bushing metal being careful not to cut the spring. Use a punch to bend the flared bushing metal down for push out.
(3) Position the spring eye in a press. (4) Press the bushing out with an appropriate size
driver.
(1) Press new bushing into the spring eye with an appropriate size driver. The bushing should be cen- tered in the spring eye.
(2) Stake the outermetal of the bushing in a mini-
mum of six points to retain the bushing.
(3) Install the spring on the vehicle.
2 - 40
REAR
JOUNCE BUMPER REMOVAL
DR
(1) Remove the two bolts securing the jounce
bumper to the bracket (Fig. 1).
(2) Remove the jounce bumper.
Fig.1JOUNCEBUMPER
1 - MOUNTING BOLTS 2 - JOUNCE BUMPER
INSTALLATION
Fig.2AUXILIARYSPRINGBUMPER(3500)
1 - NUTS 2 - AUXILIARY SPRING BUMPERS
SHOCK REMOVAL
(1) Raise vehicle and support the axle. (2) Remove the upper shock bolt and nut (Fig. 3). (3) Remove the lower shock bolt and nut. (4) Remove the rear shock absorber from the vehicle.
(1) Install the jounce bumper. (2) Install
the two bolts
securing the jounce bumper to the bracket. Tighten the bolts to 40 N·m (30 ft. lbs.).
AUXILIARY SPRING BUMPERS (3500) REMOVAL
(1) Remove the nut securing the auxiliary spring
bumper to the bracket (Fig. 2).
(2) Remove the auxiliary spring bumper.
INSTALLATION
(1) Install the auxiliary spring bumper. (2) Install the nut securing the auxiliary spring bumper to the bracket (Fig. 2). Tighten the nut to 61
N·m (45 ft. lbs.).Fig.3SHOCKABSORBER
1 - NUT 2 - AXLE 3 - SHOCK ABSORBER
INSTALLATION
(1) Position the shock absorber in the brackets. (2) Install the bolts through the brackets and the shock. Install the flag nut on the top bolt and nut on lower bolt.
(3) Tighten the upper and lower bolt/nuts Tighten
to 135 N.m (100 ft. lbs.)
(4) Remove the support and lower the vehicle.
DR
SPRING DESCRIPTION
The rear suspension system uses a multi-leaf springs and a solid drive axle. The forward end of the springs are mounted to the body rail hangers through rubber bushings. The rearward end of the springs are attached to the body by the use of shack- les. The spring and shackles use rubber bushings.
OPERATION
The springs control ride quality and maintain vehi- cle ride height. The shackles allow the springs to change their length as the vehicle moves over various road conditions.
REMOVAL
(1) Raise and support the vehicle. (2) Support the axle with a suitable holding fix-
ture.
(3) Remove the nuts, spring clamp bolts and the
plate that attach the spring to the axle (Fig. 4).
(4) Remove the nuts and bolts from the spring
front and rear shackle (Fig. 4).
(5) Remove the spring from the vehicle.
REAR
2 - 41
INSTALLATION
(1) Position spring on axle shaft tube so spring center bolt is inserted into the locating hole in the axle tube.
(2) Align the front of the spring with the bolt hole in
the front bracket. Install the eye pivot bolt and nut.
(3) Align the rear of the spring into the shackle
and install the bolt and nut.
(4) Tighten the spring front and rear eye pivot bolt
snug do not torque.
retaining nuts.
(5) Install the spring clamp bolts, plate and the
(6) Remove the holding fixture for the rear axle. (7) Remove the supports and lower the vehicle so
that the weight is being supported by the tires.
(8) Tighten the spring clamp retaining nuts to 149
N·m (110 ft. lbs.).
(9) Tighten the spring front and rear pivot bolt
nuts to 163 N·m (120 ft. lbs.).
SPRING TIP INSERTS REMOVAL
(1) Raise and support the vehicle. (2) Remove both rear tireand wheel assemblies (3) Position a large C-Clamp adjacent to the spring clinch clip and clamp the leaves of the spring together
CAUTION: When working on the front leaf spring clinch clamps finish the front before starting on the rear to prevent personal injury.
(4) Use an appropriate pry bar to bend open the spring clinch clip (Fig. 5). If necessary, remove the existing spring clinch clip isolators.
Fig.4REARSPRING
1 - LEAF SPRING 2 - PLATE 3 - NUTS 4 - FRONT NUT & BOLT 5 - SPRING CLAMP BOLTS 6 - SHACKLES
Fig.5C-CLAMPANDPRYBAR
1 - REAR LEAF SPRING CLINCH CLAMP 2 - PRY BAR 3 - C-CLAMP
REAR
2 - 42
SPRING TIP INSERTS (Continued)DR
(5) Use the pry bar to spread apart the leaf (Fig. 6). The clearance between the leaves should be enough to remove the old liner (if necessary) and install the replacement liner.
NOTE: THE SPRING TIP LINER IS PROPERLY INSTALLED WHEN THE RETAINING PIN IS POINT- ING TOWARD THE PAVEMENT AND THE WEAR PAD IS CONTACTING THE LEAF SPRING.
Fig.6SPRINGSEPARATION
Fig.8CLINCHCLIP
1 - REAR LEAF SPRING 2 - PRY BAR
1 - C-CLAMP 2 - SPRING CLINCH CLAMP
(6) If necessary, remove the old spring tip liner
(Fig. 7).
Fig.7SPRINGTIPLINERREMOVAL
1 - SPRING TIP LINER 2 - RUBBER MALLET
INSTALLATION
(1) With the prybar still
inserted between the
leaves, install a new spring tip liner onto the leaf.
(2) Firmly seat the spring tip liner onto the leaf. A C-Clamp can be used to compress the adjacent leaves together (Fig. 8) which will seat the liner retaining pin into the hole.
(3) Apply a small amount of lubricant oil onto the
tip liner wear pad.
(4) Install all the spring tip liners. (5) Place one spring clinch clip isolator onto the outboard side of the spring clinch clip (Fig. 9) and one isolator on the inboard side of the spring clinch clip.
Fig.9CLINCHCLIPISOLATOR
1 - SPRING CLINCH CLIP ISOLATOR 2 - C-CLAMP
DR SPRING TIP INSERTS (Continued)
(6) Using large adjustable pliers, close the spring clinch clip until the isolator contacts the leaf spring (Fig. 10).
CAUTION: DO NOT USE A HAMMER TO CLOSE THE SPRING CLINCH CLIP. DAMAGE TO THE ISOLATOR MAY RESULT.
REAR
2 - 43
(7) Use an appropriate pry bar to bend open the spring clinch clip. If necessary, remove the existing spring clinch clip isolators.
(8) Repeat procedure for the other side of the vehi-
cle.
(9) Iinstall the tire wheel assemblies. (10) Lower the vehicle.
Fig.10CLINCHCLIPREASSEMBLY
1 - SPRING CLINCH CLIP 2 - ADJUSTABLE PLIERS 3 - C-CLAMP
DR
DIFFERENTIAL & DRIVELINE
3 - 1
DIFFERENTIAL & DRIVELINE
TABLE OF CONTENTS
page
page
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . 1
HALF SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
FRONT AXLE - C205F . . . . . . . . . . . . . . . . . . . . 18
FRONT AXLE - 9 1/4 AA . . . . . . . . . . . . . . . . . . . 45REAR AXLE - 9 1/4
. . . . . . . . . . . . . . . . . . . . . . . 69
REAR AXLE - 10 1/2 AA . . . . . . . . . . . . . . . . . . 100
REAR AXLE - 11 1/2 AA . . . . . . . . . . . . . . . . . . 127PROPELLER SHAFT
TABLE OF CONTENTS
page
page
PROPELLER SHAFT
. . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING STANDARD PROCEDURE . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIAL TOOLSFRONT PROPELLER SHAFT
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CENTER BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . . . . . . . . 8
ADJUSTMENTSSINGLE CARDAN UNIVERSAL JOINTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9REAR PROPELLER SHAFT
REMOVAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PROPELLER SHAFT DIAGNOSIS AND TESTING
PROPELLER SHAFT VIBRATION
Tires that are out-of-round or wheels that are
unbalanced, will cause a low frequency vibration.
Brake drums that are unbalanced will cause a
harsh, low frequency vibration.
Driveline vibration can also result from loose or
damaged engine mounts.
Propeller shaft vibration increases as the vehicle speed is increased. A vibration that occurs within a specific speed range is not usually caused by a pro- peller shaft being unbalanced. Defective universal joints or an incorrect propeller shaft angle are usu- ally the cause of such a vibration.
PROPELLER SHAFT
3 - 2
PROPELLER SHAFT (Continued)DRIVELINE VIBRATION
DR
Drive Condition
Possible Cause
Correction
Propeller Shaft Noise
1) Undercoating or other foreign material on shaft. 2) Loose U-joint clamp screws.
3) Loose or bent U-joint yoke or excessive runout. 4) Incorrect driveline angularity.
5) Rear spring center bolt not in seat. 6) Worn U-joint bearings. 7) Propeller shaft damaged or out of balance. 8) Broken rear spring. 9) Excessive runout or unbalanced condition. 10) Excessive drive pinion gear shaft runout. 11) Excessive axle yoke deflection.
12) Excessive transfer case runout.
Universal Joint Noise
1) Loose U-joint clamp screws.
2) Lack of lubrication.
1) Clean exterior of shaft and wash with solvent. 2) Install new clamps and screws and tighten to proper torque. 3) Install new yoke.
4) Measure and correct driveline angles. 5) Loosen spring u-bolts and seat center bolt. 6) Install new U-joint. 7) Installl new propeller shaft.
8) Install new rear spring. 9) Re-index propeller shaft, test, and evaluate. 10) Re-index propeller shaft and evaluate. 11) Inspect and replace yoke if necessary. 12) Inspect and repair as necessary.
1) Install new clamps and screws and tighten to proper torque. 2) Replace as U-joints as necessary.
PROPELLER SHAFT BALANCE
NOTE: Removing and re-indexing the propeller shaft 180° relative to the yoke may eliminate some vibrations.
If propeller shaft is suspected of being unbalanced,
it can be verified with the following procedure:
(1) Raise the vehicle. (2) Clean all the foreign material from the propel-
ler shaft and the universal joints.
(3) Inspect the propeller shaft for missing balance weights, broken welds, and bent areas. If the pro- peller shaft is bent, it must be replaced.
(4) Inspect the universal joints to ensure that they are not worn, are properly installed, and are cor- rectly aligned with the shaft.
(5) Check the universal joint clamp screws torque. (6) Remove the wheels and tires. Install the wheel
lug nuts to retain the brake drums or rotors.
(7) Mark and number the shaft six inches from the
yoke end at four positions 90° apart.
(8) Run and accelerate the vehicle until vibration occurs. Note the intensity and speed the vibration occurred. Stop the engine.
(9) Install a screw clamp at position 1 (Fig. 1). (10) Start the engine and re-check for vibration. If there is little or no change in vibration, move the clamp to one of the other three positions. Repeat the vibration test.
(11) If there is no difference in vibration at the other positions, the source of the vibration may not be propeller shaft.
(12) If the vibration decreased, clamp (Fig. 2) and repeat the test.
install a second
(13) If the additional clamp causes an additional vibration, separate the clamps (1/2 inch above and below the mark). Repeat the vibration test (Fig. 3).
(14) Increase distance between the clamp screws and repeat the test until the amount of vibration is at the lowest level. Bend the slack end of the clamps so the screws will not loosen.
DR PROPELLER SHAFT (Continued)
PROPELLER SHAFT
3 - 3
(15) If the vibration remains unacceptable, apply the same steps to the front end of the propeller shaft. (16) Install the wheel and tires. Lower the vehicle.
PROPELLER SHAFT RUNOUT
Fig.1CLAMPSCREWATPOSITION1
1 - CLAMP 2 - SCREWDRIVER
(1) Remove dirt, rust, paint and undercoating from the propeller shaft surface where the dial indicator will contact the shaft.
(2) The dial indicator must be installed perpendic-
ular to the shaft surface.
(3) Measure runout at the center and ends of the shaft sufficiently far away from weld areas to ensure that the effects of the weld process will not enter into the measurements.
(4) Refer to Runout Specifications chart. (5) If the propeller shaft runout is out of specifica- tion, remove the propeller shaft, index the shaft 180°, and re-install the propeller shaft. Measure shaft runout again.
(6) If the propeller shaft runout is now within specifications, mark the shaft and yokes for proper orientation.
(7) If the propeller shaft runout is not within spec- ifications, verify that the runout of the transmission/ transfer case and axle are within specifications. Correct as necessary and re-measure propeller shaft runout.
(8) Replace the propeller shaft if the runout still
exceeds the limits.
RUNOUT SPECIFICATIONS
Fig.2TWOCLAMPSCREWS
0.020 in. (0.50 mm) 0.025 in. (0.63 mm) 0.020 in. (0.50 mm)
Front of Shaft Center of Shaft Rear of Shaft note: Measure front/rear runout approximately 3 inches (76
mm) from the weld seam at each end of the shaft tube for tube lengths over 30 inches. For tube lengths under 30 inches, the maximum allowed runout is 0.020 in. (0.50 mm) for the full length of the tube.STANDARD PROCEDURE
PROPELLER SHAFT ANGLE
Fig.3CLAMPSCREWSSEPARATED
1 - 1⁄2 INCH
This procedure applies to both the front/rear pro- peller shafts. To obtain the front output angle (A) on the front propeller shaft, place the inclinometer the machined surface of the C/V joint.
(1) To check driveline alignment, raise and support the vehicle at the axles as level as possible. Allow the wheels and propeller shaft to turn.
(2) Remove any external bearing snap rings,
if equipped from universal joint so protractor base sits flat.
PROPELLER SHAFT
3 - 4
PROPELLER SHAFT (Continued)DR
(3) Rotate the shaft until
transmission/transfer
case output yoke bearing is facing downward.
NOTE: Always make measurements from front to rear and from the same side of the vehicle.
(4) Place Inclinometer 7663 on yoke bearing (A) parallel to the shaft (Fig. 4). Center bubble in sight glass and record measurement.
This measurement will give you the transmis-
sion yoke Output Angle (A).
Fig.4OUTPUTANGLE(A)
(5) Rotate propeller shaft 90 degrees and place Inclinometer on yoke bearing parallel to the shaft (Fig. 5). Center bubble in sight glass and record mea- surement. This measurement can also be taken at the rear end of the shaft.
This measurement will give you the Propeller
Shaft Angle (C).
(6) Rotate propeller shaft 90 degrees and place Inclinometer on companion flange yoke bearing par- allel to the shaft (Fig. 6). Center bubble in sight glass and record measurement.
This measurement will give you the pinion
Companion Flange Input Angle (B).
(7) Subtract smaller figure from larger (C minus to obtain Transmission/Transfer Case Output
A) Operating Angle.
(8) Subtract smaller figure from larger (C minus
B) to obtain axle Input Operating Angle.
Fig.5PROPELLERSHAFTANGLE(C)
Fig.6INPUTANGLE(B)
7) for additional information.
Refer to rules given below and the example in (Fig. † Good cancellation of U-joint operating angles † Operating angles should be less than 3°. † At least 1/2 of one degree continuous operating
should be within 1°.
(propeller shaft) angle.
DR PROPELLER SHAFT (Continued)
PROPELLER SHAFT
3 - 5
1 - 4.9° Angle (C) 2 - 3.2° Angle (B) 3 - Input Yoke
Fig.7UNIVERSALJOINTANGLEEXAMPLE
4 - 3.0° Angle (A) 5 - Output Yoke
TWO-PIECE PROPELLER SHAFT
The procedure to measure the propeller shaft angles involved with a two-piece (Fig. 8) propeller shaft is the same as those for a one-piece propeller shaft.
1 - YOKES MUST BE IN SAME PLANE
Fig.8UNIVERSALJOINTANGLE
PROPELLER SHAFT
3 - 6
PROPELLER SHAFT (Continued) SPECIFICATIONSDR
DESCRIPTION
Center Bearing Bolts
Front Pinion Flange Bolts Rear Pinion Flange Bolts
SPECIAL TOOLS
TORQUE SPECIFICATIONS
N·m 54
115
115Ft. Lbs.
In. Lbs.
40
85
85FRONT PROPELLER SHAFT REMOVAL
INCLINOMETER7663
BearingSplitter1130
INSTALLER6052
(1) Position transmission and transfer case into
neutral.
(2) Raise and support vehicle. (3) Remove exhaust crossover pipe. (4) Mark a line across the axle companion flange and propeller shaft flange yoke (Fig. 9) for installa- tion reference.
Fig.9COMPANIONFLANGE
1 - COMPANION FLANGE 2 - PROPELLER SHAFT 3 - FLANGE YOKE 4 - REFERENCE MARK
(5) Remove companion flange bolts. (6) Remove dust boot clamp (Fig. 10) from the C/V
jonit end of the shaft.
(7) Remove propeller shaft.
DR FRONT PROPELLER SHAFT (Continued)
PROPELLER SHAFT
3 - 7
Fig.10DUSTBOOT
Fig.11COMPANIONFLANGE
1 - C/V JOINT 2 - TRANSFER CASE 3 - BOOT CLAMP 4 - PROPELLER SHAFT
INSTALLATION
1 - PROPELLER SHAFT 2 - COMPANION FLANGE 3 - REFERENCE MARK 4 - SHAFT FLANGE YOKE
(1) Install propeller shaft with with all reference
marks aligned.
(2) Install transfer case companion flange bolts
and tighten to 30.5 N·m (22.5 ft. lbs.).
(3) Install axle companion flange bolts and tighten
to 108 N·m (80 ft. lbs.).
(4) Install skid plate, if equipped. (5) Lower vehicle and road test to verify repair.
REAR PROPELLER SHAFT REMOVAL
(1) Shift transmission into Neutral. (2) Raise and support vehicle. (3) Mark a line across the pinion companion flange and propeller shaft flange yoke (Fig. 11) for installa- tion reference.
(4) Mark the outline of the center bearing (Fig. 12) if
on the crossmember for installation reference, equipped.
(5) Remove center bearing mounting nuts,
equipped.
(6) Remove pinion yoke companion flange bolts. (7) Slide slip yoke off of the transmission or trans-
fer case output shaft and remove propeller shaft.
if
Fig.12CENTERBEARING
1 - CENTER BEARING 2 - DUST BOOT 3 - MOUNTING NUTS
PROPELLER SHAFT
3 - 8
REAR PROPELLER SHAFT (Continued) INSTALLATIONDR
(1) Slide the slip yoke onto the transmission/trans-
fer case output shaft.
(2) Align and install center bearing on crossmem- ber, if necessary and tighten nutts to 54 N·m (40 ft. lbs.).
(3) Align reference marks on the propeller shaft
yoke and pinion companion flange (Fig. 13).
(4) Tighten pinion companion flange bolts to 115
N·m (85 ft. lbs.).
Fig.14REFERENCEMARKS
1 - REFERENCE MARK 2 - CENTER BEARING 3 - BOOT CLAMP 4 - DUST BOOT
INSTALLATION
NOTE: Two types of center bearings are used and are not interchangeable. Install the same type as the vehicle was built with.
Fig.13REARPROPELLERSHAFT
1 - COMPANION FLANGE 2 - PROPELLER SHAFT
(5) Lower the vehicle.
CENTER BEARING REMOVAL
(1) Remove rear propeller shaft. (2) Mark the two shafts (Fig. 14) for installation
(3) Remove slip joint boot clamp and separate the
reference.
two shafts.
(4) Use hammer and punch to tap slinger away
from shaft to provide room for bearing splitter.
(5) Position Bearing Splitter Tool 1130 between
slinger and shaft.
CAUTION: Do not damage shaft spline during removal of center bearing.
(6) Set shaft in press and press bearing off the
shaft.
(1) Install new slinger on shaft and drive into posi-
tion with appropriate installer tool.
(2) Install new center bearing on shaft with Bear- ing Installer Tool 6052. Drive on shaft with hammer until bearing is seated.
(3) Clean shaft splines and apply a coat of multi-
purpose grease.
(4) Align master splines and slide front and rear half-shafts together. Reposition slip yoke boot and install new clamp.
(5) Install propeller shaft in vehicle.
ADJUSTMENTS
CENTER BEARING
Launch shudder is a vibration that occurs at first acceleration from a stop. Shudder vibration usually peaks at the engines highest torque output. Shudder is a symptom associated with vehicles using a two- piece propeller shaft. To decrease shudder, lower the center bearing in 1/8 inch increments. Use shim stock or fabricated plates. Plate stock must be used to maintain compression of the rubber insulator around the bearing. Do not use washers. Replace the original bolts with the appropriate increased length bolts.
DR
PROPELLER SHAFT
3 - 9
SINGLE CARDAN UNIVERSAL JOINTS DISASSEMBLY
NOTE: The following procedure is described for a propeller shaft equipped with only a cardan joint in the tube yoke. If the propeller shaft is equipped with a companion yoke, simply repeat the following steps to remove the cardan joint from the compan- ion yoke after removing the cardan joint from the tube yoke.
Individual components of cardan universal joints are not serviceable. If worn or leaking, they must be replaced as an assembly.
(1) Remove the propeller shaft. (2) Using a soft drift, tap the outside of the bear-
ing cap assembly to loosen snap ring.
(3) Remove snap rings from both sides of yoke
(Fig. 15).
Fig.16PressOutBearing
1 - PRESS 2 - SOCKET
(7) If the bearing cap will not pull out of the yoke by hand after pressing, tap the yoke ear near the bearing cap to dislodge the cap.
(8) To remove the opposite bearing cap, turn the yoke over and straighten the cross in the open hole. Then, carefully press the end of the cross until the remaining bearing cap can be removed (Fig. 17).
If
the cross or bearing cap are not CAUTION: straight during installation, the bearing cap will score the walls of the yoke bore and damage can occur.
ASSEMBLY
NOTE: The following procedure is described for a propeller shaft equipped with only a cardan joint in the tube yoke. If the propeller shaft is equipped with a companion yoke, simply repeat the following steps to remove the cardan joint from the compan- ion yoke after removing the cardan joint from the tube yoke.
(1) Apply extreme pressure (EP) N.L.G.I. Grade 1
or 2 grease to inside of yoke bores to aid in installa- tion.Fig.15SnapRing
1 - SNAP RING
(4) Set the yoke in an arbor press or vise with a socket whose inside diameter is large enough to receive the bearing cap positioned beneath the yoke. if
(5) Position the yoke with the grease fitting,
equipped, pointing up.
(6) Place a socket with an outside diameter smaller than the upper bearing cap on the upper bearing cap and press the cap through the yoke to release the lower bearing cap (Fig. 16).
PROPELLER SHAFT
3 - 10
SINGLE CARDAN UNIVERSAL JOINTS (Continued)DR
(3) Place a bearing cap over the trunnion and align the cap with the yoke bore (Fig. 19). Keep the needle bearings upright in the bearing assembly. A needle bearing lying at the bottom of the cap will prevent proper assembly.
Fig.17PressOutRemainingBearing
1 - CROSS 2 - BEARING CAP
(2) Position the cross in the yoke with its lube fit-
ting, if equipped, pointing up (Fig. 18).
Fig.19InstallBearingOnTrunnion
1 - BEARING CAP 2 - TRUNNION
(4) Press the bearing cap into the yoke bore
enough to install a snap ring.
(5) Install a snap ring. (6) Repeat Step 3 and Step 4to install the opposite bearing cap. If the joint is stiff or binding, strike the yoke with a soft hammer to seat the needle bearings.
(7) Add grease to lube fitting, if equipped. (8) Install the propeller shaft.
Fig.18CrossInYoke
1 - CROSS 2 - YOKE
DR
HALF SHAFT
3 - 11
HALF SHAFT
TABLE OF CONTENTS
page
page
HALF SHAFT
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 12
. . . . . . . . . . . . . . . . . . . . . . . 12
SPECIAL TOOLSCV JOINT-OUTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13CV JOINT-INNER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16HALF SHAFT CAUTION
CAUTION:: Never grasp half shaft assembly by the boots. This may cause the boot to pucker or crease and reduce the service life of the boot. Avoid over angulating or stroking the C/V joints when handling the half shaft. Half shafts exposed to battery acid, transmission fluid, brake fluid, differential fluid or gasoline may cause the boots to deteriorate.
DIAGNOSIS AND TESTING
Check for grease at the inboard and outboard C/V
joint. This is a sign of boot or boot clamp damage.
NOISE/VIBRATION IN TURNS
A clicking noise or a vibration in turns could be caused by a damaged outer C/V or inner tripod joint seal boot or seal boot clamps. This will result in the loss/contamination of the joint grease, resulting in inadequate lubrication of the joint. Noise could also be caused by another component of the vehicle com- ing in contact with the half shafts.
CLUNKING NOISE DURING ACCELERATION
This noise may be a result of a damaged or worn C/V joint. A torn boot or loose/missing clamp on the inner/outer joint which has allowed the grease to be lost will damage the C/V joint.
SHUDDER/VIBRATION DURING ACCELERATION
This problem could be a result of a worn/damaged inner tripod joint or a sticking tripod joint. Improper wheel alignment may also cause a shudder or vibra- tion.
VIBRATION AT HIGHWAY SPEEDS
This problem could be a result of out of balance front tires or tire/wheel runout. Foreign material (mud, etc.) packed on the backside of the wheel(s) will also cause a vibration.
REMOVAL
(1) Loosen lug nuts and hub nut while the with
the vehicle brakes applied.
(2) Raise and support the vehicle. (3) Remove wheel and tire assembly (4) Remove half shaft hub nut. (5) Remove brake caliper and rotor. (6) Position hydraulic jack under lower suspension
arm and raise jack to unload rebound bumper.
(7) Remove lower shock absorber bolt. (8) Remove upper ball joint nut and seperate ball
with Remover 8677 (Fig. 1).
Fig.1UPPERBALLJOINTSEPARATION
1 - UPPER CONTROL ARM 2 - REMOVER 3 - STEERING KNUCKLE
HALF SHAFT
3 - 12
HALF SHAFT (Continued)DR
(9) Disengage inner C/V joint from the axle shaft snap-ring by apply pressure with two pry bars between the C/V housing and axle housing.
(10) Tilt the knuckle out and push the half shaft
out of the knuckle (Fig. 2).
CAUTION: Do not damage outer C/V threads while removing half shaft.
Fig.2STEERINGKNUCKLE
1 - STEERING KNUCKLE 2 - SHOCK 3 - HALFSHAFT 4 - DISC BRAKE CALIPER 5 - HUB/BEARING
(11) Remove the half shaft from the vehicle.
INSTALLATION
(1) Clean hub bearing bore, hub bearing mating
surface and half shaft splines.
(2) Apply a light coating of grease to the front axle
shaft output splines.
(3) Install half shaft into the knuckle (Fig. 3).
Fig.3HALFSHAFTANDHUB/BEARING
1 - HUB/BEARING MOUNTING NUTS 2 - HALF SHAFT
(4) Install half shaft on the axle output shaft. Push firmly to engage the axle output shaft snap ring into the inner C/V housing.
(5) Install upper ball joint into the knuckle. (6) Install upper ball joint nut and tighten to spec-
ification.
specification.
(7) Install lower shock absorber bolt and tighten to
(8) Install brake rotor and caliper. (9) Install half shaft hub nut and tighten to 251
N·m (185 ft. lbs.).
(10) Install the wheel and tire assembly.
SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION Half Shaft Nut
N·m 251
Ft. Lbs.
185
In. Lbs.
SPECIAL TOOLS
CLAMPINSTALLERC-4975A
DR
CV JOINT-OUTER REMOVAL
HALF SHAFT
3 - 13
(1) Clamp shaft in a vise (with soft jaws) and sup-
(2) Remove clamps with a cut-off wheel or grinder
port C/V joint.
(Fig. 4).
CAUTION: Do not damage C/V housing or half shaft.
Fig.4BOOTCLAMPLOCATIONS
1 - C/V HOUSING 2 - CLAMP 3 - HALF SHAFT 4 - CLAMP 5 - C/V BOOT
Fig.5OUTERC/VJOINT
1 - SNAP RING 2 - SNAP RING GROVE 3 - SNAP RING PLIERS
(3) Slide the boot down the shaft. (4) Remove lubricant to expose the C/V joint snap
(5) Spread snap ring and slide the joint off the
ring.
shaft (Fig. 5).
(6) Slide boot off the shaft and discard old boot. (7) Mark alignment marks on the inner race/hub, bearing cage and housing with dabs of paint (Fig. 6). (8) Clamp C/V joint in a vertical position in a soft
jawed vise.
(9) Press down one side of the bearing cage to gain
access to the ball at the opposite side.
NOTE: If joint is tight, use a hammer and brass drift to loosen the bearing hub. Do not contact the bear- ing cage with the drift.
(10) Remove ball from the bearing cage (Fig. 7). (11) Repeat step above until all six balls are
removed from the bearing cage.
(12) Lift cage and inner race upward and out from
the housing (Fig. 8).
(13) Turn inner race 90° in the cage and rotate the
inner race/hub out of the cage (Fig. 9).
Fig.6BEARINGACCESS
1 - ALIGNMENT MARKS 2 - BEARING HUB 3 - BEARING CAGE 4 - HOUSING
INSTALLATION
NOTE: If C/V joint is worn, replace entire C/V joint and boot.
(1) Clean all C/V joint components and shaft. (2) Apply a light coat of grease supplied with the joint/boot to the C/V joint components before assem-
