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SUSPENSION - Ertyu.org

1. 80ae0e68 Fig 35 Pressing Hub Out Of Wheel Bearing 1 STEERING KNUCKLE 2 SPECIAL TOOL 6644 2 3 SPECIAL TOOL 1130 4 ARBOR PRESS BLOCKS 5 HUB SUSPENSION 2 27 8 Remove the bearing splitter from the steering knuckle 9 Remove the three bolts mounting the bearing retainer plate to the steering knuckle Fig 36 Remove the bearing retainer plate from the steering knuckle 80ae0e69 Fig 36 Wheel Bearing Retainer Plate 1 MOUNTING BOLTS 2 BEARING RETAINER PLATE 3 STEERING KNUCKLE 10 Place the steering knuckle back in the arbor press supported by press blocks as shown Fig 37 The press blocks must not obstruct the bore in the steering knuckle so the wheel bearing can be pressed out of the steering knuckle Place Bearing Driver Special Tool MB 990799 on the outer race of wheel bearing Fig 37 Press the wheel bearing out of the steering knuckle 11 Install Bearing Splitter Special Tool 1130 on the hub The bearing splitter is to be installed on the hub so it is between the flange of the hub and the outer bearing race on the hub Fig 38 Place the hub bearing race and bearing splitter in an arbor press as shown Fig 38 Place Driver Special Tool 6644 2 on end of hub Press the hub out of the outer bearing race 2 28 SUSPENSION DISASSEMBLY AND ASSEMBLY Continued 9502 71 Fig 37 Wheel Bearing Removal From Steering Knuckle 1 ARBOR PRESS 2 SPECIAL T
2. REAR BOLT INSTALLATION 1 Position the lower control arm into the cross member Fig 17 Install but do not fully tighten the rear pivot bolt attaching the lower control arm to the front suspension crossmember and frame rail Install the front pivot bolt attaching the lower con trol arm to the front suspension crossmember 2 Tighten the lower control arm rear pivot and suspension crossmember bolt to a torque of 203 N m 150 ft Ibs then tighten the lower control arm front pivot bolt to a torque of 163 N m 120 ft Ibs 3 Install the ball joint stud into the steering knuckle aligning the bolt hole in the knuckle boss 2 20 SUSPENSION REMOVAL AND INSTALLATION Continued with the notch formed in the side of the ball joint stud 4 If the right lower control arm has been ser viced install the engine torque strut Fig 16 Follow the procedure described in the ENGINE service man ual group to properly align and tighten the torque strut 5 Install a new ball joint stud pinch bolt and nut Fig 15 Tighten the nut to a torque of 95 N m 70 ft Ibs 6 Rotate the forward ends of the stabilizer bar into mounting position 7 Install both stabilizer bar links back on vehicle Fig 14 Start each stabilizer bar link bolt with bushing from the bottom through the stabilizer bar inner link bushings lower control arm and into the upper retainer nut and bushing Fig 1 Do not fully tighten the link assem
3. ing the spring rotate the spring to the position determined in the note prior to step 9 in disassembly 2 Slowly compress the coil spring until enough room is available for strut assembly reassembly 3 Install the lower spring isolator on the lower spring seat of the strut matching the step built into SUSPENSION 2 49 the isolator with the step in the lower spring seat on the strut Fig 19 4 Install the jounce bumper on the strut shaft The jounce bumper is to be installed with the pointed end pointing downward toward the lower seat 5 Install the dust shield on the strut shaft Fig 19 The bottom of the dust shield will snap past the retainer on top of the strut housing 6 Install the strut through the bottom of the coil spring until the lower spring seat contacts the lower end of the coil spring Rotate the strut until the end of the coil spring fits against the step in the lower spring seat Fig 17 If done correctly the clevis on the bottom of the strut should face toward the com pressor 7 Install the clamp on the lower end of the coil spring and strut so the strut is held in place with the coil spring NOTE Before installing the upper mount check to make sure the correct side mount is being installed Left and right upper mounts are different A left mount will be marked with the letter L while a right mount will be marked with the letter R Fig 20 80bce977 Fig 20 Upper Mount M
4. 200005 5 SPECIFICATIONS WHEEL ALIGNMENT SPECIFICATIONS 8 e Caster is the number of degrees of forward or rearward tilt of the steering knuckle Forward tilt provides a negative caster angle while rearward tilt provides a positive caster angle Caster is not adjust able on this vehicle e Cross Camber is the difference between left and right camber The right side camber is to be sub tracted from the left resulting in the cross camber reading For example if the left camber is 0 3 and the right camber is 0 0 the cross camber would be 0 3 e Toe is measured in degrees or inches and is the difference in width between the centered leading and trailing edges of the tires on the same axle Fig 1 Toe in means that the front width is more narrow than the rear Toe out means that the front width is wider than the rear e Thrust Angle is defined as the average of the toe settings on each rear wheel If this measurement is out of specification readjust the rear wheel toe so that each wheel has 1 2 of the total toe measure ment When readjusting do not exceed the total toe specification 2 2 SUSPENSION CCCP DESCRIPTION AND OPERATION Continued 80bbc345 Fig 1 Alignment Camber And Toe 1 LOOSEN NUT TO ADJUST TOE 5 CAMBER 2 TOE ADJUSTMENT 6 TOE OUT 3 POSITIVE 7 TOE IN 4 NEGATIVE PL DIAGNOSIS AND TESTING SUSPENSION AND STEERING DIAGNOSIS CONDITION POSSIB
5. Assembly 1 STRUT ASSEMBLY 2 STRUT 3 LOWER SPRING ISOLATOR 4 COIL SPRING 5 JOUNCE BUMPER 6 DUST SHIELD 7 UPPER MOUNT KNUCKLE REAR The rear knuckle is not a repairable component of the rear suspension Upon visual inspection if it is determined that the knuckle is cracked bent or bro ken no attempt is to be made to repair or to straighten the knuckle The knuckle must be replaced if found to be damaged in any way HUB AND BEARING REAR The hub and bearing is designed for the life of the vehicle and requires no type of periodic maintenance Fig 1 The following procedure may be used for diagnosing the condition of the hub and bearing With the wheel disc brake rotor or brake drum removed rotate the hub Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing If the bearing exhibits any of these condi tions during diagnosis the hub and bearing will require replacement The bearing is not serviceable alone Damaged bearing seals and the resulting excessive grease loss may also require hub and bearing replacement Moderate grease weapage from the SUSPENSION 2 39 bearing is considered normal and should not require replacement of the wheel bearing To diagnose a bent hub refer to BRAKE ROTOR in the DIAGNOSIS AND TESTING section in the BRAKES service manual group for the procedure on measuring hub runout LATERAL ARMS Inspect each lateral arm Fi
6. DESCRIPTION AND OPERATION Continued 80bce90c Fig 2 Lateral Arms 1 REAR STABILIZER BAR 2 REAR LATERAL ARMS 3 RIGHT FRONT LATERAL ARM 4 LEFT FRONT LATERAL ARM The lateral arms are made of stamped steel and have rubber isolator bushings at each end The lat eral arms are attached to the rear crossmember and knuckle using a unique bolt and nut assembly at each end The lateral arm to rear crossmember attaching bolts are longer than the lateral arm to knuckle attaching bolts Each lateral arm to knuckle attaching bolt and nut assembly uses two flat wash ers Each lateral arm to rear crossmember attaching bolt uses one flat washer and one adjustment cam to provide a means for rear wheel alignment toe adjust ment TENSION STRUT The tension strut controls the fore and aft move ment of the rear knuckle Fig 1 There is one tension strut per side of the rear sus pension The leading end of the tension strut attaches to the frame rail while the trailing end of the strut attaches to the lower end of the rear knuckle The tension strut is isolated from the rest of the rear suspension through the use of rubber bush ings located at each end The rear bushings bayonet type can be serviced separately the front bushings spool type cannot STABILIZER BAR REAR The stabilizer bar interconnects both rear strut assemblies and is attached to the rear frame rails of the vehicle Fig 3 The rear stabilizer bar
7. DO NOT REMOVE THE STRUT SHAFT NUT BEFORE THE COIL SPRING IS COMPRESSED THE COIL SPRING IS HELD UNDER PRESSURE AND MUST BE COMPRESSED REMOVING SPRING TENSION FROM THE UPPER MOUNT AND PIVOT BEARING BEFORE THE SHAFT NUT IS REMOVED 3 Compress the coil spring until all coil spring tension is removed from the upper mount 4 Once the spring is sufficiently compressed install Strut Nut Socket Special Tool 6864 on the strut shaft retaining nut Fig 26 Next install a socket on the hex on the end of the strut shaft While SUSPENSION 2 23 80bce908 Fig 25 Strut Assembly In Compressor Upper 1 NOTCH IN UPPER SEAT 2 UPPER MOUNT 3 UPPER HOOKS 4 CLEVIS BRACKET holding the strut shaft from turning remove the nut from the strut shaft i 4 ty Y SS i i T5 KA Q o OK 80bce909 Fig 26 Shaft Nut Removal installation 1 SPRING COMPRESSOR 2 SPECIAL TOOL 6864 3 UPPER MOUNT 2 24 SUSPENSION DISASSEMBLY AND ASSEMBLY Continued 5 Remove the upper mount from the strut shaft Fig 27 SS 80bce910 Fig 27 Strut Assembly Components 1 NUT 2 STRUT ASSEMBLY 3 STRUT 4 LOWER SPRING ISOLATOR 5 COIL SPRING 6 JOUNCE BUMPER 7 DUST SHIELD 8 SPRING SEAT AND BEARING WITH SPRING ISOLATOR 9 UPPER MOUNT 6 Remove the upper spring seat and bearing along with the upper spring isolator as an assembly from the top of
8. Retainer Plate 1 WHEEL BEARINGS 2 MOUNTING BOLTS 3 STEERING KNUCKLE 4 BEARING RETAINER PLATE 4 Place the previously removed wheel mounting stud back into the hub flange Place the hub in the arbor press supported by Special Tool C 4698 1 Fig 41 Press wheel mounting stud into hub flange until it is fully seated against the back side on the hub flange Remove the hub from the press 80ae846 Fig 41 Wheel Mounting Stud Installation 1 ARBOR PRESS RAM 2 HUB 3 SPECIAL TOOL C 4698 1 4 NO GAP IS ALLOWED BETWEEN STUD FLANGE AND HUB 5 WHEEL MOUNTING STUD SUSPENSION 2 29 5 Place the steering knuckle with the wheel bear ing installed back in the arbor press with Receiver Special Tool MB 990799 supporting the inner race of the wheel bearing as shown Fig 42 Place the hub in wheel bearing making sure it is square with the bearing inner race Press the hub into the wheel bearing until it is fully bottomed in the wheel bear ing Remove the knuckle from the press 80ae8464 Fig 42 Pressing Hub Into Wheel Bearing 1 ARBOR PRESS RAM 2 HUB 3 STEERING KNUCKLE 4 SPECIAL TOOL MB 990799 5 BEARING RETAINER PLATE 6 WHEEL BEARING 6 Install the steering knuckle assembly on the vehicle LOWER CONTROL ARM BALL JOINT NOTE The removal and installation of the lower ball joint from the lower control arm is to be done with the lower control arm re
9. ace 46 STABILIZER BAR REAR 00 47 DISASSEMBLY AND ASSEMBLY STRUT ASSEMBLY REAR 47 SPECIFICATIONS REAR SUSPENSION FASTENER TORQUE SPECIFICATIONS 00000 50 SPECIAL TOOLS REAR SUSPENSION 004 50 When the vehicle strikes a bump the force is trans ferred through the hub bearing and knuckle into the strut assembly to absorb the force and dampen it Lateral movement of the rear knuckle is controlled by lateral arms going from the front and rear of the knuckle to the rear crossmember Fore and aft move ment of the knuckle is controlled by a tension strut 2 36 SUSPENSION _ _ RPL DESCRIPTION AND OPERATION Continued P FRONT OF VEHICLE g0hceag9 Fig 1 Rear Suspension System PL DESCRIPTION AND OPERATION Continued 1 VEHICLE STRUT TOWER 2 STRUT ASSEMBLY 3 TENSION STRUT 4 LATERAL ARMS 5 KNUCKLE 6 HUB AND BEARING 7 WHEEL ALIGNMENT ADJUSTMENT CAM 8 STRUT SUSPENSION 9 LOWER SPRING ISOLATOR 10 COIL SPRING 11 STABILIZER BAR 12 JOUNCE BUMPER 13 DUST SHIELD 14 UPPER MOUNT 15 STABILIZER BAR LINK 16 STABILIZER BAR CUSHION AND RETAINER For more information on the description and oper ation of an individual component refer to the appli cable component heading in this section STRUT ASSEMBLY REAR The rear strut assemblies suppo
10. allows jounce and rebound movements affecting one wheel to be partially trans mitted to the opposite wheel of the vehicle to stabi lize body roll PL Attachment of the stabilizer bar to the rear frame rails of the vehicle is through two rubber isolator cushions and retainers Fig 1 The stabilizer bar attachment to each strut assembly is done utilizing a rubber isolated stabilizer bar link All parts of the stabilizer bar are serviceable and the stabilizer bar to frame rail isolator cushions are split for easy removal and installation Fig 3 Rear Stabilizer Bar 1 REAR STABILIZER BAR 2 REAR LATERAL ARMS 3 RIGHT FRONT LATERAL ARM 4 LEFT FRONT LATERAL ARM DIAGNOSIS AND TESTING STRUT ASSEMBLY REAR Inspect the strut assembly for the following condi tions Fig 4 e Inspect for a damaged or broken coil spring e Inspect for a torn or damaged strut assembly dust shield e Lift the dust shield and inspect the strut assem bly for evidence of fluid running from the upper end of the strut fluid reservoir Actual leakage will be a stream of fluid running down the side and dripping off lower end of unit A slight amount of seepage between the strut shaft and strut shaft seal is not unusual and does not affect performance of the strut assembly e Lift the dust shield and inspect the jounce bumper for signs of damage or deterioration PL DIAGNOSIS AND TESTING Continued 80bce978 Fig 4 Strut
11. and bearing is mounted on the rear knuckle s spindle Fig 1 The hub and bearing adapts the tire and wheel assembly to the knuckle It s bearing allows the tire and wheel assembly to rotate freely on the vehicle All vehicles are equipped with permanently lubri cated and sealed for life rear wheel bearings There is no periodic lubrication or maintenance recom mended for these units The only servicable components of the hub and bearing are the wheel mounting studs If a vehicle is equipped with antilock brakes the tone wheels for the rear wheel speed sensors are pressed onto the hub LATERAL ARMS The lateral arms control the lateral movement of the rear suspension specifically the knuckle Fig 1 There are two lateral arms per side of the rear sus pension One arm is attached to the front end of the knuckle and the other is attached to the rear of the knuckle The other end of each lateral arm attaches to the rear crossmember Visually it appears that the left rear arm is mounted backwards in relation to the other arms Fig 2 Although the left rear arm looks like it is same as the right rear arm just reversed it is not the same the arms are not interchangeable The front arms are interchangeable but should be mounted with the side displaying the word FOR WARD stamped into it toward the front of the vehi cle The trimmed outer edge of the arms will then be facing the rear of the vehide 2 38 SUSPENSION
12. assembly 9 Perform the above procedure to any of the remaining struts as required 10 Lower the vehicle and jounce the front and rear of the vehicle 11 Adjust the front or rear camber to the pre ferred setting by pushing or pulling on the top of the tire When camber is set to specifications tighten the upper and lower strut clevis bracket bolts Again jounce the front and rear of the vehicle then verify the camber settings 12 Torque front strut devis bracket to steering knuckle attaching bolts to 53 N m 40 ft Ibs plus an additional 1 4 turn after the torque is met Torque the rear strut clevis bracket to rear knuckle attach ing bolts to 95 N m 70 ft Ibs 13 Once camber is within specifications adjust toe to meet the preferred specification setting Refer to TOE within this wheel alignment service proce dure TOE 1 Center the steering wheel and lock it in place using a steering wheel clamp NOTE When performing the toe setting procedure make sure the rear toe is set to the preferred spec ification before setting the front toe to the preferred specification REAR TOE 1 Loosen the nuts on the left and right rear lat eral link attaching bolts at the rear crossmember as necessary to allow rotation of the rear toe adjustment cams Fig 4 SUSPENSION 2 7 80be4ef3 Fig 4 Adjustment Cams 1 BOLTS 2 ADJUSTMENT CAMS 3 NUTS CAUTION When adjusting rear toe the notches on th
13. at the knuckle to 95 N m 70 ft Ibs 2 46 SUSPENSION REMOVAL AND INSTALLATION Continued 10 With suspension at curb height tighten the lateral arm mounting bolt nut at the crossmember to 88 N m 65 ft Ibs 11 Set the rear toe on the vehicle to the required specification as necessary Refer to WHEEL ALIGN MENT in this service manual group TENSION STRUT NOTE Before proceeding with this procedure review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section REMOVAL 1 Raise the vehicle Refer to HOISTING in the LUBRICATION AND MAINTENANCE group for the proper lifting procedure 2 Remove the rear wheel and tire assembly from the vehicle 3 Disconnect the tension strut from the knuckle To do this first hold the tension strut from turning by using a wrench on the flat on the tension strut and then remove the nut from the rear of the tension strut Fig 14 Next remove the tension strut retainer then the rear tension strut bayonet bushing from the tension strut 80bce973 Fig 14 Tension Strut Nut Removal nstallation 1 KNUCKLE 2 TENSION STRUT 3 FLAT 4 Remove the nut attaching the parking brake cable to the stud on the inboard tension strut mount ing bolt at the frame Fig 15 Remove the parking brake cable from the stud 5 Remove the two mounting bolts holding the tension bolts to the frame then remove the tension strut from the vehic
14. away from the control arm once installed Fig 47 Start the sealing boot over the sides of the ball joint by hand 7 Position the Installer Special Tool 6758 over the sealing boot outer diameter as shown Fig 47 By hand apply pressure to the top of the Installer until the seal boot is pressed squarely down against the top surface of lower control arm 8 Remove the tool 9 Install the lower control arm on the vehicle Refer to LOWER CONTROL ARM in the REMOVAL AND INSTALLATION section NOTE If the ball joint is equipped with a lubeable grease fitting the joint will need to be lubricated once the lower control arm installation is complete SUSPENSION 2 31 LOWER CONTROL ARM REAR ISOLATOR BUSHING NOTE The removal and installation of the rear iso lator bushing from the lower control arm is only to be done with the lower control arm removed from the vehicle Refer to LOWER CONTROL ARM in the REMOVAL AND INSTALLATION section The front isolator bushing is not serviceable DISASSEMBLY 1 Install the Remover Receiver Special Tool 8373 1 into the cup of the Ball J oint Press Special Tool C 4212F and tighten the set screw Install the Remover Driver Special Tool 8373 2 on the tip of the Ball J oint Press screw drive 2 Place the lower control arm outer flange against the Receiver as shown Fig 48 Tighten the screw drive until the Driver contacts the outer cir cumference of the bushing evenly Fig 48 Con
15. considered adjustable angles Camber and caster should be checked to ensure they meet vehicle speci fications If either front or rear camber is found not to meet alignment specifications it can be adjusted using an available camber adjustment bolt package Before installing a camber adjustment bolt package on a vehicle found to be outside the specifications inspect the suspension components for any signs of damage or bending No adjustment can be made to the caster setting on this vehicle If the vehicle s caster is not within alignment specifications check for damaged suspen sion components or body parts CAUTION Do not attempt to adjust the vehicles wheel alignment by heating or bending any of the suspension components CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION NOTE The following procedure should only be used on vehicles without the ACR competition package The camber adjustment bolt package contains new bolts and nuts for attaching the strut clevis bracket to the steering knuckle The bolts contained in the package are slightly undersize allowing for move ment between the strut clevis bracket and the steer ing knuckle The movement allowed by the undersize bolts provide approximately two degrees of camber adjustment per side of the vehicle To install and adjust the camber adjustment bolt package follow the procedure below CAUTION There are separate camber adjustment bolt packages for the front and rear of the ve
16. end of the drive shaft and snug it 13 Have a helper apply the brakes With vehicle brakes applied to keep brake rotor and hub from turning tighten the hub nut to a torque of 244 N m 180 ft Ibs 14 Install the tire and wheel assembly Install the wheel mounting nuts and tighten them to a torque of 135 N m 100 ft Ibs 15 Lower the vehicle 16 Set the front toe on the vehicle to required specification Refer to WHEEL ALIGNMENT in this service manual group LOWER CONTROL ARM NOTE Before proceeding with this procedure review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section REMOVAL 1 Raise the vehicle Refer to HOISTING in the LUBRICATION AND MAINTENANCE group for the proper lifting procedure 2 Remove the front tire and wheel assembly 3 Remove both stabilizer bar links from the vehi cle Fig 14 Remove each link by holding the upper retainer nut with a wrench and turning the link bolt 80bce903 Fig 14 Stabilizer Bar Links 1 STABILIZER BAR CUSHION RETAINERS 2 CUSHIONS 3 FRONT STABILIZER BAR 4 STABILIZER BAR LINKS 4 Rotate the forward ends of the stabilizer bar downward It may be necessary to loosen the stabi PL REMOVAL AND INSTALLATION Continued lizer bar cushion retainer bolts a little to ease any turning resistance 5 Remove the nut and pinch bolt clamping the ball joint stud to the steering
17. hub and bearing on the knuckle s spindle then install a new retaining nut Fig 7 Do not reuse the original nut Tighten the nut to a torque of 217 N m 160 ft Ibs 9 Install the dust cap on the end of the hub and bearing Fig 7 10 If the vehicle is equipped with rear disc brakes Fig 7 install the brake rotor and disc brake caliper on the knuckle Install the two guide pin bolts securing the front disc brake caliper to the steering knuckle Tighten the guide pin bolts to a torque of 22 N m 192 in Ibs 11 If the vehide is equipped with rear drum brakes install the screw securing the brake hose bracket to the rear of the strut assembly Fig 5 Tighten the screw to a torque of 31 N m 275 in Ibs 12 If the vehicle is equipped with the antilock brake system ABS install the screw securing the ABS wheel speed sensor bracket to the rear of the strut assembly Fig 6 Tighten the mounting screw to a torque of 13 N m 120 in Ibs 13 Install the tire and wheel assembly Tighten the wheel mounting nuts in proper sequence until all nuts are torqued to half specification Repeat the tightening sequence this time to full specified torque of 135 N m 100 ft Ibs 14 Lower the vehicle to ground level 15 Tighten the lateral arm to knuckle mounting bolt nut to a torque of 95 N m 70 ft Ibs 16 Set the rear toe on the vehicle to the required specification if necessary Refer to WHEEL ALIGN MENT in t
18. knuckle must be done using the following procedure DISASSEMBLY 1 Remove steering knuckle hub and wheel bear ing aS an assembly from the vehicle Refer to STEERING KNUCKLE in the REMOVAL AND INSTALLATION section in this service manual group 2 Using Remover Special Tool 4150A Fig 29 press one wheel mounting stud out of hub flange Rotate the hub to align the removed wheel mounting stud with the notch in bearing retainer plate Fig 30 Remove the wheel mounting stud from the hub G 80ae0e62 Fig 29 Pressing Out Wheel Mounting Stud 1 SPECIAL TOOL 4150A 2 WHEEL MOUNTING STUD 3 HUB FLANGE 4 STEERING KNUCKLE 3 Rotate the hub so the hole in the hub that wheel mounting stud was removed from is facing away from brake caliper lower rail on steering knuckle Fig 31 Install one half of the Bearing Splitter Special Tool 1130 between the hub and the bearing retainer plate Fig 31 NOTE Align the threaded hole in this first half of the bearing splitter with the caliper rail on the steer ing knuckle Fig 31 2 26 SUSPENSION _ io RPL DISASSEMBLY AND ASSEMBLY Continued 4 Install the remaining pieces of Bearing Splitter Special Tool 1130 on the steering knuckle Fig 32 Hand tighten the nuts to hold bearing splitter in place on steering knuckle 80ae0e63 Fig 30 Stud Removal From Hub 1 BEARING RETAINER PLATE 2 HUB 3 STEERING KNUCKLE 4 WHEEL MOUNTI
19. m 192 in Ibs 6 Install the tire and wheel assembly Install the wheel mounting nuts and tighten them to a torque of 135 N m 100 ft Ibs 7 Lower the vehicle DISASSEMBLY AND ASSEMBLY STRUT ASSEMBLY FRONT The Strut assembly must be removed from the vehicle for it to be disassembled and assembled Refer to REMOVAL AND INSTALLATION in this section for the required procedure For the disassembly and assembly of the strut assembly use strut spring compressor Pentastar Ser vice Equipment PSE tool W 7200 or the equivalent to compress the coil spring Follow the manufactur er s instructions closely DISASSEMBLY 1 If both struts are being serviced at the same time mark the coil spring and strut assembly accord ing to which side of the vehicle the strut was PL DISASSEMBLY AND ASSEMBLY Continued removed from and which strut the coil spring was removed from 2 Position the strut assembly in the strut coil spring compressor following the manufacturers instructions Set the lower hooks Fig 24 then set the upper hooks Fig 25 Position the strut clevis bracket straight outward away from the compressor Place a clamp on the lower end of the coil spring so the strut is held in place once the strut shaft nut is removed Fig 24 80bce907 Fig 24 Strut Assembly In Compressor Lower 1 LOWER HOOKS 2 CLAMP 3 STRUT ASSEMBLY 4 CLEVIS BRACKET 5 SPRING COMPRESSOR WARNING
20. manual group KNUCKLE REAR NOTE Before proceeding with this procedure review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section REMOVAL 1 Raise the vehicle Refer to HOISTING in the LUBRICATION AND MAINTENANCE group for the proper lifting procedure 2 Remove the rear wheel and tire assembly from the vehicle 3 If the vehicle is equipped with rear drum brakes remove the screw securing the brake hose bracket to the rear of the strut assembly Fig 5 4 If the vehicle is equipped with the antilock brake system ABS remove the screw securing the ABS wheel speed sensor bracket to the rear of the strut assembly Fig 6 5 If the vehicle is equipped with rear drum brakes remove any retainer clips from the wheel mounting studs then pull the brake drum off the hub and bearing 6 If the vehicle is equipped with rear disc brakes Fig 7 perform the following PL e Remove the two guide pin bolts securing the front disc brake caliper to the steering knuckle e Remove the disc brake caliper from the knuckle and brake rotor e Hang the caliper out of the way using a wire hanger or cord Do not support the caliper by letting it hang by the hydraulic hose e Remove any retainer clips from the wheel mounting studs then pull the brake rotor off the hub and bearing 7 Remove the dust cap from the hub and bearing assembly Fig 7 8 Remove the retaining nut then
21. requiring strut removal 3 If both strut assemblies are to be removed mark the strut assemblies right or left according to which side of the vehicle they were removed from 4 Remove the screw securing the ground strap to the rear of the strut Fig 5 Fig 5 Ground Strap And ABS Sensor Bracket 1 ABS WHEEL SPEED SENSOR ROUTING BRACKET IF EQUIPPED 2 GROUND STRAP 3 GROUND STRAP SCREW 4 ABS SENSOR BRACKET SCREW IF EQUIPPED 5 If the vehicle is equipped with Antilock brakes ABS remove the screw securing the ABS wheel speed sensor to the rear of the strut Fig 5 CAUTION The strut assembly to steering knuckle attaching bolts are serrated and must not be turned during removal Hold the bolts stationary in the steering knuckle while removing the nuts then tap the bolts out using a pin punch PL REMOVAL AND INSTALLATION Continued 6 Remove the two bolts attaching the strut to the steering knuckle Fig 1 7 Lower the vehicle just enough to open the hood but without letting the tires touch the floor 8 Remove the three nuts attaching the upper mount of the strut assembly to the vehicle s strut tower Fig 6 80bc4ef7 Fig 6 Upper Mounting Nuts 1 STRUT TOWER 2 MOUNTING NUTS 9 Remove the strut assembly from the vehicle 10 For disassembly and assembly procedures refer to STRUT ASSEMBLY in the DISASSEMBLY AND ASSEMBLY section in this section of this ser vi
22. seal does not get cut 15 Separate the ball joint stud from the steering knuckle by prying down on lower control arm and up against the ball joint boss on the steering knuckle Fig 12 NOTE Do not allow the driveshaft to hang by the inner C V joint it must be supported to keep the joint from separating during this operation 16 Pull the steering knuckle off the driveshaft outer C V joint splines and remove the steering knuckle NOTE The cartridge type front wheel bearing used on this vehicle is not transferable to the replace ment steering knuckle If the replacement steering knuckle does not come with a wheel bearing a new bearing must be installed in the steering knuckle Installation of the new wheel bearing and hub must SUSPENSION 2 17 80bce902 Fig 12 Separate Ball Joint from Knuckle 1 STEERING KNUCKLE 2 PRY BAR 3 LOWER CONTROL ARM 4 BALL JOINT STUD be done before installing the steering knuckle on the vehicle 17 If the steering knuckle is to be replaced refer to STEERING KNUCKLE in the DISASSEMBLY AND ASSEMBLY section in this section of this ser vice manual group for the wheel bearing and hub removal and installation procedure Do not reuse the wheel bearing INSTALLATION 1 If the steering knuckle has been replaced refer to STEERING KNUCKLE in DISASSEMBLY AND ASSEMBLY found in this section of this service man ual group for the wheel bearing and hub installation proc
23. the coil spring by pulling them straight up Fig 27 The upper spring isolator can be separated from the spring seat and bearing once removed from vehicle 7 Remove the dust shield then the jounce bumper from the strut shaft by pulling each straight up Fig 27 8 Remove the clamp from the bottom of the coil spring and remove the strut out through the bottom of the coil spring 9 Remove the lower spring isolator from the lower spring seat on the strut NOTE If the coil spring needs to be serviced pro ceed with the next step otherwise proceed with step 11 PL 10 Release the tension from the coil spring by backing off the compressor drive completely Push back the compressor hooks and remove the coil spring 11 Inspect the strut assembly components for the following and replace as necessary e Inspect the strut for any condition of shaft bind ing over the full stroke of the shaft e Inspect the jounce bumper for cracks and signs of deterioration e Check the upper mount for cracks and distortion and its retaining studs for any sign of damage e Check the upper spring seat and bearing for cracks and distortion e Check for binding of the upper spring seat and bearing pivot bearing e Inspect the dust shield for rips and deteriora tion e Inspect the upper and lower spring isolators for material deterioration and distortion e Inspect the coil spring for any sign of damage to the coating ASSEMBLY N
24. upper hooks on the coil spring Fig 17 Position the strut clevis bracket straight inward toward the compressor Place a clamp on the lower end of the coil spring so the strut is held in place once the strut shaft nut is removed 80bce975 Fig 17 Strut Assembly In Compressor 1 UPPER HOOKS 2 COIL SPRING 3 CLEVIS BRACKET 4 CLAMP 5 LOWER HOOKS WARNING DO NOT REMOVE THE STRUT SHAFT NUT BEFORE THE COIL SPRING IS COMPRESSED THE COIL SPRING IS HELD UNDER PRESSURE AND MUST BE COMPRESSED REMOVING SPRING TENSION FROM THE UPPER MOUNT AND PIVOT BEARING BEFORE THE SHAFT NUT IS REMOVED 3 Compress the coil spring until all coil spring tension is removed from the upper mount PL 4 Once the spring is sufficiently compressed install Strut Nut Socket Special Tool 6864 on the strut shaft retaining nut Fig 18 Next install a socket on the hex on the end of the strut shaft While holding the strut shaft from turning remove the nut from the strut shaft 80bce976 Fig 18 Shaft Nut Removal installation 1 UPPER MOUNT 2 FRONT HOOK 5 Remove the upper mount from the strut shaft Fig 19 6 Remove the clamp from the bottom of the coil spring and remove the strut out through the bottom of the coil spring 7 Remove the dust shield then the jounce bumper from the strut shaft by pulling each straight up Fig 19 8 Remove the lower spring isolator from the lower spring seat lo
25. 0A 2 LUG NUT 3 HUB BEARING 4 STEERING KNUCKLE 5 WHEEL STUD 80aa4beb Fig 22 Installing Wheel Stud 1 STEERING KNUCKLE 2 WHEEL LUG NUT 3 WASHERS 4 HUB BEARING 2 Tighten the wheel mounting nut This will pull the wheel mounting stud into the flange of the hub When the head of the stud is fully seated against the rear of the hub flange remove the wheel mounting nut and washers from the stud 3 Install the brake rotor on the hub Fig 20 4 Install the disc brake caliper with pads on the brake rotor and steering knuckle The left side cali per is installed by first sliding the top of the caliper past the top abutment on the steering knuckle to hook the top edge of the caliper then pushing the PL lower end of the caliper into place against the knuckle Fig 23 The right side caliper is installed by first sliding the bottom edge of the caliper past the lower abutment on the steering knuckle to hook the lower edge of the caliper then pushing the top of the caliper into place against the steering knuckle 80aa4b6d Fig 23 Brake Caliper Installation 1 SLIDE TOP OF BRAKE CALIPER UNDER TOP ABUTMENT OF STEERING KNUCKLE AS SHOWN 2 BRAKING DISC 3 DISC BRAKE CALIPER 4 STEERING KNUCKLE BRAKE ABUTMENT 5 Install the two guide pin bolts securing the front disc brake caliper to the steering knuckle Fig 20 Tighten the guide pin bolts to a torque of 22 N
26. 9 mm 8mm ALL NEON 26 46 in 0 32 in 26 73 in 0 32 in WHEEL ALIGNMENT PRE WHEEL ALIGNMENT VEHICLE INSPECTION CAUTION If during the inspection the front sus pension crossmember shows any sign of impact damage the steering column lower coupling must be inspected Refer to DIAGNOSIS AND TESTING in the STEERING group in this service manual Before any attempt is made to change or correct the wheel alignment the following inspection and necessary corrections must be made to the vehicle to ensure proper alignment 1 Be sure the fuel tank is full of fuel If the fuel tank is not full the reduction in weight will affect the curb height of the vehicle and the alignment specifications 2 The passenger and luggage compartments of the vehicle should be free of any load that is not fac tory equipment 3 Check the tires on the vehicle The tires are to be inflated to the recommended air pressure All tires must be the same size and in good condition with approximately the same tread wear 4 Check the front tire and wheel assemblies for excessive radial runout 5 Inspect all suspension component fasteners for looseness and torque 6 Inspect the lower front ball joints and all steer ing linkage for looseness and any sign of wear or damage 7 Inspect the rubber bushings on all the suspen sion components for signs of wear or deterioration If any bushings show signs of wear or deterioration they should be replac
27. EMBLY AND ASSEMBLY Continued 80bce90b Fig 28 Coil Spring Positioning 1 UPPER END OF COIL 2 COIL SPRING 3 LOWER END OF COIL 4 SPRING COMPRESSOR 9 Install the strut upper mount over the strut shaft and onto the top of the upper spring seat and bearing 10 Loosely install the retaining nut on the strut shaft Install Strut Nut Socket on the end of a torque wrench Special Tool 6864 on the strut shaft retaining nut Fig 26 Next install a socket on the hex on the end of the strut shaft While holding the strut shaft from turning tighten the strut shaft retaining nut to a torque of 75 N m 55 ft Ibs 11 Slowly release the tension from the coil spring by backing off the compressor drive completely As the tension is relieved make sure the upper mount and seat and bearing align properly Verify the upper mount does not bind 12 Remove the clamp from the lower end of the coil spring and strut Push back the spring compres sor upper and lower hooks then remove the strut assembly from the spring compressor 13 Install the strut assembly on the vehicle Refer to REMOVAL AND INSTALLATION in this section for the required procedure SUSPENSION 2 25 STEERING KNUCKLE WHEEL BEARING AND HUB NOTE The removal and installation of the wheel bearing and hub from the steering knuckle is only to be done with the steering knuckle removed from the vehicle Removal of the wheel bearing from the steering
28. ILIZER BAR 2 LINK 3 DOWNWARD CURVE 4 CUSHION RETAINER 4 Lower the vehicle NOTE It may be necessary to put the vehicle on a platform hoist or alignment rack to gain access to the stabilizer bar mounting bolts with the vehicle at curb height 5 Tighten each stabilizer bar link by holding the upper retainer nut with a wrench and turning the link bolt Tighten each link bolt to a torque of 23 N m 200 in Ibs 6 Tighten the stabilizer bar cushion retainer bolts to a torque of 28 N m 250 in Ibs WHEEL MOUNTING STUD FRONT NOTE Before proceeding with this procedure review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section Use the following procedure to remove and install one of five studs on one wheel hub REMOVAL 1 Raise the vehicle Refer to HOISTING in the LUBRICATION AND MAINTENANCE group for the proper lifting procedure 2 Remove the front tire and wheel assembly 3 Remove the two guide pin bolts securing the front disc brake caliper to the steering knuckle Fig 20 4 Remove the disc brake caliper from the steer ing knuckle The caliper is removed by first tipping either the top right side or bottom left side of the SUSPENSION 2 21 80bce90a Fig 20 Brake Caliper And Rotor 1 RETAINER CLIP 2 BRAKE ROTOR 3 HUB 4 GUIDE PIN BOLTS 5 DISC BRAKE CALIPER caliper away from the brake rotor then pulling the cal
29. LE CAUSES SUSPENSION 2 3 POTENTIAL CORRECTIONS Front End Whine On Turns 1 Defective Wheel Bearing 2 Incorrect Wheel Alignment 3 Worn Tires 1 Replace Wheel Bearing 2 Check And Reset Wheel Alignment 3 Replace Tires Front End Growl Or Grinding On Turns 1 Defective Wheel Bearing 2 Engine Mount Grounding Against Frame Or Body Of Vehicle 3 Worn Or Broken C V Joint Loose Wheel Lug Nuts Incorrect Wheel Alignment Worn Tires 1 Replace Wheel Bearing 2 Check For Motor Mount Hitting Frame Rail And Reposition Engine As Required 3 Replace C V Joint 4 Verify Wheel Lug Nut Torque 5 Check And Reset Wheel Alignment 6 Replace Tires Front End Clunk Or Snap On Turns Loose Wheel Lug Nuts Worn Or Broken C V Joint Worn Or Loose Tie Rod Or Ball Joint Worn Control Arm Bushing Loose Sway Bar Or Upper Strut Attachment 1 Verify Wheel Lug Nut Torque 2 Replace C V Joint 3 Tighten Or Replace Tie Rod End Or Ball Joint 4 Replace Control Arm Bushing 5 Tighten Sway Bar Or Upper Strut Attachment To Specified Torque Front End Whine With Vehicle Going Straight At A Constant Speed 1 Defective Wheel Bearing 2 Incorrect Wheel Alignment 3 Worn Tires 1 Replace Wheel Bearing Check And Reset Wheel Alignment Replace Tires Front End Growl Or Grinding With Vehicle Going Straight At A Constant Speed 1 Engine Mount Grounding 2 Worn Or Broken C
30. LLATION Continued 80bce90f Fig 7 Rear Disc Brakes 1 DISC BRAKE CALIPER 2 DISC BRAKE ADAPTER 3 GUIDE PIN BOLTS 4 HUB AND BEARING 5 BRAKE ROTOR 6 RETAINER CLIP 7 DUST CAP 8 NUT CAUTION The strut to knuckle attaching bolts are serrated and must not be turned during removal Hold the bolts stationary in the steering knuckle while removing the nuts then tap the bolts out using a pin punch 7 Remove the two nuts and bolts attaching the strut to the rear knuckle Fig 1 8 Lower the vehicle just enough to access the luggage compartment without letting the tires touch the floor Access to rear upper strut mount attaching bolts is through the luggage compartment 9 Open the deck lid 10 If equipped remove the carpet from the top of the strut tower 11 Loosen but do not completely remove the 3 nuts securing the strut assembly to the strut tower Fig 8 Grasp the strut assembly to keep it from moving then remove the 3 mounting nuts at the strut tower 12 Remove the strut assembly from the knuckle by sliding it away from the knuckle lowering it between the two lateral arms then tipping the top outward and removing it out through the well open ing 13 For disassembly and assembly procedures of the strut assembly refer to STRUT ASSEMBLY in the DISASSEMBLY AND ASSEMBLY section in this section of this service manual group SUSPENSION 2 41 fy Fig 8 Mounting A
31. NG STUD 5 NOTCH 80ae0e65 Fig 32 Bearing Splitter Installed 1 STEERING KNUCKLE 2 HUB 3 SPECIAL TOOL 1130 4 NUTS 5 Once the bearing splitter in fully installed be sure the three bolts attaching the bearing retainer plate to steering knuckle Fig 33 are contacting the bearing splitter Fig 33 The bearing retainer plate should not support the steering knuckle or contact the bearing splitter 80ae0e64 Fig 31 Bearing Splitter Half Installed 1 CALIPER RAIL 2 THREADED HOLE 3 SPECIAL TOOL 1130 4 STEERING KNUCKLE 5 HOLE FOR WHEEL MOUNTING STUD 6 HUB 80ae0e66 Fig 33 Correct Installation Of Bearing Splitter 1 STEERING KNUCKLE 2 SPECIAL TOOL 1130 3 BEARING RETAINER PLATE MOUNTING BOLTS 4 BEARING RETAINER PLATE PL DISASSEMBLY AND ASSEMBLY Continued 6 Place the steering knuckle in an arbor press supported by the bearing splitter as shown Fig 34 ILSE A A iD a n S Dm IS 80ae0e67 Fig 34 Steering Knuckle Supporting For Hub Removal 1 STEERING KNUCKLE 2 WHEEL BEARING 3 HUB 4 ARBOR PRESS BLOCKS 5 SPECIAL TOOL 1130 7 Position Driver Special Tool 6644 2 on the small end of the hub Fig 35 Using the arbor press remove the hub from the wheel bearing The outer bearing race will normally come out of the wheel bearing when the hub is pressed out of the bearing
32. NGE 2 ISOLATOR BUSHING 5 Back off the Ball J oint Press screw drive and remove the power steering gear from the press 6 Install the lower control arm on the vehicle PL SPECIFICATIONS FRONT SUSPENSION FASTENER TORQUE SPECIFICATIONS DESCRIPTION TORQUE STRUT ASSEMBLY Tower Nuts 34 N m 300 in Ibs Steering Knuckle Nuts 54 Nem 40 ft Ibs 90 Turn Strut Shaft Nut 75 N m 55 ft Ibs STEERING KNUCKLE Ball J oint Stud Pinch Bolt Nut 95 Ne m 70 ft Ibs Disc Brake Caliper Guide Bolts 22 N m 192 in Ibs WHEEL BEARING AND HUB Bearing Retainer Plate Bolts 28 N m 250 in Ibs Driveshaft Hub Nut 244 N m 180 ft Ibs Wheel Mounting Nuts 109 150 N m 80 110 ft Ibs STEERING GEAR Crossmember Bolts 68 N m 50 ft Ibs Tie Rod Adjusting Jam Nut 75 N m 55 ft Ibs Tie Rod End Steering Knuckle Nut 54 Nm 40 ft Ibs LOWER CONTROL ARM Front Pivot Bolt 163 N m 120 ft Ibs Rear Pivot Bolt 203 N m 150 ft Ibs STABILIZER BAR Cushion Retainer Bolts 28 N m 250 in Ibs Link Nut 23 N m 200 in Ibs SPECIAL TOOLS FRONT SUSPENSION S Q 6864 Socket Wrench Strut Nut 6864 SUSPENSION 2 33 Remover 6804 30110923 Installer 6758 Remover Installer 6908 2 2 Installer 6760 80114836E Remover MB991113 2 34 SUSPENSION
33. OOL MB 990799 3 STEERING KNUCKLE 4 PRESS BLOCKS 80ae8460 Fig 38 Removing Bearing Race From Hub 1 ARBOR PRESS 2 HUB 3 SPECIAL TOOL 1130 4 PRESS BLOCKS 2 5 BEARING RACE 6 SPECIAL TOOL 6644 2 PL ASSEMBLY 1 Wipe the bore of the steering knuckle clean of any grease or dirt with a clean dry shop towel 2 Place the new wheel bearing into the bore of the steering knuckle Be sure the wheel bearing is placed squarely into the bore Place the steering knuckle in an arbor press with Receiver Special Tool C 4698 2 supporting the steering knuckle Fig 39 Place Driver Special Tool 5052 on the outer race of the wheel bearing Press the wheel bearing into the steering knuckle until it is fully bottomed in the bore of the steering knuckle Remove the knuckle from the press 80a 8461 Fig 39 Pressing Wheel Bearing Into Steering Knuckle 1 ARBOR PRESS 2 SPECIAL TOOL 5052 3 SPECIAL TOOL C 4698 2 4 STEERING KNUCKLE 5 WHEEL BEARING NOTE Only the original or identical replacement bolts are to be used to mount the bearing retainer plate to the steering knuckle 3 Install the bearing retainer plate on the steer ing knuckle Fig 40 Install the three bearing retainer mounting bolts Tighten the bearing retainer plate mounting bolts to a torque of 28 N m 250 in Ibs PL DISASSEMBLY AND ASSEMBLY Continued j 80ae8462 Fig 40 Wheel Bearing
34. OTE If the coil spring has been removed from the spring compressor proceed with the next step oth erwise proceed with step 3 1 Place the coil spring in the compressor follow ing the manufacturers instructions Before compress ing the spring rotate the spring so the end of the top coil is directly in the back as shown Fig 28 2 Slowly compress the coil spring until enough room is available for strut assembly reassembly 3 Install the lower spring isolator on the lower spring seat of the strut 4 Install the strut through the bottom of the coil spring until the lower spring seat contacts the lower end of the coil spring Rotate the strut as necessary until the clevis bracket is positioned straight outward away from the compressor Fig 24 Install the clamp on the lower end of the coil spring and strut so the strut is held in place 5 Install the jounce bumper on the strut shaft The jounce bumper is to be installed with the smaller end pointing downward toward the lower seat Fig 27 6 Install the dust shield on the strut shaft Fig 27 The bottom of the dust shield will snap past the retainer on top of the strut housing 7 If disassembled reinstall the upper spring iso lator on the upper spring seat and bearing 8 Install the upper spring seat and bearing on top of the coil spring Position the notch formed into the edge of the upper seat straight out away from the compressor Fig 25 PL DISASS
35. PL SUSPENSION TABLE OF CONTENTS page WHEEL ALIGNMENT 000c cee eeeee 1 FRONT SUSPENSION 26 ccccasiccasccnswaa ne 9 WHEEL ALIGNMENT TABLE OF CONTENTS page DESCRIPTION AND OPERATION WHEEL ALIGNMENT 000004 1 DIAGNOSIS AND TESTING SUSPENSION AND STEERING DIAGNOSIS 3 SERVICE PROCEDURES CURB HEIGHT MEASUREMENT 5 DESCRIPTION AND OPERATION WHEEL ALIGNMENT Proper vehicle wheel alignment is the proper adjustment of all interrelated front and rear suspen sion angles These angles are what affects the han dling and steering of the vehicle when it is in motion The method of checking a vehicle s front and rear wheel alignment will vary depending on the type and manufacturer of the equipment being used Instruc tions furnished by the manufacturer of the equip ment being used should always be followed to ensure accuracy of the alignment except when alignment specifications recommended by this corporation differ Typical wheel alignment angles and measurements are camber caster toe and thrust angle e Camber is the number of degrees the top of the tire and wheel are tilted either inward or outward Fig 1 Camber is a tire wearing angle Excessive negative camber will cause tread wear at the inside of the tire while excessive positive camber will cause outside tire wear SUSPENSION 2 1 page REAR SUSPENSION 00ceeeeaeaes 35 page WHEEL ALIGNMENT
36. RNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section REMOVAL 1 Raise the vehicle Refer to HOISTING in the LUBRICATION AND MAINTENANCE group for the proper lifting procedure 2 Remove the rear wheel and tire assembly from the vehicle 3 If the vehicle is equipped with rear drum brakes remove the screw securing the brake hose bracket to the rear of the strut assembly Fig 5 4 If the vehicle is equipped with the antilock brake system ABS remove the screw securing the ABS wheel speed sensor bracket to the rear of the strut assembly Fig 6 5 Remove the nut from the end of the rear stabi lizer bar link bolt Fig 5 Pull the bolt out through the top of the link and remove the link 6 If the vehicle is equipped with rear disc brakes Fig 7 perform the following e Remove the two guide pin bolts securing the front disc brake caliper to the steering knuckle e Remove the disc brake caliper from the knuckle and brake rotor PL OD NI B ith gt DA o Fig 5 Rear of Strut Assembly 1 BRAKE HOSE BRACKET SCREW 2 STABILIZER BAR LINK 3 NUT 4 STRUT ASSEMBLY Fig 6 Rear of Strut Assembly with ABS 1 ABS WHEEL SPEED SENSOR BRACKET SCREW 2 STABILIZER BAR LINK 3 NUT 4 STRUT ASSEMBLY e Hang the caliper out of the way using a wire hanger or cord Do not support the caliper by letting it hang by the hydraulic hose PL REMOVAL AND INSTA
37. SPECIAL TOOLS Continued 1136 80109803 Splitter Bearing 1130 Remover MB 990799 Remover installer 6644 2 PL Installer Bearing 5052 Installer Adapter C 4698 2 Remover C 4150A PL REAR SUSPENSION TABLE OF CONTENTS page DESCRIPTION AND OPERATION REAR SUSPENSION SYSTEM 35 STRUT ASSEMBLY REAR 37 KNUCKLE REAR onanan aaan 37 HUB AND BEARING REAR 37 LATERAL ARMS oonan 37 TENSION STRUT ooann 38 STABILIZER BAR REAR 38 DIAGNOSIS AND TESTING STRUT ASSEMBLY REAR 38 KNUCKLE REAR 00 e00ee 39 HUB AND BEARING REAR 39 LATERAL ARMS 00 0 0000 39 TENSION STRUT 000000 eee 39 STABILIZER BAR REAR 39 DESCRIPTION AND OPERATION REAR SUSPENSION SYSTEM The rear suspension system used on this vehicle is a fully independent type rear suspension system Fig 1 This means that each side of the rear suspension acts independently from the other The rear suspension is supported by a strut assem bly The strut assembly also controls ride quality SUSPENSION 2 35 page REMOVAL AND INSTALLATION SERVICE WARNINGS AND CAUTIONS 40 STRUT ASSEMBLY REAR 40 KNUCKLE REAR gt acia sa iasi ddiad e aiaia 42 HUB AND BEARING REAR 44 LATERAL ARMS 000000 00 45 TENSION STRUT aoaeaaiaee nai ea at ale
38. V Joint Reposition Engine As Required Replace C V Joint Front End Whine When Accelerating Or Decelerating 1 Worn Or Defective Transaxle Gears Or Bearings Replace Transaxle Gears Or Bearings Front End Clunk When Accelerating Or Decelerating 1 Worn Or Broken Engine Mount 2 Worn Or Defective Transaxle Gears Or Bearings Replace Engine Mount Replace Transaxle Gears Or Bearings 2 4 SUSPENSION DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES PL POTENTIAL CORRECTIONS Loose Wheel Lug Nuts Worn Or Broken C V Joint Worn Or Loose Ball Joint Worn Or Loose Control Arm Bushing Loose Crossmember Bolts 3 Verify Wheel Lug Nut Torque 4 Replace C V Joint 5 Tighten Or Replace Ball Joint 6 Tighten To Specified Torque Or Replace Control Arm Bushing 7 Tighten Crossmember Bolts To Specified Torque Road Wander Incorrect Tire Pressure Incorrect Front Or Rear Wheel Toe Worn Wheel Bearings Worn Control Arm Bushings Excessive Friction In Steering Gear 6 Excessive Friction In Steering Shaft Coupling 7 Excessive Friction In Strut Upper Bearing Inflate Tires To Rcommended Pressure Check And Reset Front Wheel Toe Replace Wheel Bearing Replace Control Arm Bushing Replace Steering Gear Replace Steering Coupler Replace Strut Bearing Lateral Pull 1 Unequal Tire Pressure Radial Tire Lead Incorrect Front
39. WHEEL BEARING AND HUB 13 LOWER CONTROL ARM 0005 13 BALL JOINT ka ci did eet beta dha bak wg 13 STABILIZER BAR FRONT 14 SERVICE PROCEDURES LUBRICATION siiscnc care eee he hee eens 14 REMOVAL AND INSTALLATION SERVICE WARNINGS AND CAUTIONS 14 DESCRIPTION AND OPERATION FRONT SUSPENSION SYSTEM The front suspension allows each front wheel on a vehicle to adapt to different road surfaces and condi tions without greatly affecting the opposite wheel and the ability to control the vehicle Each side of the front suspension is allowed to pivot so the vehicle can be steered in the direction preferred This vehicle has a gas pressurized MacPherson strut type front suspension design Fig 1 SUSPENSION 2 9 page STRUT ASSEMBLY FRONT 14 STEERING KNUCKLE 00 15 LOWER CONTROL APM 005 18 STABILIZER BAR FRONT 20 WHEEL MOUNTING STUD FRONT 21 DISASSEMBLY AND ASSEMBLY STRUT ASSEMBLY FRONT ao ao anaana 22 STEERING KNUCKLE WHEEL BEARING AND HUB naana aaraa 25 LOWER CONTROL ARM BALL JOINT 29 LOWER CONTROL ARM REAR ISOLATOR BUSHING onana aana ce cece eee seen 31 SPECIFICATIONS FRONT SUSPENSION FASTENER TORQUE SPECIFICATIONS 000200 eee 33 SPECIAL TOOLS FRONT SUSPENSION 00000 33 A strut assembly is used in place of the front sus pension upper control arm an
40. Wheel Camber Power Steering Gear Imbalance Wheel Braking 1 Inflate All Tires To Recommended Pressure 2 Perform Lead Correction Procedure 3 Check And Reset Front Wheel Camber 4 Replace Power Steering Gear 5 Correct Braking Condition Causing Lateral Pull Excessive Steering Free Play Incorrect Steering Gear Adjustment Worn Or Loose Tie Rod Ends Loose Steering Gear Mounting Bolts Loose Or Worn Steering Shaft Coupler 1 Adjust Or Replace Steering Gear 2 Replace Or Tighten Tie Rod Ends 3 Tighten Steering Gear Bolts To The Specified Torque 5 Replace Steering Shaft Coupler Excessive Steering Effort Low Tire Pressure Lack Of Lubricant In Steering Gear Low Power Steering Fluid Level Loose Power Steering Pump Belt Lack Of Lubricant In Steering Ball Joints Steering Gear Malfunction Lack Of Lubricant In Steering Coupler 1 Inflate All Tires To Recommended Pressure 2 Replace Steering Gear 3 Fill Power Steering Fluid Reservoir To Correct Level 4 Check and replace automatic belt tensioner as necessary If drive belt is worn or glazed replace belt 5 Lubricate Or Replace Steering Ball Joints 6 Replace Steering Gear 7 Replace Steering Coupler PL SERVICE PROCEDURES CURB HEIGHT MEASUREMENT The wheel alignment is to be checked and all align ment adjustments made with the vehicle at its required curb height specification Vehicle height is to be checke
41. alignment equipment 6 Road test the vehicle to verify the steering wheel is straight and the vehicle does not pull or wander SPECIFICATIONS WHEEL ALIGNMENT SPECIFICATIONS NOTE All specifications are given in degrees NOTE All wheel alignments are to be set with the vehicle at curb height Refer to CURB HEIGHT MEA SUREMENT in SERVICE PROCEDURES FRONT WHEEL ALIGNMENT PREFERRED SETTING ACCEPTABLE RANGE CAMBER Cross Camber Maximum Side To Side Difference CASTER Cross Caster Maximum Side To Side Difference TOTAL TOE 0 00 0 00 0 50 2 60 0 00 0 10 0 40 to 0 40 1 60 to 3 60 1 00 0 10 to 0 30 REAR WHEEL ALIGNMENT PREFERRED SETTING ACCEPTABLE RANGE CAMBER D650 0 15 TOTAL TOE THRUST ANGLE 10 0 0 10 Note TOTAL TOE is the sum of both the left and right wheel toe settings TOTAL TOE must be equally split between each front wheel to ensure the steering wheel is centered after setting toe Positive toe is toe in and negative toe is Toe out PL FRONT SUSPENSION TABLE OF CONTENTS page DESCRIPTION AND OPERATION FRONT SUSPENSION SYSTEM 9 STRUT ASSEMBLY FRONT 11 STEERING KNUCKLE 00 11 LOWER CONTROLARM 11 STABILIZER BAR FRONT 12 DIAGNOSIS AND TESTING STRUT ASSEMBLY FRONT 12 STEERING KNUCKLE 04 13
42. arkings 1 SIDE INDICATING LETTER 2 DIRECTIONAL INDICATOR 3 UPPER MOUNT 8 Install the upper mount over the strut shaft and onto the top of the upper spring Near the center on the top of the mount is the word OUT and an arrow Fig 20 Point the arrow on the mount in the same direction that the clevis bracket on the lower end of the strut is pointed in This direction should be straight toward the compressor 9 Loosely install the retaining nut on the strut shaft Install Strut Nut Socket on the end of a torque wrench Special Tool 6864 on the strut shaft retaining nut Fig 18 Next install a socket on the 2 50 SUSPENSION DISASSEMBLY AND ASSEMBLY Continued hex on the end of the strut shaft While holding the strut shaft from turning tighten the strut shaft retaining nut to a torque of 75 N m 55 ft Ibs 10 Slowly release the tension from the coil spring by backing off the compressor drive completely As the tension is relieved make sure the upper mount s seat aligns properly with the coil spring 11 Verify the arrow on the upper mount is point ing in the same direction as the strut devis bracket as mentioned in step 9 12 Remove the clamp from the lower end of the coil spring and strut Push back the spring compres sor upper and lower hooks then remove the strut assembly from the spring compressor 13 Install the strut assembly on the vehicle Refer to REMOVAL AND INSTALLATION in th
43. blies at this time 8 Lower the vehicle to ground level NOTE It may be necessary to put the vehicle on a platform hoist or alignment rack to gain access to the stabilizer bar mounting bolts with the vehicle at curb height 9 Tighten each stabilizer bar link by holding the upper retainer nut with a wrench and turning the link bolt Tighten each link bolt to a torque of 23 N m 200 in Ibs 10 If previously loosened tighten the stabilizer bar cushion retainer bolts to a torque of 28 N m 250 in Ibs STABILIZER BAR FRONT NOTE Before proceeding with this procedure review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section REMOVAL 1 Raise the vehicle Refer to HOISTING in the LUBRICATION AND MAINTENANCE group for the proper lifting procedure 2 Remove both stabilizer bar links from the vehi cle Fig 18 Remove each link by holding the upper retainer nut with a wrench and turning the link bolt 3 Remove the stabilizer bar cushion retainer bolts and retainers Fig 18 and remove the stabi lizer bar with cushions attached from the vehicle 4 To remove the cushions from the stabilizer bar peel back each cushion at the slit and roll it off the bar PL 80bce903 Fig 18 Stabilizer Bar 1 STABLILIZER BAR CUSION RETAINERS 2 CUSHIONS 3 FRONT STABLIZER BAR 4 STABILIZER BAR LINKS INSTALLATION NOTE Before stab
44. cated on the strut NOTE If the coil spring needs to be serviced pro ceed with the next step otherwise proceed with step 10 NOTE Before removing the coil spring from the compressor make not of its position in the com pressor for easy reassembly 9 Release the tension from the coil spring by backing off the compressor drive completely Push back the compressor hooks and remove the coil spring 10 Inspect the strut assembly components for the following and replace as necessary e Inspect the strut for any condition of shaft bind ing over the full stroke of the shaft e Inspect the jounce bumper for cracks and signs of deterioration PL DISASSEMBLY AND ASSEMBLY Continued 80bce978 Fig 19 Strut Assembly Components 1 STRUT ASSEMBLY 2 STRUT 3 LOWER SPRING ISOLATOR 4 COIL SPRING 5 JOUNCE BUMPER 6 DUST SHIELD 7 UPPER MOUNT e Check the upper mount for cracks and distortion and its retaining studs for any sign of damage e Inspect the dust shield for rips and deteriora tion e Inspect the upper and lower spring isolators for material deterioration and distortion e Inspect the coil spring for any sign of damage to the coating ASSEMBLY NOTE If the coil spring has been removed from the spring compressor proceed with the next step oth erwise proceed with step 3 1 Place the coil spring in the compressor follow ing the manufacturers instructions Before compress
45. ce manual group INSTALLATION 1 Install the strut assembly into the strut tower aligning the three studs on the strut upper mount with the holes in strut tower Install the three mounting nuts on the studs Fig 6 Tighten the three nuts to a torque of 34 N m 300 in Ibs 2 Close the hood of the vehicle CAUTION The strut assembly to steering knuckle attaching bolts are serrated and must not be turned during installation Install the nuts while holding the bolts stationary in the steering knuckle 3 Position the lower end of the strut assembly in line with the upper end of the steering knuckle and align the mounting holes Fig 1 Install the two attaching bolts The bolts should be installed with so that the nuts face towards the front of the vehicle once installed Install the nuts Holding the bolts in place tighten the nuts to a torque of 53 N m 40 ft Ibs plus an additional 90 turn after the specified torque is met SUSPENSION 2 15 4 If the vehicle is equipped with Antilock brakes ABS attach the ABS wheel speed sensor to the rear of the strut rearward ear using its mounting screw Fig 5 Tighten the mounting screw to a torque of 13 N m 120 in Ibs 5 Attach the ground strap to the rear of the strut forward ear using its mounting screw Fig 5 Tighten the mounting screw to a torque of 13 N m 120 in Ibs 6 Install the tire and wheel assembly Install and tighten the wheel mounting nuts
46. d upper ball joint When a vehicle strikes a bump the force is trans ferred through the hub bearing and knuckle into the strut assembly to absorb the force and dampen it The top of the strut is mounted directly to the strut tower of the vehicle During steering maneuvers the strut assembly through a pivot bearing in the upper strut mount and steering knuckle through the lower ball joint mounted on the lower control arm turn as an assembly 2 10 SUSPENSION DESCRIPTION AND OPERATION Continued Fig 1 Front Suspension System 80b46c26 PL PL DESCRIPTION AND OPERATION Continued 1 VEHICLE STRUT TOWER 2 OUTER TIE ROD 3 STEERING GEAR 4 STRUT ASSEMBLY 5 JAM NUT 6 LOWER CONTROL ARM 7 CROSSMEMBER 8 BALL JOINT 9 STABILIZER BAR 10 STABILIZER BAR CUSHION AND RETAINER SUSPENSION 2 11 11 STABILIZER BAR LINK 12 HUB 13 KNUCKLE 14 STRUT 15 LOWER SPRING ISOLATOR 16 COIL SPRING 17 JOUNCE BUMPER 18 DUST SHIELD 19 SPRING SEAT AND BEARING 20 UPPER MOUNT For more information on the description and oper ation of an individual component refer to the appli cable component heading in this section STRUT ASSEMBLY FRONT A Macpherson type design strut assembly is used in place of the front suspension upper control arm and upper ball joint Fig 1 The bottom of the strut mounts directly to the steering knuckle using 2 a
47. d with the vehicle on a flat level surface preferably a vehicle alignment rack The tires are to be inflated to the recommended pressure All tires are to be the same size as stan dard equipment Vehicle height is checked with the fuel tank full of fuel and no passenger or luggage compartment load Vehicle height is not adjustable If the measure ment is not within specifications inspect the vehicle for bent or weak suspension components Compare the parts tag on the suspect coil spring s to the parts book and the vehicle sales code checking for a match Once removed from the vehicle compare the SUSPENSION 2 5 coil spring height to a correct new or known good coil spring The heights should vary if the suspect spring is weak NOTE Prior to reading the curb height measure ment the front an rear of the vehicle should be jounced Induce jounce by grasping the center of the rear then front bumper or fascia and jouncing the vehicle an equal number of times Release the bumper at the bottom of the jounce cycle 1 Measure from the inboard edge of the wheel opening fender lip directly above the wheel center spindle to the floor or alignment rack surface 2 When measuring maximum left to right differ ential is not to exceed 10 mm 0 39 in 3 Compare the measurements to specifications listed in the following CURB HEIGHT SPECIFICA TIONS chart CURB HEIGHT SPECIFICATIONS VEHICLE FRONT REAR 672 mm 8mm 67
48. diagnosing the condition of the wheel bearing and hub With the wheel disc brake caliper and brake rotor removed rotate the wheel hub Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing If the bearing exhibits any of these conditions during diagnosis the hub bearing will require replacement The bearing is not service able SUSPENSION 2 13 Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement Moderate grease weapage from the bearing is consid ered normal and should not require replacement of the wheel bearing To diagnose a bent hub refer to BRAKE ROTOR in the DIAGNOSIS AND TESTING section in the BRAKES service manual group for the procedure on measuring hub runout LOWER CONTROL ARM Inspect the lower control arm for signs of damage from contact with the ground or road debris If the lower control arm shows any sign of damage look for distortion Do not attempt to repair or straighten a broken or bent lower control arm If damaged the lower control arm stamping is serviced only as a complete component The serviceable components of the lower control arm are the ball joint the ball joint grease seal and the lower control arm rear isolator bushing Inspect both lower control arm isolator bushings for severe deterioration and replace as required Inspect the ball joint per the inspection procedure in this section of the service manual and
49. e toe adjustment cams are not to be facing down The notches in the adjustment cams are only to be facing up or toward one side 2 Rotate each toe adjustment cam until the pre ferred rear toe specification is obtained Fig 4 Refer to WHEEL ALIGNMENT SPECIFICATIONS in this section of this service manual group 3 While holding the toe adjustment cams from turning tighten the attaching bolt nuts This will securely hold the adjustment cams in position Tighten the attaching bolt nuts to a torque of 88 N m 65 ft Ibs 4 Proceed to FRONT TOE to set the front toe FRONT TOE CAUTION Do not twist the inner tie rod to steering gear rubber boots while turning the inner tie rod during the front toe adjustment 1 Loosen the tie rod adjusting jam nuts Fig 5 Grasp each inner tie rod at its hex and rotate it one way or the other until the front wheel toe is set to the preferred specification Refer to WHEEL ALIGN MENT SPECIFICATIONS in this section of this ser vice manual group 2 8 SUSPENSION SERVICE PROCEDURES Continued FWD 80bc4ef4 Fig 5 Jam Nuts 1 OUTER TIE ROD 2 INNER TIE ROD HEX 3 JAM NUT PL 2 Tighten tie rod adjusting jam nuts to a torque of 75 N m 55 ft Ibs 3 Make sure the inner tie rod to steering gear rubber boots are not twisted If twisted loosen the boot clamp at the inner tie rod and move the boot as necessary 4 Remove steering wheel clamp 5 Remove the
50. ed prior to aligning the vehicle WHEEL ALIGNMENT SETUP 1 Position the vehicle on an alignment rack 2 Install all required alignment equipment on the vehicle per the alignment equipment manufac turer s instructions On this vehicle a four wheel alignment is recommended NOTE Prior to reading the vehicle s alignment readouts the front and rear of vehicle should be jounced Induce jounce rear first then front by grasping the center of the bumper and jouncing each end of vehicle an equal number of times The bumper should always be released when vehicle is at the bottom of the jounce cycle 3 Read the vehicle s current front and rear align ment settings Compare the vehicle s current align ment settings to the vehicle specifications for camber caster and toein Refer to WHEEL ALIGNMENT 2 6 SUSPENSION SERVICE PROCEDURES Continued SPECIFICATIONS in this section of this service manual group 4 If the rear alignment is out of specification adjust it first before proceeding to the front CAMBER AND CASTER Front and rear camber and caster settings on this vehicle are determined at the time the vehicle is designed by the location of the vehicle s suspension components This is referred to as Net Build The result is no required adjustment of camber and caster after the vehicle is built or when servicing the suspension components Thus when performing a wheel alignment caster and camber are not normally
51. edure Do not reuse the old wheel bearing 2 Slide the hub of the steering knuckle onto the splines on the driveshaft C V joint 3 Install the steering knuckle onto the ball joint stud aligning the bolt hole in the knuckle boss with the notch formed in the side of the ball joint stud 4 Install a new ball joint stud pinch bolt and nut Fig 11 Tighten the nut to a torque of 95 N m 70 ft Ibs CAUTION The strut assembly to steering knuckle attaching bolts are serrated and must not be turned during installation Install the nuts while holding the bolts stationary in the steering knuckle 5 Position the lower end of the strut assembly in line with the upper end of the steering knuckle and align the mounting holes Fig 1 Install the two attaching bolts The bolts should be installed with so that the nuts face towards the front of the vehicle 2 18 SUSPENSION REMOVAL AND INSTALLATION Continued once installed Install the nuts Holding the bolts in place tighten the nuts to a torque of 53 N m 40 ft Ibs plus an additional 90 turn after the specified torque is met 6 Place the tie rod heat shield on the steering knuckle arm so that the shield is positioned straight away from the steering gear and tie rod end once installed Algn the hole in the shield with the hole in the steering knucle arm 7 Install the outer tie rod ball stud into the hole in the steering knuckle arm Start the tie rod attach ing nut onto
52. g 1 Look for signs of contact with an object that has caused damage to the lateral arm If the lateral arm is bent or damaged the lateral arm will require replacement Do not attempt to repair or straighten a lateral arm Inspect the lateral arm isolator bushings and their sleeves for signs of damage or deterioration If dam age or deterioration is present replacement of the entire lateral arm will be required The isolator bushings cannot be serviced separately from the lat eral arms TENSION STRUT Inspect the tension strut Fig 1 Look for signs of contact with any object that has bent or caused other damage to the tension strut If the tension strut is bent or damaged the tension strut will require replacement Do not attempt to repair or straighten a tension strut Inspect the tension strut front spool type bushing and rear bayonet type bushings and retainers for signs of deterioration or damage If the front bushing is damaged or shows signs of deteriation the tension strut must be replaced The front bushing cannot be replaced separately If the rear bushings are deterio rated or damaged or the retainers are damaged replacement is necessary The bushings and retainers can be replaced separately from the tension strut STABILIZER BAR REAR Inspect the stabilizer bar Fig 1 Look for damage or bending If damage is evident the bar must be replaced Inspect for broken cracked or distorted stabilizer bar cushi
53. g coating and lead to a corrosion failure of the spring CAUTION At no time when servicing a vehicle can a sheet metal screw bolt or other metal fastener be installed into the shock tower to take the place of an original plastic clip Also do not drill holes into the front shock tower for the installation of any metal fasteners into the shock tower area indicated Fig 2 S Time 9402 56 Al e AD Fig 2 Shock Tower Area Typical 1 SHOCK TOWER 2 COIL SPRING 3 NO SHEET METAL SCREWS BOLTS OR ANY OTHER METAL FASTENERS ARE TO BE INSTALLED INTO SHOCK TOWER IN THIS AREA ALSO NO HOLES ARE TO BE DRILLED INTO SHOCK TOWER IN THIS SAME AREA PL DIAGNOSIS AND TESTING Continued 80bce910 Fig 3 Strut Assembly 1 NUT 2 STRUT ASSEMBLY 3 STRUT 4 LOWER SPRING ISOLATOR 5 COIL SPRING 6 JOUNCE BUMPER 7 DUST SHIELD 8 SPRING SEAT AND BEARING WITH SPRING ISOLATOR 9 UPPER MOUNT STEERING KNUCKLE The front suspension steering knuckle is not a repairable component of the front suspension It must be replaced if found to be damaged in any way If it is determined that the steering knuckle is bent when servicing the vehicle no attempt is to be made to straighten the steering knuckle WHEEL BEARING AND HUB The wheel bearing is designed for the life of the vehicle and requires no type of periodic maintenance The following procedure may be used for
54. he frame rail of the vehicle using a thru bolt The thru bolt goes through both the crossmember and rear lower control arm bushing threading directly into the frame rail of the vehicle The left and right lower control arms are intercon nected through a linked rubber isolated stabilizer bar The outboard end of each lower control arm con nects to the steering knuckle using a ball joint 2 12 SUSPENSION DESCRIPTION AND OPERATION Continued BALL JOINT The lower control arm connects to the steering knuckle through a ball joint mounted at the outboard end of the arm Fig 1 The ball joint is pressed into the lower control arm and has a non tapered stud with a notch for steering knuckle pinch bolt clear ance The ball joint stud is clamped and locked to the steering knuckle lower leg using a pinch bolt The ball joint is lubricated for life during the man ufacturing process Once lubricated for life the grease fitting head is snapped off by the manufac turer This is done to eliminate the possibility of lubrication later in the ball joints life thus damaging the non vented ball joint seal boot The ball joint used on this vehicle is replaceable and if found defective can be serviced as a separate component of the lower control arm STABILIZER BAR FRONT The stabilizer bar helps control vehicle body roll J ounce and rebound movements affecting one wheel are partially transmitted to the opposite wheel of the vehicle to stab
55. hen filling the ball joint with grease Damage to the grease seal can result REMOVAL AND INSTALLATION SERVICE WARNINGS AND CAUTIONS WARNING DO NOT REMOVE THE STRUT SHAFT NUT WHILE STRUT ASSEMBLY IS INSTALLED IN VEHICLE OR BEFORE THE COIL SPRING IS COM PRESSED WITH A COMPRESSION TOOL THE SPRING IS HELD UNDER HIGH PRESSURE CAUTION Only frame contact hoisting equipment can be used on this vehicle All vehicles have a fully independent rear suspension The vehicles cannot be hoisted using equipment designed to lift a vehicle by the rear axle If this type of hoisting equipment is used damage to rear suspension components will occur CAUTION At no time when servicing a vehicle can a sheet metal screw bolt or other metal fastener be installed in the shock tower to take the place of an original plastic clip It may come into contact with the strut or coil spring PL CAUTION Wheel bearing damage will result if after loosening the hub nut the vehicle is rolled on the ground or the weight of the vehicle is allowed to be supported by the tires for a length of time STRUT ASSEMBLY FRONT NOTE Before proceeding with this procedure review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section REMOVAL 1 Raise the vehicle Refer to HOISTING in the LUBRICATION AND MAINTENANCE group for the proper lifting procedure 2 Remove tire and wheel assembly from location on front of vehicle
56. hicle Be sure to use the correct package 1 Raise the vehicle until its tires are not support ing the weight of the vehicle PL CAUTION The knuckle to strut assembly attaching bolt shanks are serrated and must not be turned during removal Remove the nuts while holding the bolts stationary 2 Remove the original upper bolt attaching the strut clevis bracket to the knuckle Fig 2 Fig 3 Fig 2 Front Strut Clevis Bracket Attaching Bolts 1 STRUT CLEVIS BRACKET 2 STRUT CLEVIS BRACKET TO STEERING KNUCKLE ATTACHING BOLTS 3 STEERING KNUCKLE 4 LOOSEN THIS BOLT 5 REMOVE AND REPLACE THIS BOLT 9402 48 Fig 3 Rear Strut Clevis Bracket Attaching Bolts 1 KNUCKLE 2 STRUT ASSEMBLY CLEVIS BRACKET 3 CLEVIS BRACKET TO KNUCKLE ATTACHING BOLTS 3 Install a bolt from the adjustment package into the hole where the original bolt was removed Install the bolt from the rear PL SERVICE PROCEDURES Continued 4 Install a nut provided in adjustment package on the replacement bolt Tighten the nut until it s snug but still allowing the knuckle to slide in the devis bracket 5 Remove the original lower bolt 6 Install a bolt from the adjustment package into the bottom hole of the strut clevis bracket Install the bolt from the rear 7 Install a nut provided in adjustment package on the replacement bolt Tighten the nut until it s snug 8 Reinstall the tire and wheel
57. hing the rear knuckle to the strut Fig 11 80bce972 Fig 11 Rear Knuckle Mounting 1 STRUT ASSEMBLY 2 KNUCKLE 3 LATERAL ARMS 4 NUT 5 NUTS 12 Remove the nuts and bolt attaching the rear knuckle to the lateral arms Fig 11 SUSPENSION 2 43 13 Disconnect the tension strut from the knuckle To do this first hold the tension strut from turning by using a wrench on the flat on the tension strut and then remove the nut from the rear of the tension strut Fig 12 Next remove the tension strut retainer then the rear tension strut bayonet bushing from the tension strut ACH we ve AO Er 80bce973 Fig 12 Tension Strut Nut Removal installation 1 KNUCKLE 2 TENSION STRUT 3 FLAT 14 Remove the two nuts and bolts attaching the rear knuckle to the strut Fig 11 Tap the bolts from the knuckle using a pin punch 15 Remove the knuckle INSTALLATION 1 To install the knuckle on the vehicle first align the hole in the lower end of the rear knuckle with the forward bayonet bushing on the tension strut Be sure the stepped area of the bushing is squarely seated into the hole in the knuckle Next Rotate the knuckle until the upper mounting holes in the knuckle is aligned with the holes in the strut s clevis bracket CAUTION The strut to knuckle attaching bolts are serrated and must not be turned during installation Once installed hold the bolts stationary in
58. his service manual group PL HUB AND BEARING REAR NOTE Before proceeding with this procedure review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section REMOVAL 1 Raise the vehicle Refer to HOISTING in the LUBRICATION AND MAINTENANCE group for the proper lifting procedure 2 Remove the rear wheel and tire assembly from the vehicle 3 If the vehicle is equipped with rear drum brakes remove any retainer clips from the wheel mounting studs then pull the brake drum off the hub and bearing 4 If the vehicle is equipped with rear disc brakes Fig 7 perform the following e Remove the two guide pin bolts securing the front disc brake caliper to the steering knuckle e Remove the disc brake caliper from the knuckle and brake rotor e Hang the caliper out of the way using a wire hanger or cord Do not support the caliper by letting it hang by the hydraulic hose e Remove any retainer clips from the wheel mounting studs then pull the brake rotor off the hub and bearing 5 Remove the dust cap from the hub and bearing assembly Fig 7 6 Remove the retaining nut then the hub and bearing from the knuckle s spindle Fig 7 INSTALLATION 1 Install the hub and bearing on the knuckle s spindle then install a new retaining nut Fig 7 Do not reuse the original nut Tighten the nut to a torque of 217 N m 160 ft Ibs 2 Install the dust cap on the end of the
59. hub and bearing Fig 7 3 If the vehicle is equipped with rear disc brakes Fig 7 install the brake rotor and disc brake caliper on the knuckle Install the two guide pin bolts secur ing the front disc brake caliper to the steering knuckle Tighten the guide pin bolts to a torque of 22 N m 192 in Ibs 4 Install the tire and wheel assembly Tighten the wheel mounting nuts in proper sequence until all nuts are torqued to half specification Repeat the tightening sequence this time to full specified torque of 135 N m 100 ft Ibs 5 Lower the vehicle to ground level PL REMOVAL AND INSTALLATION Continued LATERAL ARMS NOTE Before proceeding with this procedure review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section Use the following procedure for removal and instal lation of one or both lateral arms on one side of the vehicle s rear suspension REMOVAL 1 Raise the vehicle Refer to HOISTING in the LUBRICATION AND MAINTENANCE group for the proper lifting procedure 2 Remove the rear tire and wheel assembly 3 Remove the nut bolt and washers attaching both lateral arms to the knuckle Fig 1 4 Remove nut washer bolt and wheel alignment cam attaching the lateral arms to the rear crossmem ber Fig 1 5 Remove the lateral arms from vehicle INSTALLATION NOTE Both lateral arms when being installed must be specifically positioned and orien
60. ies on the vehicle Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification Repeat the tightening sequence this time to full specified torque of 135 N m 100 ft Ibs 7 Lower the vehicle to ground level or curb height 8 Tighten the rear stabilizer bar cushion retainer bolts to a torque of 34 N m 300 in Ibs 9 Tighten the stabilizer bar link nuts to a torque of 23 N m 200 in Ibs 10 Set the rear toe on the vehicle to the required specification if necessary Refer to WHEEL ALIGN MENT in this service manual group DISASSEMBLY AND ASSEMBLY STRUT ASSEMBLY REAR The strut assembly must be removed from the vehicle for it to be disassembled and assembled Refer to REMOVAL AND INSTALLATION in this section for the required procedure For the disassembly and assembly of the strut assembly use strut spring compressor Pentastar Ser vice Equipment PSE tool W 7200 or the equivalent to compress the coil spring Follow the manufactur er s instructions closely 2 48 SUSPENSION DISASSEMBLY AND ASSEMBLY Continued DISASSEMBLY 1 If both struts are being serviced at the same time mark the coil spring and strut assembly accord ing to which side of the vehicle the strut was removed from and which strut the coil spring was removed from 2 Position the strut assembly in the strut coil spring compressor following the manufacturers instructions Set the lower then
61. ilize body roll The stabilizer bar interconnects both front lower control arms of the vehicle and is attached to the front suspension crossmember Fig 1 Attachment of the stabilizer bar to the front sus pension crossmember is through 2 rubber isolator cushion and retainers Fig 1 The stabilizer bar attachment to the lower control arm is done by uti lizing an isolated stabilizer bar link at each arm All components of the stabilizer bar are serviceable DIAGNOSIS AND TESTING STRUT ASSEMBLY FRONT Inspect the strut assembly for the following condi tions Fig 3 e Inspect for a damaged or broken coil spring e Inspect for a torn or damaged strut assembly dust shield PL e Lift the dust shield and inspect the strut assem bly for evidence of fluid running from the upper end of the strut fluid reservoir Actual leakage will be a stream of fluid running down the side and dripping off lower end of unit A slight amount of seepage between the strut shaft and strut shaft seal is not unusual and does not affect performance of the strut assembly e Lift the dust shield and inspect the jounce bumper for signs of damage or deterioration e Inspect the clearance between the shock tower and the coil spring Make sure no fasteners are pro truding through the shock tower possibly contacting the coil spring and strut Because of the minimum clearance in this area Fig 2 installation of metal fasteners could damage the coil sprin
62. ilizer bar installation inspect the cushions and links for excessive wear cracks dam age and distortion Replace any pieces failing inspection 1 If removed install the stabilizer bar cushions on the stabilizer bar utilizing the slit in each cush ion Position the cushions at each end of the bar s straight beam just before it begins to curve NOTE Before installing the stabilizer bar make sure the bar is not upside down The stabilizer bar must be installed with the curve on the outboard ends of the bar facing downward to clear the con trol arms once fully installed Fig 19 2 First place the stabilizer bar in position on the front suspension crossmember The slits in each cushion must point toward the front of the vehicle and sit directly on top of the raised beads formed into the stamping on the crossmember Next install the cushion retainers matching the raised beads formed into the cushion retainers to the grooves formed into the cushions Install the cushion retainer bolts but do not completely tighten them at this time 3 Install both stabilizer bar links back on vehicle Fig 18 Start each stabilizer bar link bolt with bushing from the bottom through the stabilizer bar inner link bushings lower control arm and into the upper retainer nut and bushing Fig 1 Do not fully tighten the link assemblies at this time PL REMOVAL AND INSTALLATION Continued 80bce906 Fig 19 Downward Curve 1 STAB
63. in proper sequence until all nuts are torqued to half specification Next repeat the tightening sequence to the full specified torque of 135 N m 100 ft Ibs 7 Lower the vehicle STEERING KNUCKLE NOTE Before proceeding with this procedure review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section REMOVAL 1 Apply the brakes and hold in place 2 Raise the vehicle Refer to HOISTING in the LUBRICATION AND MAINTENANCE group for the proper lifting procedure 3 Remove the front tire and wheel assembly 4 While the brakes are applied loosen and remove the hub nut on the end of the driveshaft Fig 7 GB 80bc4ef8 Fig 7 Hub Nut 1 DRIVESHAFT 2 HUB 3 HUB NUT 5 Release the brakes 2 16 SUSPENSION REMOVAL AND INSTALLATION Continued 6 Remove the two guide pin bolts securing the front disc brake caliper to the steering knuckle Fig 8 80bce90a Fig 8 Brake Caliper And Rotor 1 RETAINER CLIP 2 BRAKE ROTOR 3 HUB 4 GUIDE PIN BOLTS 5 DISC BRAKE CALIPER 7 Remove the disc brake caliper from the steer ing knuckle The caliper is removed by first tipping either the top right side or bottom left side of the caliper away from the brake rotor then pulling the caliper off the opposite end s caliper slide on the knuckle and rotor 8 Hang the caliper out of the way using a wire hanger or cord Do not suppor
64. ions STEERING KNUCKLE The steering knuckle is a single casting with legs machined for attachment to the front strut assembly on the top and the lower control arm ball joint on the bottom Fig 1 The steering knuckle also has machined abutments on the casting to support and align the front brake caliper assembly WHEEL BEARING AND HUB The knuckle also supports the wheel bearing and hub Fig 1 The wheel hub is pressed into a sealed for life wheel bearing that is pressed into the steer ing knuckle A retainer plate also holds it in place The hub supports the driveshaft outer constant veloc ity CM joint Each is splined and meshes in the center of the hub The outer C V joint is retained to the hub using a nut The nut is held on the outer C V stub shaft using a nut retainer and cotter pin The wheel bearing is a Unit 1 type cartridge bear ing that requires no maintenance The wheel bearing is serviced separately from the hub LOWER CONTROL ARM There is one lower control arm on each side of the vehicle Each lower control arm is a stamped steel unit using rubber isolated pivot bushings to isolate it from the front suspension crossmember and frame of the vehicle Fig 1 The rear bushing can be serviced separately The front of the lower control arm is bolted to the front crossmember using a bolt through the center of the rubber pivot bushing The rear of the lower con trol arm is mounted to both the front crossmember and t
65. iper off the opposite end s caliper slide on the knuckle and rotor 5 Hang the caliper out of the way using a wire hanger or cord Do not support the caliper by letting it hang by the hydraulic hose 6 Remove any retainer clips from the wheel mounting studs Remove the brake rotor from the front hub Fig 20 CAUTION Do not hammer wheel mounting studs out of the hub Damage to the wheel bearing will occur leading to premature bearing failure 7 Install a wheel mounting nut on the wheel mounting stud being removed from the hub far enough so the threads on the stud are even with end of lug nut Rotate the hub so the stud requiring removal is aligned with notch cast into front of the steering knuckle Install Remover Special Tool C 4150 on hub flange and wheel stud Fig 21 8 Tighten the remover pushing the whee mount ing stud out the rear of the hub flange When the shoulder of the stud is past the flange remove the remover from the hub Remove the nut from the stud then remove the stud from the flange INSTALLATION 1 Install the wheel mounting stud in the flange of hub from the rear side Install several washers and a wheel mounting nut on the stud Fig 22 The wheel mounting nut must be installed with the flat side of the wheel mounting nut against the washers to eliminate binding 2 22 SUSPENSION REMOVAL AND INSTALLATION Continued 80aa4bea Fig 21 Wheel Stud Removal 1 SPECIAL TOOL C 415
66. is section for the required procedure SPECIFICATIONS REAR SUSPENSION FASTENER TORQUE SPECIFICATIONS DESCRIPTION TORQUE STRUT ASSEMBLY Tower Attaching Nuts 34 N m 300 in Ibs Knuckle Attaching Bolts 88 N m 65 ft Ibs Strut Assembly Shaft Nut 75 N m 55 ft Ibs Brake Hose Bracket Mounting Bolt 31N m 275 in Ibs KNUCKLE Brake Support Plate Mounting Bolts 75N m 55 ft Ibs Disc Brake Adapter Mounting Bolts 75 Nem 55 ft Ibs HUB AND BEARING To Knuckle Retaining Nut 217 Nem 160 ft Ibs Wheel Mounting Nuts 109 150 N m 80 110 ft Ibs LATERAL ARM Nut At Crossmember 88 N m 65 ft Ibs Nut At Knuckle 95 N m 70 ft Ibs TENSION STRUT Rear Nut 00008 95 N m 70 ft Ibs Frame Rail Bolts 95 N m 70 ft Ibs Parking Brake Cable Nut STABILIZER BAR Cushion Retainer Bolts 34 N m 300 in Ibs Link Bolt Nut 23 N m 200 in Ibs 28 N m 250 in Ibs PL SPECIAL TOOLS REAR SUSPENSION S Q 6864 Socket Wrench Strut Rod Nut 6864
67. knuckle Fig 15 80bb0 24 Fig 15 Ball Joint Bolt And Nut 1 NUT 2 BOLT 3 BALL JOINT CAUTION After removing the steering knuckle from the ball joint stud do not pull outward on the knuckle Pulling the steering knuckle outward at this point can separate the inner C V joint on the driveshaft Refer to FRONT DRIVESHAFTS in the DIFFERENTIAL AND DRIVELINE group for further information NOTE Use caution when separating the ball joint stud from the steering knuckle so the ball joint seal does not get cut 6 Separate the ball joint stud from the steering knuckle by prying down on lower control arm and up against the ball joint boss on the steering knuckle Fig 12 7 If the right lower control arm is being serviced remove the bolts mounting the engine torque strut in place Fig 16 then remove the engine torque strut from the vehicle 8 Remove the front pivot bolt attaching the lower control arm to the front suspension crossmember Fig 17 Remove the rear pivot bolt attaching the lower control arm to the front suspension crossmem ber and frame rail Remove the lower control arm from the crossmember SUSPENSION 2 19 NEE Fig 16 Engine Torque Strut 1 MOUNTING BOLTS 2 ENGINE TORQUE ISOLATOR STRUT 3 FRONT SUSPENSION CROSSMEMBER 80bce904 80bce905 Fig 17 Lower Control Arm Attaching Bolts 1 LOWER CONTROL ARM 2 FRONT BOLT 3 CROSSMEMBER 4
68. le PL Fig 15 Tension Strut Mounting At Frame 1 TENSION STRUT MOUNTING BOLTS 2 TENSION STRUT 3 SPOOL BUSHING 4 NUT 5 PARKING BRAKE CABLE 6 Remove the forward bayonet bushing and retainer from the tension strut INSTALLATION 1 Install the forward retainer and a bayonet bushing on the tension strut trailing end Be sure the stepped area of the bushing is installed to face the knuckle 2 To install the knuckle on the tension first stick the trailing end through the hole in the lower end of the knuckle seating the bayonet bushing squarely against the hole Next raise the end of the tension strut with the spool bushing into its mounting posi tion on the frame Fig 15 Install the mounting bolts securing the tension strut to the frame Remember the mounting bolt with the stud on the head is installed on the inboard side 3 Tighten the two mounting bolts at the frame to a torque of 95 N m 70 ft Ibs 4 Place the parking brake cable routing bracket on the stud of the inboard mounting bolt and install the nut securing it in place Fig 15 Tighten the nut to a torque of 28 N m 250 in Ibs 5 Install the rear bayonet bushing on the tension strut Be sure the stepped area of the bushing is squarely seated into the hole in the knuckle 6 Install the rear tension strut retainer then the nut To completely install the nut place a wrench on the flat formed into the tension strut and tigh
69. moved from the vehi cle Refer to LOWER CONTROL ARM in the REMOVAL AND INSTALLATION section DISASSEMBLY 1 Using a screwdriver or other suitable tool pry the seal boot off of the ball joint Fig 43 2 Position the Receiver Special Tool 6908 2 on a hydraulic press to support the lower control arm Fig 44 Place the control arm on top of Tool 6908 2 so that the bottom of the ball joint sets into the Receiver cup 3 Place the larger end of the Adapter Special Tool 6804 on top of the ball joint as shown Fig 44 2 30 SUSPENSION DISASSEMBLY AND ASSEMBLY Continued 80bdbc91 Fig 43 Seal Boot Removal 1 TOOL 2 SEAL BOOT 3 LOWER CONTROL ARM an Fig 44 Ball Joint Removal 1 PRESS 2 BALL JOINT 4 Using the hydraulic press press the ball joint completely out of the lower control arm into the receiver 5 Remove the tools ball joint and arm from the hydraulic press ASSEMBLY CAUTION When installing a ball joint in its mount ing hole in the lower control arm position the ball joint so the notch in the ball joint stud is facing the lower control arm front isolator bushing Fig 45 This will ease assembly of the ball joint to the steering knuckle when the installation of the pinch bolt is attempted PL D 80bdbc93 Fig 45 Ball Joint Alignment BALL JOINT STUD NOTCH LOWER CONTROL ARM FRONT ISOLATOR BUSHING AUN 1 By ha
70. nd position ball joint into it s bore on the lower control arm Fig 45 To avoid binding upon installation be sure the ball joint is not cocked in the bore 2 Position the Installer Special Tool 6758 on a hydraulic press to support the lower control arm Fig 46 Place the control arm on top of Tool 6758 in the upside down position aligning the ball joint stud squarely with the Installer s cup Fig 46 Ball Joint Installation 1 PRESS 2 BALL JOINT 3 Place the larger end of the Adapter Special Tool 6804 on top of the ball joint as shown Fig 46 4 Using the hydraulic press press the ball joint into the lower control arm until the shoulder on the PL DISASSEMBLY AND ASSEMBLY Continued ball joint bottoms against the lower control arm ball joint bore Do not apply excessive pressure against ball joint and lower control arm once the ball joint bottoms 5 Remove the tools and arm from the hydraulic press CAUTION When installing the sealing boot on the ball joint position the upward lip on the outside perimeter of the seal boot outward away from the control arm once installed Fig 47 It is there to help shield heat from the sealing boot 6758 80bdbc95 Fig 47 Seal Boot Installation 1 SEAL BOOT UPWARD LIP 2 BALL JOINT 6 Place a new ball joint seal boot over the ball joint stud The upward lip located on the outside perimeter of the seal boot must point outward
71. ons and cushion retainers The horizontal slit at the front of each cushion is supposed to be there If damage is evident the cushions can be replaced separately from the stabilizer bar utilizing the horizontal slit Inspect the stabilizer bar links that attach the sta bilizer bar to each rear strut Look for damage or deterioration of the bushings on the ends of each link Inspect the stabilizer bar link to ensure it is not bent or broken If any of these conditions are present the stabilizer bar link must be replaced The links can be replaced separately from the stabilizer bar 2 40 SUSPENSION REMOVAL AND INSTALLATION SERVICE WARNINGS AND CAUTIONS WARNING DO NOT REMOVE THE STRUT SHAFT NUT WHILE STRUT ASSEMBLY IS INSTALLED IN VEHICLE OR BEFORE THE COIL SPRING IS COM PRESSED WITH A COMPRESSION TOOL THE SPRING IS HELD UNDER HIGH PRESSURE CAUTION Only frame contact or wheel lift hoisting equipment can be used on vehicles having a fully independent rear suspension Vehicles with inde pendent rear suspension can not be hoisted using equipment designed to lift a vehicle by the rear axle If this type of hoisting equipment is used dam age to rear suspension components will occur NOTE If a rear suspension component becomes bent damaged or fails no attempt should be made to straighten or repair it Always replace it with a new component STRUT ASSEMBLY REAR NOTE Before proceeding with this procedure review SERVICE WA
72. replace as required Refer to BALL J OINT in this section of this service manual group BALL JOINT With the weight of the vehicle resting on the road wheels grasp the headless grease fitting as shown Fig 4 With no mechanical assistance or added force attempt to move the grease fitting If the ball joint is worn the grease fitting will move If move ment is noted replace the ball joint K HOLE x AT A 80b 4efi Fig 4 Checking Ball Joint Wear 1 BALL JOINT 2 HEADLESS GREASE FITTING 2 14 SUSPENSION DIAGNOSIS AND TESTING Continued CAUTION No attempt should be made to service the headless grease fitting on the ball joint It has been purposely snapped off by the manufacturer to avoid over greasing STABILIZER BAR FRONT Inspect for broken cracked or distorted stabilizer bar cushions and retainers Inspect for worn or dam aged stabilizer bar links Fig 1 SERVICE PROCEDURES LUBRICATION There are no serviceable lubrication points on the front suspension The front lower ball joints have grease fittings which have had the head snapped off by the manufacturer after they have been filled This has been done to eliminate the possibility of damag ing the non vented seals Grease will not leak from the broken grease fittings The ball joints are sealed for life and require no maintenance CAUTION No attempt should be made to replace the ball joint grease fitting with a new fitting t
73. rt the weight of the vehicle using coil springs positioned around struts The coil springs are contained between the upper mount of the strut assembly and a lower spring seat on the body of the strut The top of each strut assembly is bolted to the top of the inner fender through a rubber isolated mount The bottom of the strut assembly attaches to the rear knuckle using 2 thru bolts with prevailing torque nuts The rear strut assembly includes the following components Fig 1 A rubber isolated upper mount a dust shield a jounce bumper a coil spring a lower spring isolator and a strut Any component in need of service requires removal of the strut assembly from the vehicle and disassembly of it COIL SPRING Rear coil springs are rated separately for each cor ner or side of the vehicle depending on optional equipment and type of vehicle service If a coil spring requires replacement be sure the spring needing replacement is replaced with a spring meeting the correct load rating for the vehicle with its specific options KNUCKLE REAR A forged rear knuckle bolts to each rear strut assembly Fig 1 The rear knuckle s spindle sup ports the rear hub and bearing Together they sup port the rear tire and wheel The movement of the rear knuckle is controlled laterally using two lateral arms attached to the knuckle Fore and aft move ment of the knuckle is controlled by using a tension strut HUB AND BEARING REAR The hub
74. shion retainers off the cushions 6 The cushions can be removed from the bar by utilizing the pre formed slit in each cushion and peel ing it off the bar SUSPENSION 2 47 INSTALLATION 1 Install the cushions on the stabilizer bar by opening the slit in the cushion and wrapping the cushion around the bar When installed properly the slit in the cushion should face in the same direction as the ends of the stabilizer bar or toward the front of the car once the bar is installed The flat side of each cushion should face upward 2 Install the retainers on the cushions matching the contour of each retainer with its cushion 3 Install the stabilizer bar cushions and retain ers on the car as an assembly The dipped area in the center of the bar must face down to clear the well in the luggage compartment 4 Install two bolts in each cushion retainer and secure the stabilizer bar to the frame of the vehicle Fig 1 Do not completely install the bolts at this time 5 Reinstall each stabilizer bar link Fig 1 e Place the link center sleeve and_ bushings between the eye in the end of the stabilizer bar and the link mounting bracket on the strut e Start the stabilizer bar link bolt with bushing from the top down through the stabilizer bar inner link bushings and sleeve and strut link mounting bracket e Install a lower bushing then the nut Do not tighten the nut at this time 6 Install both tire and wheel assembl
75. t 4 Hold the rear lateral arm up against the cross member and install the long mounting bolt with the adjustment cam through the lateral arm bushing and rear crossmember Fig 1 The bolt must be installed with the notch in the adjustment cam pointing straight up 5 Position the forward lateral arm against the rear crossmember hole Pass the long mounting bolt through the lateral arm bushing sleeve 6 Install a washer and nut onto the end of lateral arm mounting bolt at the rear crossmember but do not completely tighten the bolt at this time NOTE Once installed each lateral arm should have the bow in its length facing downward Both right side arms should have the trimmed outer edge fac ing toward the rear of the car Left side arms should have the trimmed outer edge facing each other The mounting bolt at the knuckle should have the nut at the rear and the mounting bolt at the crossmember should have the nut at the front Fig 13 Fig 13 Lateral Arms 1 REAR STABILIZER BAR 2 REAR LATERAL ARMS 3 RIGHT FRONT LATERAL ARM 4 LEFT FRONT LATERAL ARM 7 Install tire and wheel assembly on the vehicle Tighten the wheel mounting nuts in proper sequence until all nuts are torqued to half specification Repeat the tightening sequence to the full specified torque of 135 N m 100 ft Ibs 8 Lower the vehicle to the ground 9 With suspension at curb height tighten the lat eral arm mounting bolt nut
76. t Strut Tower 1 UPPER MOUNT 2 MOUNTING NUTS 3 STRUT TOWER INSTALLATION 1 To place the strut assembly into mounting posi tion start the lower end of the strut over the top of the knuckle and down the back between the two lat eral arms Next lift the top of the strut assembly up into the strut tower aligning the studs on top of the upper mount with the three mounting holes in the strut tower While holding the strut assembly in place install the three mounting nuts on the upper mount studs inside the luggage compartment Fig 8 Tighten the 3 mounting nuts to a torque of 34 N m 300 in Ibs 2 Install the carpeting back on top of the rear strut tower 3 Close the deck lid 4 Raise the vehicle CAUTION The strut to knuckle attaching bolts are serrated and must not be turned during installation Once installed hold the bolts stationary in the steering knuckle while installing and tightening the nuts 5 Align the holes in the strut clevis bracket on the lower end of the strut with the mounting holes in the knuckle Install the two bolts attaching the strut to the rear knuckle Fig 1 Install the nuts Tighten the two nuts to 88 N m 65 ft Ibs 6 If the vehicle is equipped with disc brakes Fig 7 install the brake rotor and disc brake caliper on the knuckle Install the two guide pin bolts securing the front disc brake caliper to the steering knuckle Tighten the guide pin bolts to a
77. t the caliper by letting it hang by the hydraulic hose 9 Remove any retainer dips from the wheel mounting studs Remove the brake rotor from the front hub Fig 8 10 Remove the nut attaching the outer tie rod to the steering knuckle To do this hold the tie rod end stud with a wrench while loosening and removing the nut with a standard wrench or crowfoot wrench Fig 9 11 Remove the tie rod end from the steering knuckle using Remover Special Tool MB991113 Fig 10 Gee EY e ISTAS M D S CCC PL Ts BAEN 80bhc4ef9 Fig 9 Tie Rod Nut Removal installation 1 OUTER TIE ROD 2 STUD 3 NUT a GAY MB991113 80bce901 Fig 10 Tie Rod Removal 1 OUTER TIE ROD 2 STEERING KNUCKLE PL REMOVAL AND INSTALLATION Continued 12 Remove the tie rod heat shield 13 Remove the nut and pinch bolt clamping the ball joint stud to the steering knuckle Fig 11 80bb0 24 Fig 11 Ball Joint Bolt And Nut 1 NUT 2 BOLT 3 BALL JOINT CAUTION The strut assembly to steering knuckle attaching bolts are serrated and must not be turned during removal Hold the bolts stationary in the steering knuckles while removing the nuts then tap the bolts out using a pin punch 14 Remove the two bolts attaching the strut to the steering knuckle Fig 1 NOTE Use caution when separating the ball joint stud from the steering knuckle so the ball joint
78. tated on the vehicle The lateral arm that has the same size bushing sleeves on both ends must be mounted on the forward side of the crossmember and knuckle with the trimmed outer edge facing rearward This front arm is also marked with the word FOR WARD The side of the arm displaying this must face forward The lateral arm with two different size bushing sleeves must be mounted on the rearward side of the crossmember and knuckle Position the smaller bushing sleeve end at the knuckle and the larger bushing sleeve end at the rear crossmember the larger bushing sleeve is necessary to accommodate the rear wheel alignment adjustment cam If the rear arm is to be mounted on the right side the trimmed outer edge must face rearward If the rear arm is to be mounted on the left side the trimmed outer edge must face forward 1 Following the note above place the forward lat eral arm against the leading end of the knuckle and then install the short lateral arm mounting bolt with a washer through the lateral arm and knuckle and out the trailing end of the knuckle Fig 1 2 Following the note above install the small bushing sleeved end of the rear lateral arm onto the end of the bolt just installed through the knuckle Fig 1 Install a washer and nut onto the end of the mounting bolt but do not completely tighten the bolt at this time SUSPENSION 2 45 3 Install a wheel alignment adjustment cam on the long arm mounting bol
79. ten the nut Fig 14 Tighten the nut to a torque of 95 N m 70 ft Ibs 7 Install the tire and wheel assembly Tighten the wheel mounting nuts in proper sequence until all PL REMOVAL AND INSTALLATION Continued nuts are torqued to half specification Repeat the tightening sequence this time to full specified torque of 135 N m 100 ft Ibs 8 Lower the vehicle to ground level 9 Set the rear toe on the vehicle to the required specification if necessary Refer to WHEEL ALIGN MENT in this service manual group STABILIZER BAR REAR NOTE Before proceeding with this procedure review SERVICE WARNINGS AND CAUTIONS at the beginning of REMOVAL AND INSTALLATION in this section REMOVAL 1 Raise the vehicle Refer to HOISTING in the LUBRICATION AND MAINTENANCE group for the proper lifting procedure 2 Remove both rear wheel and tire assemblies from the vehicle 3 Remove the nut from the end of each rear sta bilizer bar link bolt Fig 16 Pull the bolt out through the top of the link and remove the link from each end of the stabilizer bar o D p lo a NI B AN 3 DA _ Fig 16 Stabilizer Bar Link 1 BRAKE HOSE BRACKET SCREW 2 STABILIZER BAR LINK 3 NUT 4 STRUT ASSEMBLY 4 Remove the two bolts securing each of the two cushion retainers to the frame rails Fig 1 then remove the cushion retainers cushions and stabilizer bar from the vehicle as an assembly 5 Pull the cu
80. the steering knuckle while installing and tightening the nuts 2 Install the two bolts attaching the strut to the rear knuckle from the front side Install the nuts on the bolts Fig 11 Tighten the two nuts to a torque of 88 N m 65 ft Ibs 3 Align the lateral arms with the hole in the cen ter of the knuckle Install the bolt attaching the arms to the knuckle When installing the bolt start it from 2 44 SUSPENSION REMOVAL AND INSTALLATION Continued the front side Install the nut but do not completely tighten it at this time The nut will need to be tight ened when the vehicle is at curb height 4 Install the rear bayonet bushing on the tension strut Be sure the stepped area of the bushing is squarely seated into the hole in the knuckle 5 Install the rear tension strut retainer then the nut To completely install the nut place a wrench on the flat formed into the tension strut and tighten the nut Fig 12 Tighten the nut to a torque of 95 N m 70 ft Ibs 6 If vehicle is equipped with rear drum brakes install the brake support plate on the knuckle and attach it using it s four mounting bolts Fig 9 Tighten the mounting bolts to a torque of 75 N m 55 ft Ibs 7 If the vehicle is equipped with rear disc brakes install the disc brake adapter on the knuckle and attach it using it s four mounting bolts Fig 10 Tighten the mounting bolts to a torque of 75 N m 55 ft Ibs 8 Install the
81. the hub and bearing from the knuckle s spindle Fig 7 9 If vehicle is equipped with rear drum brakes remove the four bolts attaching the rear brake sup port plate to the knuckle Fig 9 Next remove the brake support plate brake shoes and wheel cylinder as an assembly from the rear knuckle then hang it out of the way using a wire hanger or cord Do not overextend the brake hose when being hung It is not necessary to remove the brake hose from the wheel cylinder when removing the support plate 9502 22 Fig 9 Support Plate Mounting 1 BRAKE SHOES 2 WHEEL CYLINDER 3 KNUCKLE 4 BRAKE SUPPORT PLATE MOUNTING BOLTS 5 BRAKE SUPPORT PLATE 10 If the vehicle is equipped with rear disc brakes remove the four bolts mounting the disc brake adapter to the rear knuckle Fig 10 Next remove the adapter rotor shield parking brake shoes and parking brake cable as an assembly from the knuckle then hang it out of the way using a wire hanger or cord PL REMOVAL AND INSTALLATION Continued t J DN 80bce971 Fig 10 Disc Brake Adapter Mounting 1 DISC BRAKE ADAPTER 2 KNUCKLE 3 MOUNTING BOLTS CAUTION The strut to knuckle attaching bolts are serrated and must not be turned during removal Hold the bolts stationary in the steering knuckle while removing the nuts then tap the bolts out using a pin punch 11 Loosen but do not completely remove the two nuts and bolts attac
82. the stud Hold the tie rod end stud with a wrench while tightening the nut with a standard wrench or crowfoot wrench Fig 9 To fully tighten the nut to specifications use a crowfoot wrench on a torque wrench to turn the nut and a wrench on the stud Tighten the nut to a torque of 55 N m 40 ft Ibs 8 Install the brake rotor on the hub Fig 8 9 Install the disc brake caliper with pads on the brake rotor and steering knuckle The left side cali per is installed by first sliding the top of the caliper past the top abutment on the steering knuckle to hook the top edge of the caliper then pushing the lower end of the caliper into place against the knuckle Fig 13 The right side caliper is installed by first sliding the bottom edge of the caliper past the lower abutment on the steering knuckle to hook the lower edge of the caliper then pushing the top of the caliper into place against the steering knuckle 80aa4b6d Fig 13 Brake Caliper Installation 1 SLIDE TOP OF BRAKE CALIPER UNDER TOP ABUTMENT OF STEERING KNUCKLE AS SHOWN 2 BRAKING DISC 3 DISC BRAKE CALIPER 4 STEERING KNUCKLE BRAKE ABUTMENT 10 Install the two guide pin bolts securing the front disc brake caliper to the steering knuckle Fig 8 Tighten the guide pin bolts to a torque of 22 N m 192 in Ibs PL 11 Clean all foreign matter from the threads of the driveshaft outer C V joint Fig 7 12 Install the hub nut in the
83. tinue to tighten the screw drive until the bushing is pressed completely out of the lower control arm 8373 1 C 4212F 80bbc3b7 Fig 48 Removing Bushing 1 CONTROL ARM ISOLATOR BUSHING 2 FLANGE 3 Back off the screw drive and remove the lower control arm and isolator bushing from the Receiver 4 Remove the driver 8373 2 and receiver 8373 1 from the ball joint press C 4212F 2 32 SUSPENSION DISASSEMBLY AND ASSEMBLY Continued ASSEMBLY 1 Back the ball joint press C 4212F set screw outward so it does not extend out into the cup area Fig 49 C 4212F 80bbc3b Fig 49 Set Screw Backed Outward 1 SET SCREW 2 CUP AREA 2 Start the bushing in the lower control arm bushing bore by hand Position the bushing so the voids in the rubber are aligned in relationship to the ball joint as shown Fig 50 80bceadd Fig 50 Aligning Bushing With Ball Joint 1 BALL JOINT 2 VOIDS 3 REAR ISOLATOR BUSHING 3 Install the Receiver Special Tool 6760 on the tip of the Ball J oint Press screw drive 4 Place the lower control arm flange against the cup area of the ball joint press and tighten the screw PL drive until the Receiver contacts the outer circumfer ence of the bushing Fig 51 Slowly tighten the screw drive until the bushing bottoms in the lower control arm bushing bore C 4212F 80bbc3b9 Fig 51 Installing Bushing 1 LOWER CONTROL ARM FLA
84. torque of 22 N m 192 in Ibs 7 Reinstall the stabilizer bar link Fig 1 2 42 SUSPENSION REMOVAL AND INSTALLATION Continued e Place the link center sleeve and bushings between the eye in the end of the stabilizer bar and the link mounting bracket on the strut e Start the stabilizer bar link bolt with bushing from the top down through the stabilizer bar inner link bushings and sleeve and strut link mounting bracket e Install a lower bushing then the nut Do not tighten the nut at this time 8 If the vehicle is equipped with the antilock brake system ABS install the screw securing the ABS wheel speed sensor bracket to the rear of the strut assembly Fig 6 Tighten the mounting screw to a torque of 13 N m 120 in Ibs 9 If the vehicle is equipped with rear drum brakes install the screw securing the brake hose bracket to the rear of the strut assembly Fig 5 Tighten the screw to a torque of 31 N m 275 in Ibs 10 Install the tire and wheel assembly on vehicle Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specifica tion Repeat the tightening sequence this time to full specified torque of 135 N m 100 ft Ibs 11 Lower the vehicle to ground level 12 Tighten the stabilizer bar link nut to a torque of 23 N m 200 in Ibs 13 Set the rear toe on the vehicle to the required specification if necessary Refer to WHEEL ALIGN MENT in this service
85. ttaching bolts and nuts going through the strut de vis bracket and steering knuckle The top of the strut mounts directly to the strut tower of the vehicle using the three threaded studs on the strut assem blies upper mount During steering maneuvers the strut assembly through a pivot bearing in the upper strut mount and steering knuckle through the lower ball joint turn as an assembly The strut assembly is used to dampen the front suspension and smooth the ride of the vehicle The strut assembly includes the following compo nents A rubber isolated upper mount an upper spring seat and bearing a dust shield a jounce bumper a coil spring a lower spring isolator and a strut Fig 1 Each component is serviced by remov ing the strut assembly from the vehicle and disas sembling it COIL SPRING The strut and front suspension of the vehicle is supported by coil springs positioned around the upper half of each strut The springs are contained between the upper and the lower seats of the strut assembl y Coil springs are rated separately for each corner or side of the vehicle depending on optional equipment and type of vehicle service During service procedures of the strut assembly if both springs are removed mark the springs to ensure installation in its original position NOTE If a coil spring requires replacement be sure that it is replaced with a spring meeting the correct load rating for the vehicle and its specific opt

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