being used. The instructions furnished by the manu-facturer of the equipment should always be followed.With the exception that the wheel alignment specifi-cations recommended by Chrysleralways be used. The Chrysler Cmended alignment specifications, afications at the end of this gro

this vehicle (Fig. 1).Camber adjustment is allowed in the event that a

vehicle is involved in an accident and after repairsare made meeting manufacturerstions, the camber setting will noers specifications. If camber adjurefer to the following ServiceProcedure for the required steps

sion or steering components to meet vehicle align-

from a true vertical line. Inboard tilt is negative cam-ber. Outboard tilt is positive camber (Fig. 1).

Excessive camber is a tire wear factor: negativer on the inside of the tires treaditive camber causes wear to thes tread surface. See Front Wheel

Drive Specifications for Camber. settings.Toe is measured in degrees or inches and is the

SUSPENSION 2 - 1tolerance specifica-t meet manufactur-stment is required,

Camber Adjustmentmanual section.There are six basic factors which are the founda-

tion to front wheel alignment. These are vehicleheight, caster, camber, toe-in, steering axis inclina-tion and toe-out on turns. Of the six basic factorsonly toe-in is normally mechanically adjustable onto be followed.distance the front edges of the tires are closer (or far-ther apart) than the rear edges. See Front WheelDrive Specifications for Toe. settings.Corporation shouldorporation recom-re listed in Speci-

up in the service

camber causes weasurface, while posoutside of the tireGENERAL INFORMATIONWheel alignment is the proper adjustment of all

the interrelated suspension angles affecting the run-ning and steering of the front and rear wheels of thevehicle.

The method of checking front and rear wheel align-ment will vary depending on the type of equipmentment specifications, by heating and or bending.

Alignment checks and adjustments should be madein the following sequence.

(1) Camber(2) ToeCamber is the number of degrees the top of the

wheel and tire assembly is tilted inboard or outboardSUSPE

CONT

page

FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . 10REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . 39

WHEEL AL

IND

page

DESCRIPTION AND OPERATIONGENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1

DIAGNOSIS AND TESTINGPRE-WHEEL ALIGNMENT INSPECTION . . . . . . . 4SUSPENSION AND STEERING DIAGNOSIS . . . . 3

DESCRIPTION AND OPERATION

NS/GSNSION

ENTS

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WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . 1

IGNMENT

EX

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SERVICE PROCEDURESWHEEL ALIGNMENT CHECK AND

ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . 5SPECIFICATIONS

ALIGNMENT SPECIFICATIONS . . . . . . . . . . . . . . 8

CAUTION: Do not attempt to modify any suspen-

ADJUST TOERE-ADJUST BOOTS 0NEGATIVE POSITIVECAMBERTOETOE OUTTOE INFRONT

2 - 2 SUSPENSION NS/GS

DESCRIPTION AND OPERATION (Continued)Fig. 1 Front Suspension Alignment Angles

DIAGNOSIS AND TESTING

SUSPENSION AND STEERING DIAGNOSIS

CONDITION POSSIBLE CAUSES CORRECTIONFront End Whine On Turns 1. Defective wheel bearing 1. Replace wheel bearing

2. Incorrect wheel alignment 2. Check and reset wheel alignment3. Worn tires 3. Replace tires

Front End Growl Or Grinding OnTurns

1. Defective wheel bearing 1. Replace wheel bearing

2. Engine mount grounding 2. Check for motor mount hittingframe rail and reposition engine asrequired

3. Worn or broken C/V joint 3. Replace C/V joint4. Loose wheel lug nuts 4. Verify wheel lug nut torque5. Incorrect wheel alignment 5. Check and reset wheel alignment6. Worn tires 6. Replace tires7. Front strut pin in upper strutmount

7. Replace the front strut uppermount and bearing

Front End Clunk Or Snap OnTurns

1. Loose lug nuts 1. Verify wheel lug nut torque

2. Worn or broken C/V joint 2. Replace C/V joint3. Worn or loose tie rod 3. Tighten or replace tie rod end4. Worn or loose ball joint 4. Tighten or replace ball joint5. Worn/loose control arm bushing 5. Replace control arm bushing6. Loose stabilizer bar. 6. Tighten stabilizer bar to specified

torque7. Loose strut mount to bodyattachment

7. Tighten strut attachment tospecified torque

8. Loose crossmember bolts 8. Tighten crossmember bolts tospecified torque

Front End Whine With VehicleGoing Straight At A ConstantSpeed

1. Defective wheel bearing 1. Replace wheel bearing

2. Incorrect wheel alignment 2. Check and reset wheel alignment3. Worn tires 3. Replace tires4. Worn or defective transaxle gearsor bearings

4. Replace transaxle gears orbearings

Front End Growl Or Grinding WithVehicle Going Straight At AConstant Speed

1. Engine mount grounding 1. Reposition engine as required

2. Worn or broken C/V joint 2. Replace C/V jointFront End Whine WhenAccelerating Or Decelerating

1. Worn or defective transaxle gearsor bearings

1. Replace transaxle gears orbearings

Front End Clunk WhenAccelerating Or Decelerating

1. Worn or broken engine mount 1. Replace engine mount

2. Worn or defective transaxle gearsor bearings

2. Replace transaxle gears orbearings

3. Loose lug nuts 3. Verify wheel lug nut torque4. Worn or broken C/V joint 4. Replace C/V joint

NS/GS SUSPENSION 2 - 35. Worn or loose ball joint 5. Tighten or replace ball joint

Cn

bRoad Wander 1. Incorrect tire pressure 1. Inflate tires to recommendedpressure

2. Incorrect front or rear wheel toe 2. Check and reset wheel toe3. Worn wheel bearings 3. Replace wheel bearing4. Worn control arm bushings 4. Replace control arm bushing5. Excessive friction in steering gear 5. Replace steering gear6. Excessive friction in steering shaftcoupling

6. Replace steering coupler

7. Excessive friction in strut upperbearing

7. Replace strut bearing

Lateral Pull 1. Unequal tire pressure 1. Inflate all tires to recommendedpressure

2. Radial tire lead 2. Perform lead correction procedure3. Incorrect front wheel camber 3. Check and reset front wheel

camber4. Power steering gear imbalance 4. Replace power steering gear5. Wheel braking 5. Correct braking condition causing

lateral pullExcessive Steering Free Play 1. Incorrect Steering Gear

Adjustment1. Adjust Or Replace Steering Gear

2. Worn or loose tie rod ends 2. Replace or tighten tie rod ends3. Loose steering gear mountingbolts

3. Tighten steering gear bolts tospecified torque

4. Loose or worn steering shaftcoupler

4. Replace steering shaft coupler

Excessive Steering Effort 1. Low tire pressure 1. Inflate all tires to recommendedpressure

2. Lack of lubricant in steering gear 2. Replace steering gear3. Low power steering fluid level 3. Fill power steering fluid reservoir

to correct level4. Loose power steering pump drivebelt

4. Correctly adjust power steeringpump drive belt

5. Lack of lubricant in ball joints 5. Lubricate or replace ball joints6. Steering gear malfunction 6. Replace steering gear7. Lack of lubricant in steeringcoupler

7. Replace steering coupler

PRE-WHEEL ALIGNMENT INSPECTIONBefore any attempt is made to change or correct

the wheel alignment factors. The following partinspection and the necessary corrections should bemade to those parts which influence the steering ofthe vehicle.

(1) Check and inflate all tires to recommended

wear. Note the type of tread wear which will aid indiagnosing, see Wheels and Tires, Group 22.

(2) Check front wheel and tire assembly for radialrunout.

(3) Inspect lower ball joints and all steering link-age for looseness.

(4) Check for broken or sagged front and rearCONDITION POSSIBLE6. Worn or loose cobushing7. Loose crossmem

8. Worn tie rod end

2 - 4 SUSPENSION

DIAGNOSIS AND TESTING (Continued)pressure. All tires should be the same size and ingood condition and have approximately the sameAUSES CORRECTIONtrol arm 6. Replace control arm bushing

er bolts 7. Tighten crossmember bolts tospecified torque8. Replace tie rod end

NS/GSsprings.

ing each end of vehicle an equal number of times.

SUSPENSION 2 - 5(5) Check vehicle ride height to verify it is withinspecifications.

(6) Alignment MUST only be checked after thevehicle has the following areas inspected and oradjusted. Recommended tire pressures, full tank offuel, no passenger or luggage compartment load andis on a level floor or a properly calibrated alignmentrack.

SERVICE PROCEDURES

WHEEL ALIGNMENT CHECK AND ADJUSTMENTPROCEDURE

CASTER AND CAMBERFront suspension Caster and Camber settings on

this vehicle are determined at the time the vehicle isdesigned. This is done by determining the precisemounting location of the vehicles suspension compo-nents throughout the design and assembly processesof the vehicle. This is called a Net Build vehicle andresults in no normal requirement to adjustment theCaster and Camber after a vehicle is built or whenservicing the suspension components. Thus Casterand Camber are not normally considered an adjust-able specification when performing an alignment onthis vehicle. Though Caster and Camber are notadjustable they should be checked during the align-ment procedure to ensure they meet the manufactur-ers specifications.

If front camber does not meet the vehicle align-ment specifications, it can be adjusted using a MoparService Kit developed to allow for camber adjust-ment. If a vehicles front camber does not meetrequired specifications, the vehicles suspension com-ponents should be inspected for any signs of damageor bending and the vehicle ride height should bechecked to verify it is within required specification.This inspection must be done before using theMopar Service Kit for setting camber to thevehicle specification.

CAUTION: Do not attempt to adjust the vehiclesCaster or Camber by heating, bending or by per-forming any other modification to the vehicles frontsuspension components.

(1) Correctly position the vehicle on the alignmentrack. Then install all required alignment equipmenton the vehicle, per the alignment equipment manu-facturers specifications.

NOTE: Prior to reading each alignment specifica-tion, front and rear of vehicle should be jounced an

NS/GS

DIAGNOSIS AND TESTING (Continued)equal number of times. Induce jounce (rear firstthen front) by grasping center of bumper and jounc-Bumper should always be released when vehicle isat the bottom of the jounce cycle.

(2) Correctly jounce vehicle and then read thevehicles current front and rear alignment settings.Compare the vehicles current alignment settings tothe vehicle specifications for camber, caster and Toe-in. See Alignment Specifications in this group of theservice manual for the required specifications. Iffront and rear camber readings are withinrequired specifications proceed to step Step 3for the Toe-in adjustment procedure ifrequired. If Camber readings are not withinspecifications refer to step Step 1 in the frontcamber adjustment cam bolt adjustment proce-dure.

CAMBER ADJUSTMENT CAM BOLT PACKAGE INSTALLATIONPROCEDURE

(1) If the front camber readings obtained are notwithin the vehicles specifications, use the followingprocedure and the Mopar Clevis Bolt Service Kit toprovide camber adjustment. The kit contains 2 flangebolts, 2 cam bolts, and 2 dog bone washers. Thesecomponents of the service kit are necessary to assem-ble the strut to the steering knuckle, after modifica-tion of the strut clevis bracket.

(2) Verify that the strut and steering knuckle arenot bent or otherwise damaged. If either componentis bent or show other signs of damage, replacerequired component(s) and check the camber settingagain. Refer to Strut Damper Assembly Service inthis group of the service manual for the requiredstrut replacement procedure.

(3) If no component is bent or damaged, use thefollowing procedure for modifying the strut clevisbracket and adjusting the camber setting.

(4) Raise front of vehicle until tires are not sup-porting the weight of the vehicle. Then remove wheeland tire assembly from the location on the vehiclerequiring the strut to be modified.

CAUTION: When removing the steering knucklefrom the strut clevis bracket, do not put a strain onthe brake flex hose. Also, do not let the weight ofthe steering knuckle assembly be supported by thebrake flex hose when removed from the strutassembly. If necessary use a wire hanger to sup-port the steering knuckle assembly or if requiredremove the brake flex hose from the caliper assem-bly.

STRUT CLEVISBRACKET ATTACHINGBOLTSTIE ROD ENDROTORSTEERING KNUCKLEUPPER STRUT TO STEER-ING KNUCKLE ATTACHINGHOLE CAMBER ADJUSTMENTSLOT INDENTATION AREAON CLEVIS BRACKETLOWER STRUT TOSTEERINGKNUCKLEATTACHING HOLESTRUT CLEVISBRACKET STEERINGKNUCKLE FLANGED BOLT IN TOP

HOLECAM BOLT IN BOTTOMHOLESTRUT CLEVISBRACKETCAUTION: The steering knuckle strut assemblyattaching bolts are serrated and must not be turnedduring removal. Remove nuts while holding boltsstationary in the steering knuckles.

(5) Remove the top and bottom, strut clevisbracket to steering knuckle attaching bolts (Fig. 2)and discard. Separate the steering knuckle from thestrut clevis bracket and position steering knuckle soit is out of the way of the strut.

CAUTION: When slotting the bottom mountinghole on the strut clevis bracket, do not enlarge thehole beyond the indentations (Fig. 3) on the sidesof the strut clevis bracket.

(6) Using an appropriate grinder and grindingwheel slot the bottom hole (Fig. 3) in both sides ofthe strut clevis bracket. When grinding slot do notgo beyond the indentation area on the sides ofthe clevis bracket (Fig. 3).

Fig. 2 Clevis Bracket To Steering Knuckle AttachingBolts

2 - 6 SUSPENSION

SERVICE PROCEDURES (Continued)Fig. 3 Strut Clevis Bracket Bolt Hole Grinding AreaCAUTION: After slotting the strut clevis brackethole, do not install the original attaching bolts whenassembling the steering knuckle to the strut assem-bly. Only the flange bolts, cam bolts, and dog bonewashers from the Mopar Clevis Bolt Service Kit, canbe used to attach the steering knuckle to the strutafter the mounting hole is slotted.

(7) Install the flanged bolt (Fig. 4) from the MoparClevis Bolt Service Kit, into the top clevis bracket tosteering knuckle mounting hole. Install the cam bolt(Fig. 4) into the bottom clevis bracket to steeringknuckle mounting hole.

(8) Install the dog bone washer (Fig. 5) on thesteering knuckle to strut clevis bracket attachingbolts. Then install the nuts from the original attach-ing bolts onto the replacement bolts from the servicekit. Tighten the bolts just enough to hold the steeringknuckle in position when adjusting camber, whilestill allowing the steering knuckle to move in clevisbracket.

(9) Lower vehicle until the full weight of the vehi-cle is supported by the vehicles suspension. Thencorrectly jounce the front and rear of vehicle an equalamount of times.

(10) Adjust the front camber to the preferred set-ting by rotating the lower eccentric cam bolt (Fig. 6)against the cam stop areas on the strut clevisbracket. When camber is correctly set, tighten theupper strut clevis bracket bolt and lower cam bolt.Again jounce front and rear of vehicle an equalamount of times and verify front camber setting. SeeAlignment Specifications in this group of the servicemanual for required specifications.

(11) When vehicle is at correct camber settingtorque both front strut to steering knuckle attachingbolts to 90 Nm (65 ft. lbs.) plus an additional 1/4

Fig. 4 Mopar Service Kit Bolts Correctly Installed

NS/GSturn after required torque is met.

FRONT TOE SETTING PROCEDURE(1) Prepare vehicle as described in the Pre-Align-

ment Vehicle Inspection procedure.(2) Center steering wheel and lock in place using a

steering wheel clamp.

CAUTION: Do not twist front inner tie rod to steer-ing gear rubber boots during front wheel Toeadjustment.

(3) Loosen front inner to outer tie rod end jamnuts (Fig. 7). Grasp inner tie rods at serrations and

STEERINGKNUCKLEDOG BONEWASHERSTRUT CLE-VISBRACKETATTACHINGNUTSSTEERINGKNUCKLE CLEVIS BRACKET CAMSTOP AREASLOWER ECCENTRIC CAM-BER ADJUSTMENT BOLT

INNER TIE ROD SER-RATION OUTER TIE ROD JAM NUT OUTER TIE RODENDINNER TIE ROD STEERINGKNUCKLE

NS/GS SUSPENSION 2 - 7

SERVICE PROCEDURES (Continued)(12) If Toe readings obtained are not within therequired specification range, adjust Toe to meet thepreferred specification setting. Toe is adjustableusing the following Toe setting procedure.

Fig. 5 Dog Bone Washer And Nuts Installed OnAttaching Bolts

Fig. 6 Camber Adjustment Cam Boltrotate inner tie rods of steering gear (Fig. 7) to setfront Toe to the preferred Toe specification. SeeAlignment Specifications in this group of the servicemanual for preferred specification.

(4) Tighten tie rod jam nuts (Fig. 7) to 75 Nm (55ft.lbs.) torque.

(5) Adjust steering gear to tie rod boots at tie rod.(6) Remove steering wheel clamp.

Fig. 7 Front Wheel Toe Adjustment

m2 - 8 SUSPENSION NS/GSANGLE................FRONT RIDE HEIGHT(MEASURED AT TOP OFFENDER WHEELOPENING)........................................

747.5 mm +or-10.0 m 753.5 mm +or-10.0mm 783.5 mm +or-10.0mmSPECIFICATIONS

ALIGNMENT SPECIFICATIONSAll alignment specifications are to be checked and

adjusted with the vehicle at its correct ride height.

Refer to the ride height specifications listed in thefollowing alignment specifications chart.

ALIGNMENT ANGLE TIRE SIZES TIRE SIZES ALTERNATIVE FUELSP205/75/R14 P205/75/R15 C.N.G.P215/65/R15 P215/65/R16 ELECTRIC

* FRONT INDIVIDUAL CAMBERINDEGREES......................................

+0.15 +or- 0.40 +0.05 +or- 0.40 +0.15 +or- 0.40

Front Side To Side CamberDifference Not ToExceed...................

0.00 - 0.50 MAX 0.00 - 0.50 MAX 0.00 - 0.50 MAX

** FRONT INDIVIDUAL CASTERINDEGREES....................................

+1.40 + or - 1.00 +1.40 + or - 1.00 +1.40 +or- 1.00

Front Side To Side CasterDifference Not ToExceed.....................................

0.00 - 1.00 MAX 0.00 - 1.00 MAX 0.00 - 1.00 MAX

*** FRONT INDIVIDUAL TOERIGHT/LEFT.........................................

+0.05+or- 0.10 +0.05 +or- 0.10 +0.05 +or- 0.10

FRONT TOTALTOE....................................................Specified In Degrees

+0.10 +or- 0.20 +0.10 +or- 0.20 +0.10 +or- 0.20

FRONT SIDE TO SIDE TOEDIFFERENTIAL...............................

0.00 - 0.06 MAX 0.00 - 0.06 MAX 0.00 - 0.06 MAX

****REAR INDIVIDUAL CAMBERINDEGREES......................................

+0.00 +or- 0.25 +0.00 +or- 0.25 -0.10 +or- 0.25

REAR INDIVIDUAL TOERIGHT/LEFT........................................

0.00 +or- 0.40 0.00 +or- 0.40 0.00 +or- 0.40

**** REAR TOTALTOE.....................Specified In DegreesTOE OUT: When Backed OnAlignment Rack Is TOE In WhenDriving

0.00 +or- 0.40 0.00 +or- 0.40 0.00 +or- 0.40

****REAR THRUSTANGLE................

0.00 +or- 0.30 0.00 +or- 0.30 0.00 +or- 0.30

STEERING WHEEL 0.00 +or- 2.50 0.00 +or- 2.50 0.00 +or- 2.50

ALIGNMENT ANGLE TIRE SIZES TIRE SIZES ALTERNATIVE FUELSFRONT RIDE HEIGHT SIDE TOSIDEDIFFERENTIAL................................

0.0 mm 12.5 mm MAX 0.0 mm 12.5 mm MAX 0.0 mm 12.5 mm MAX

*****REAR RIDE HEIGHT(MEASURED AT TOP OFFENDER WHEELOPENING)......................................

766.0 mm +or-10.0mm 772.0 mm +or-10.0mm 802.5 mm +or-10.0mm

*****REAR RIDE HEIGHT SIDETO SIDEDIFFERENTIAL.........................

0.0 mm 12.5 mm MAX 0.0 mm 12.5 mm MAX 0.0 mm 12.5 mm MAX

* Camber is adjustable using the Mopar Camber Adjustment Service Kit. Refer to the MoparParts Catalog for the required service kit part number.

** Caster is not adjustable. If found to be out of specification check for proper ride heights anddamaged/worn out suspension components and replace as necessary.

*** Toe-In is positive.**** Toe, Camber and thrust angle are not adjustable. If found to be out of specification check for

proper ride heights and damaged/worn out suspension components and replace as necessary.***** When Measuring ride heights: 1) Ensure that the tire pressures are correct. 2) Jounce the

vehicle at the bumper several times and release at the bottom of the stroke. 3) Measure from theground to the outboard, lower, center section of the fender wheel well opening. Ride heights arenot adjustable. If found to be out of specification check for damaged and/or worn out suspensioncomponents and replace as necessary.

NS/GS SUSPENSION 2 - 9

SPECIFICATIONS (Continued)

SSTABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . 13SPECIAL TOOLS

steering knuckle (through the ball joint and a pivotbearing in the struts upper retainer) turn as anassembly.

SUSPENSION CRADLE (CROSSMThis vehicle uses a one piece ca

for the front suspension. The crad

thread insert which has been specifically devel-oped for this application. Refer to the MoparParts Catalog for the specified Heli-Coil thread

or this application. The pro-ling the Heli-Coilt thread

the Service Procedures sec-of the service manual.

NS/GSEMBER)st aluminum cradlele is used as the

insert to be used fcedure for instalinsert is detailed intion in this groupSTEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . 12SERVICE PROCEDURES

SUSPENSION CRADLE THREAD REPAIR

DESCRIPTION AND OPERATION

FRONT SUSPENSION DESCRIPTIONAn independent Mc Pherson Strut type front sus-

pension is used on these vehicles. Vertical shockabsorbing Mc Pherson Struts attach to the top of thesteering knuckle and to the front strut tower. Thisinterconnection between the steering knuckle and thebody of the vehicle, provides for the correct steeringknuckle position. This steering knuckle position pro-vides for the correct front Caster and Camber set-tings for the vehicle, at the time the vehicle isdesigned.

Lower control arms are attached inboard to thecast aluminum front suspension cradle and outboardto the bottom of the steering knuckle. Attachment ofthe lower control arm to the steering knuckle is donethrough a ball joint in the lower control arm.

During steering maneuvers, the strut and theFRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . 38

attaching points for the lower control arms, stabilizerbar and steering gear. The cradle also has the powersteering hoses and the chassis brake tubes attachedto it.

The cradle is mounted to the front frame rails atfour points, two on each side of the vehicle. The cra-dle is isolated from the body of the vehicle using fourisolators, one located at each mounting bolt location.

WARNING: If a threaded hole in the suspensioncradle needs to be repaired, only use the type ofthread insert and installation procedure specifiedfor this application.

The threaded holes in the cradle that areused for attachment of the lower control armrear bushing retainer, power steering hose andchassis brake tubes can be repaired. The repairis done by the installation of a Heli-CoiltFRONT SU

IND

page

DESCRIPTION AND OPERATIONBALL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . 12COIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . 12FRONT SUSPENSION DESCRIPTION . . . . . . . . 10HUB AND BEARING ASSEMBLY . . . . . . . . . . . . 11LOWER CONTROL ARM . . . . . . . . . . . . . . . . . . 11Mc PHERSON STRUT ASSEMBLY . . . . . . . . . . 11STABILIZER BAR ATTACHING LINK . . . . . . . . . 11STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . 11STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . 11SUSPENSION CRADLE (CROSSMEMBER) . . . . 10WHEEL MOUNTING STUDS . . . . . . . . . . . . . . . 12

DIAGNOSIS AND TESTINGBALL JOINT (LOWER) . . . . . . . . . . . . . . . . . . . . 13HUB AND BEARING ASSEMBLY . . . . . . . . . . . . 13LOWER CONTROL ARM . . . . . . . . . . . . . . . . . . 12Mc PHERSON STRUT . . . . . . . . . . . . . . . . . . . . 12

2 - 10 SUSPENSIONPENSION

EX

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PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 13REMOVAL AND INSTALLATION

BALL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . 23FRONT WHEEL MOUNTING STUDS . . . . . . . . . 29HUB AND BEARING ASSEMBLY . . . . . . . . . . . . 26LOWER CONTROL ARM . . . . . . . . . . . . . . . . . . 20Mc PHERSON STRUT . . . . . . . . . . . . . . . . . . . . 14REAR WHEEL MOUNTING STUDS . . . . . . . . . . 30STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . 24STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . 15

DISASSEMBLY AND ASSEMBLYBALL JOINT SEAL BOOT . . . . . . . . . . . . . . . . . 34LOWER CONTROL ARM FRONT BUSHING . . . 35LOWER CONTROL ARM REAR BUSHING . . . . 36Mc PHERSON STRUT . . . . . . . . . . . . . . . . . . . . 31STABILIZER BAR BUSHING . . . . . . . . . . . . . . . 36

SPECIFICATIONSFRONT SUSPENSION FASTENER TORQUES . 37

FRONT STRUTASSEMBLY FRONT STEERING KNUCKLETIE ROD ENDSTUB AXLEHUB/BEARINGASSEMBLYDISC BRAKECALIPERMOUNTING

DISC BRAKECALIPER

ABUTMENTMc PHERSON STRUT ASSEMBLYThe front suspension of the vehicle is supported by

coil springs positioned around the strut assembly.The springs are contained between an upper seat,located just below the top strut mount assembly anda lower spring seat on the strut fluid reservoir.

The top of each strut assembly is bolted to theupper fender reinforcement (strut tower) through arubber isolated mount.

The bottom of the strut assembly attaches to thesteering knuckle with two through bolts. Caster is afixed setting on all vehicles and is not adjustablewhen an alignment is performed. In the event thecamber setting on a vehicle requires adjustment, aservice strut is available which will provide a methodby which the camber can be adjusted.

The strut assemblies on this vehicle are inter-con-nected by the front stabilizer bar through 2 linkassemblies attaching the struts to the stabilizer bar.

STEERING KNUCKLEThe steering knuckle (Fig. 1) is a single casting

with legs machined for attachment of the strutdamper, steering linkage, disc brake caliper, andlower control arm ball joint. The steering knucklealso has the front hub/bearing assembly mounted toit. The hub is positioned through the bearing andknuckle, with the constant velocity stub shaft splinedthrough the hub.

LOWER CONTROL ARMThe lower control arm is an iron casting. The lower

control arm is mounted to and isolated from the bodyof the vehicle using 2 types of rubber bushings. Thefront lower control arm bushing is the spool type andis pressed into the lower control arm, while the rearuses a bushing that is pushed over a stem on thelower control arm. The front and rear of the lower

Fig. 1 Front Steering Knuckle

BOSSESNS/GS

DESCRIPTION AND OPERATION (Continuedcontrol arm is mounted to the cast crossmemberusing a pivot bolt through the center of the frontpivot bushing, and a retainer which traps the rearbushing in the crossmember.

The ball joint is pressed into the control arm andhas a non-tapered stud with a notch for clamp boltclearance. The stud is clamped and locked into thesteering knuckle leg with a clamp bolt.

The ball joint is lubricated for the life of the vehi-cle and does not require any periodic lubrication.

STABILIZER BARThe stabilizer bar interconnects both Mc Pherson

strut assemblies of the vehicle and is attachedthrough rubber isolator bushings to the front suspen-sion cradle

Jounce and rebound movements affecting onewheel are partially transmitted to the opposite wheelto stabilize body roll.

Attachment of the stabilizer bar to the front sus-pension cradle is through 2 rubber-isolator bushingsand bushing retainers. The stabilizer bar to Mc Pher-son strut assembly attachment is done utilizing asway bar attaching link. All parts of the stabilizerbar are serviceable, and the stabilizer bar to cross-member bushings are split for easy removal andinstallation. The split in the stabilizer bar to cross-member bushing should be positioned toward therear of the vehicle, with the square corner downtoward the ground, when the stabilizer bar isinstalled in the vehicle.

STABILIZER BAR ATTACHING LINKThe stabilizer bar attaching links are used to

attach each end of the stabilizer bar to the frontstrut assemblies. This reduces the fore-and-aft rate ofthe stabilizer bar from the rest of the vehicles frontsuspension.

HUB AND BEARING ASSEMBLYThe Unit III Front Hub and Bearing Assembly is

used on all front wheel drive vans.All hub and bearing assemblies mount to the steer-

ing knuckle the same way, but very by the wheel sizeon the vehicle. Vehicles equipped with 14 inch wheelshave a 4 inch wheel mounting stud pattern. Vehiclesequipped with 15 inch wheels have a 4 1/2 inchwheel mounting stud pattern. If a hub and bearingassembly needs to be replaced, be sure that thereplacement assembly has the same size wheelmounting stud pattern as the original part.

This unit is serviced only as a complete assembly.It is mounted to the steering knuckle by four mount-ing bolts that are removed from the rear of the steer-ing knuckle.

SUSPENSION 2 - 11

)

BALL JOINTSEAL BOOT BALL JOINT ASSEMBLY BALL JOINT STUDGREASE FITTING DUST BOOTCOIL SPRING ISOLA-TORSTRUT ASSEMBLYCOIL SPRINGCOIL SPRINGCoil springs are rated separately for each corner or

side of the vehicle depending on optional equipmentand type of vehicle service. During service procedureswhen both springs are removed, mark springs toensure installation in original position. Each coilspring comes with a plastic sleeve on the second coilof the spring. This plastic sleeve is a noise insulatorfor the coil spring. If coil springs require replace-ment, be sure that the springs needing replace-ment, are replaced with springs meeting thecorrect load rating for the vehicle and its spe-cific options.

BALL JOINTThe ball joint (Fig. 2) is pressed into the lower con-

trol arm. The ball joint has a non-tapered stud witha notch (Fig. 2) to provide clearance for the steeringknuckle clamp bolt and to provide retention of theball stud in the steering knuckle. The ball joint studis clamped and locked into the steering knuckle legusing a pinch bolt. The ball joint used on this vehicleis replaceable and if found defective can be servicedas a separate component of the lower control armassembly.

WHEEL MOUNTING STUDSIf wheel attaching studs need to be replaced in the

hub and bearing assembly the studs CAN NOT behammered out of the hub flange. If a stud is removedby hammering it out of the bearing flange, damage tothe hub and bearing assembly will occur leading topremature bearing failure.

Use the procedure and special tools shown in theservice procedures section for the wheel mountingstuds when replacing the wheel attaching studs.

The hub and bearing assembly does not require

Fig. 2 Ball Joint Assembly

2 - 12 SUSPENSION

DESCRIPTION AND OPERATION (Continued)removal from the steering knuckle or the rearknuckle to replace the wheel attaching studs in thehub and bearing assembly.

DIAGNOSIS AND TESTING

Mc PHERSON STRUT(1) Inspect for damaged or broken coil springs

(Fig. 3).(2) Inspect for torn or damaged strut assembly

dust boots (Fig. 3).(3) Inspect the coil spring isolator on the lower

spring seat, (Fig. 3) for any signs of damage or dete-rioration.

(4) Lift dust boot (Fig. 4) and inspect strut assem-bly for evidence of fluid running from the upper endof fluid reservoir. (Actual leakage will be a stream offluid running down the side and dripping off lowerend of unit). A slight amount of seepage between thestrut rod and strut shaft seal is not unusual and doesnot affect performance of the strut assembly (Fig. 4).Also inspect jounce bumpers for signs of damage ordeterioration.

STEERING KNUCKLEThe front suspension knuckle is not a repairable

component of the vehicles front suspension IT MUSTBE REPLACED. . If bent, broken or damaged inany way, do not attempt to straighten or repair thesteering knuckle.

Service replacement of the front hub/bearingassembly can be done with the front steering knuckleremaining on the vehicle.

LOWER CONTROL ARMIf damaged, the lower control arm casting is ser-

viced only as a complete component. Inspect lower

Fig. 3 Mc Pherson Strut Assembly Inspection

NS/GScontrol arm for signs of damage from contact withthe ground or road debris. If lower control arm shows

DUSTBOOT STRUTSHAFTSTRUT FLUIDRESERVOIR INSPECT THIS AREA FOREVIDENCE OF EXCESSIVEFLUID LEAKAGELOWER CONTROL ARMGREASE FITTING STEERINGKNUCKLESEALBALL JOINT

NS/GSany sign of damage, inspect lower control arm fordistortion. Do not attempt to repair or straightena broken or bent lower control arm.

The serviceable components of the lower controlarm are: the ball joint assembly, ball joint assemblygrease seal and control arm bushings. Inspect bothcontrol arm bushings for severe deterioration, andreplace if required. Inspect ball joint per inspectionprocedure in this section of the service manual andreplace if required. Service procedures to replacethese components are detailed in the specific compo-nent removal and installation sections in this groupof the service manual.

BALL JOINT (LOWER)With the weight of the vehicle resting on the road

wheels, grasp the grease fitting as shown in (Fig. 5)and with no mechanical assistance or added forceattempt to rotate the grease fitting.

Fig. 4 Strut Assembly Leakage Inspection

Fig. 5 Checking Ball Joint Wear

DIAGNOSIS AND TESTING (Continued)If the ball joint is worn the grease fitting willrotate easily. If movement is noted, replacement ofthe ball joint is recommended.

STABILIZER BARInspect for broken or distorted sway bar bushings,

bushing retainers, and worn or damaged sway bar tostrut attaching links. If sway bar to front suspensioncradle bushing replacement is required, bushing canbe removed from sway bar by opening slit and peel-ing bushing off sway bar.

HUB AND BEARING ASSEMBLYThe condition of the front hub and bearing assem-

bly is diagnosed using the inspection and testing pro-cedure detailed below.

The bearing contained in the Unit III front hub/bearing assembly will produce noise and vibrationwhen worn or damaged. The noise will generallychange when the bearings are loaded. A road test ofthe vehicle is normally required to determine thelocation of a worn or damaged bearing.

Find a smooth level road surface and bring thevehicle up to a constant speed. When vehicle is at aconstant speed, swerve the vehicle back and forthfrom the left and to the right. This will load andunload the bearings and change the noise level.Where axle bearing damage is slight, the noise isusually not noticeable at speeds above 30 m.p.h..

SERVICE PROCEDURES

SUSPENSION CRADLE THREAD REPAIRPROCEDURE

WARNING: When performing this procedure useonly the thread inserts which are specified in theMopar Parts Catalog for this repair procedure.These thread inserts have been specifically devel-oped for this application and use of other types ofthread inserts can result in an inferior long termrepair.

The threaded holes in the front suspension cradle,if damaged, can repaired by installing a Heli-Coiltthread insert.

The threaded holes that are repairable using thethread insert, are the lower control arm rear bushingretainer mounting bolt holes, routing bracket attach-ing locations for the power steering hoses, and brakehose attachment holes.

This repair procedure now allows the threadedholes in the suspension crossmember to be repaired,eliminating the need to replace the crossmember ifdamage occurs to one of the threaded holes.

SUSPENSION 2 - 13

STRUTDAMPERWHEEL SPEED SENSORCABLE ROUTINGBRACKETHYDRAULIC BRAKEHOSEATTACHINGBOLTROUTING BRACKETTORX PLUS 40 IP BITSWAY BAR LINKSTRUT BRACKETSTRUT ASSEMBLYThe thread inserts for this application are specifiedby part number in the Mopar Parts Catalog. Do notuse a substitute thread insert.

The specific tools and equipment required to installthe thread insert are listed below. Refer to theinstructions included with the thread insert for thedetailed procedure used for the installation of thethread insert.

NOTE: The thread inserts for this application arefor the repair of M8x1.25 and M10x1.5 threads. Besure the correct tools are used for the requiredthread insert size.

TOOL REQUIREMENT FOR M8x1.25 Thread 8.3mm (5/16 in.) Drill Bit 120 Countersink Heli-Coilt Tap #4863-8 Heli-Coilt Gage #4624-8 Heli-Coilt Hand Inserting Tool 7751-8 Needle Nose Pliers For Removal Of Thread

Insert Driving Tang

TOOL REQUIREMENT FOR M10x1.5 Thread 10.5mm (25/64 in.) Drill Bit 120 Countersink Heli-Coilt Tap #4863-10 Heli-Coilt Gage #4624-10 Heli-Coilt Hand Inserting Tool 7751-10 Needle Nose Pliers For Removal Of Thread

Insert Driving Tang

REMOVAL AND INSTALLATION

Mc PHERSON STRUT

REMOVAL

WARNING: DO NOT REMOVE THE NUT FROM THESTRUT ROD WHILE STRUT ASSEMBLY ISINSTALLED IN VEHICLE, OR BEFORE STRUTASSEMBLY SPRING IS COMPRESSED.

(1) Raise vehicle on jack stands or centered on aframe contact type hoist. See Hoisting in the Lubri-cation and Maintenance section of this service man-ual, for the required lifting procedure to be used forthis vehicle.

(2) Remove the wheel and tire assembly from loca-tion on front of vehicle requiring strut removal.

(3) If both strut assemblies are to be removed,mark the strut assemblies right or left according towhich side of the vehicle they were removed from.

(4) Remove the hydraulic brake hose routing

2 - 14 SUSPENSION

SERVICE PROCEDURES (Continued)bracket and the speed sensor cable routing bracketfrom the strut damper brackets (Fig. 6).NOTE: When removing nut from stud of stabilizerbar attaching link, do not allow stud to rotate. Holdstud from rotating by inserting a Torx Plus 40IP bitin the end of the stud as shown in (Fig. 7).

(5) Remove the stabilizer bar attaching link (Fig.7) from the bracket on the strut assembly.

CAUTION: The steering knuckle to strut assemblyattaching bolts are serrated and must not be turnedduring removal. Remove nuts while holding boltsstationary in the steering knuckles.

(6) Remove the 2 strut assembly clevis bracket tosteering knuckle attaching bolts (Fig. 8).

(7) Remove the 3 nuts attaching the strut assem-bly upper mount to the strut tower (Fig. 9).

INSTALLATION(1) Install strut assembly into strut tower, aligning

and installing the 3 studs on the upper strut mountinto the holes in shock tower. Install the 3 upper

Fig. 6 Brake Hose And Speed Sensor Cable Routing

Fig. 7 Stabilizer Bar Link To Strut Attachment

NS/GSstrut mount attaching nut/washer assemblies (Fig.

STRUT CLEVISBRACKET ATTACHINGBOLTSTIE ROD ENDROTORSTEERING KNUCKLEWINDSHIELD WIPER MOD-ULE STRUT TOWERSTRUT MOUNT ATTACHINGBOLTSUPPER STRUTMOUNT9). Then using a crow foot. tighten the 3 attachingnuts to a torque of 28 Nm (250 in. lbs.).

CAUTION: The steering knuckle to strut assemblyattaching bolts are serrated and must not be turnedduring installation. Install nuts while holding boltsstationary in the steering knuckles.

(2) Align strut assembly with steering knuckle.Position arm of steering knuckle into strut assemblyclevis bracket. Align the strut assembly clevisbracket mounting holes with the steering knucklemounting holes. Install the 2 strut assembly to steer-ing knuckle attaching bolts (Fig. 8). If strut assem-bly is attached to steering knuckle using a cambolt, the cam bolt must be installed in the lowerslotted hole on strut clevis bracket. Also,attaching bolts should be installed with thenuts facing the front of the vehicle (Fig. 8).

Fig. 8 Strut Damper Attachment To SteeringKnuckle

Fig. 9 Strut Assembly To Strut Tower AttachingNuts

NS/GS

REMOVAL AND INSTALLATION (Continued)Tighten the strut assembly to steering knuckleattaching bolts to a torque of 88 Nm (65 ft. lbs.)plus an additional 1/4 turn after specifiedtorque is met.

(3) Install stabilizer bar attaching link (Fig. 7) onbracket of strut assembly. Install stabilizer barattaching link to strut bracket attaching nut.

NOTE: When torquing nut on stud of stabilizer barattaching link, do not allow stud to rotate. Hold studfrom rotating by inserting a Torx Plus 40IP bit in theend of the stud as shown in (Fig. 10).

(4) Tighten the stabilizer bar link to strut attach-ing nut using a Torx Plus 40IP bit and crowfoot asshown in (Fig. 10) to a torque of 88 Nm (65 ft. lbs.).

(5) Install hydraulic brake hose and speed sensorcable routing brackets on the strut assembly brackets(Fig. 6). Tighten the routing bracket attaching boltsto a torque of 13 Nm (10 ft. lbs.).

(6) Install the wheel/tire assembly on the vehicle.(7) Install and tighten the wheel mounting stud

nuts in proper sequence until all nuts are torqued tohalf specification. Then repeat the tighteningsequence to the full specified torque of 135 Nm (100ft. lbs.).

STEERING KNUCKLEREMOVE

(1) Raise vehicle on jack stands or centered on aframe contact type hoist. See Hoisting in the Lubri-cation And Maintenance Section of this manual forthe required lifting procedure to be used for thisvehicle.

(2) Remove the cotter pin and nut lock (Fig. 11)from the end of the stub axle.

(3) Remove the wheel and tire assembly from thevehicle.

(4) Remove the wave washer (Fig. 12) from the

Fig. 10 Torquing Stabilizer Bar Link To StrutAttaching Nut

TORQUE WRENCHSTABILIZER BAR LINKCROWFOOTTORX PLUS 40 IP BITFRONT STRUT

SUSPENSION 2 - 15end of the stub axle

HUB/BEARING NUT LOCKCOTTERPINSTUB AXLEHUB/BEARINGASSEMBLY WAVE WASHERSTUB AXLEDISC BRAKE CALI-

PER ASSEMBLYSTEERING KNUCKLEDISC BRAKECALIPERMOUNTINGBOLTSDRIVESHAFTCALIPERASSEMBLY ROTORSTEERINGKNUCKLEMACHINEDABUT-MENT STEERINGKNUCKLEBRAKE FLEXHOSECALIPERASSEMBLYWIRE HANGERSTRUT ASSEM-BLY

2 - 16 SUSPENSION NS/GSCAUTION: Wheel bearing damage will result if afterloosening hub nut, vehicle is rolled on the groundor the weight of the vehicle is allowed to be sup-ported by the tires.

(5) With the vehicles brakes applied to keep hubfrom turning, loosen and remove the stub axle tohub nut.

(6) Remove the 2 front disc brake caliper to steer-ing knuckle attaching bolts (Fig. 13).

(7) Remove the disc brake caliper from the steer-ing knuckle. Caliper is removed by first rotating topof caliper away from steering knuckle and thenremoving bottom of caliper out from under machinedabutment on steering knuckle (Fig. 14).

(8) Support disc brake caliper assembly by using awire hook and suspending it from the strut assembly(Fig. 15). Do not allow the brake caliper assem-bly to hang by the brake flex hose.

(9) Remove the brake rotor from the hub and bear-

Fig. 11 Hub/Bearing To Stub Axle Retaining Nut

Fig. 12 Wave Washer

REMOVAL AND INSTALLATION (Continued)ing assembly (Fig. 16).(10) Remove nut attaching outer tie rod end tosteering knuckle (Fig. 17). Nut is to be removedfrom tie rod end using the following procedure,

Fig. 13 Front Disc Brake Caliper Attaching Bolts

Fig. 14 Brake Caliper Mounting To Steering Knuckle

Fig. 15 Correctly Supported Disc Brake Caliper

HUBSTEERINGKNUCKLEBRAKINGDISC(ROTOR) WHEELMOUNTINGSTUDTIE ROD END STEERING KNUCKLEWRENCH11/32 SOCKETTIE ROD ENDSTUD

TIE ROD END SPECIAL TOOL MB-990635STEERINGKNUCKLE ARMSTUD MOUNTING BOLT WHEEL SPEED SEN-SORSTEERINGKNUCKLESTEERINGKNUCKLE WHEEL STOP LOWER CON-TROL ARMROTOR

NS/GShold tie rod end stud with a 11/32 socket whileloosening and removing nut with a wrench.

(11) Remove the tie rod end stud from steeringknuckle arm, using Remover, Special ToolMB-990635 (Fig. 18).

(12) Remove the front wheel speed sensor (Fig. 19)from the steering knuckle.

(13) If equipped, remove the wheel stop (Fig. 20)from the steering knuckle. When installing thepinch bolt when assembling the steeringknuckle to the ball joint, the pinch bolt must beinstalled from the rear facing the front on thevehicle.

Fig. 16 Remove/Install Brake Rotor

Fig. 17 Removing Tie Rod End Attaching Nut

REMOVAL AND INSTALLATION (Continued)(14) Remove the steering knuckle to ball jointstud, clamping nut and bolt (Fig. 21) from the steer-

Fig. 18 Tie Rod End Removal From SteeringKnuckle Arm

Fig. 19 Front Wheel Speed Sensor

Fig. 20 Wheel Stop Location On Steering Knuckle

SUSPENSION 2 - 17ing knuckle.

CLAMPING NUT/BOLT LOWER CON-TROL ARMBALLJOINTSTEERING KNUCKLEROTORSTEERING KNUCKLE BALL JOINT STUDBALL JOINT SEALLOWER CONTROL ARMPRY BARDRIVESHAFT STUB

AXLEHUB/BEARING

ASSEMBLYLOWER CON-TROL ARM BALL JOINT STEERINGKNUCKLESTRUT CLEVIS BRACKET ATTACHING NUTS/BOLTSSTEERINGKNUCKLE

NS/GS(15) Using a pry bar, separate steering knucklefrom ball joint stud (Fig. 22). Note: Use cautionwhen separating ball joint stud from steeringknuckle, so ball joint seal does not get cut.

NOTE: Care must be taken not to separate theinner C/V joint during this operation. Do not allowdriveshaft to hang by inner C/V joint after removingouter C/V Joint from the hub/bearing assembly insteering knuckle, end of driveshaft must be sup-ported.

(16) Pull steering knuckle assembly out and awayfrom the outer C/V joint of the driveshaft assembly(Fig. 23).

CAUTION: The steering knuckle to strut assemblyattaching bolts are serrated and must not be turnedduring removal. Remove nuts while holding bolts

Fig. 21 Control Arm To Steering KnuckleAttachment

Fig. 22 Separating Ball Joint Stud From SteeringKnuckle

2 - 18 SUSPENSION

REMOVAL AND INSTALLATION (Continued)stationary in the steering knuckles.(17) Remove the 2 steering knuckle to strutdamper clevis bracket attaching bolts (Fig. 24).

(18) Remove the steering knuckle from the strut.

INSTALL(1) Transfer, or install if necessary, a new hub/

bearing assembly into the steering knuckle. Refer toHub And Bearing Assembly Service in this section ofthe service manual for the required removal andinstallation procedure for the front hub/bearingassembly.

CAUTION: The steering knuckle to strut assemblyattaching bolts are serrated and must not be turnedduring installation. Install nuts while holding boltsstationary in the steering knuckles.

Fig. 23 Steering Knuckle Separation FromDriveshaft

Fig. 24 Strut To Steering Knuckle Attaching Bolts

STEERINGKNUCKLEFLANGED BOLT IN TOP

HOLECAM BOLT IN BOTTOMHOLESTRUT CLEVISBRACKET STEERINGKNUCKLE

TIE ROD ENDCROWFOOT11/32 SOCKETTORQUE WRENCH TORQUEWRENCH

SUSPENSION 2 - 19CAUTION: If the vehicle being serviced isequipped with eccentric strut assembly attachingbolts, the eccentric bolt must be installed in thebottom (slotted) hole on the strut clevis bracket(Fig. 25).

(2) Install steering knuckle back in clevis bracketof strut damper assembly (Fig. 24). Install the strutdamper to steering knuckle attaching bolts. Tightenboth attaching bolts to a torque of 90 Nm (65 ft. lbs.)plus an additional 1/4 turn.

(3) Slide drive shaft back into front hub and bear-ing assembly. Then install steering knuckle onto thestud of the ball joint assembly (Fig. 23).

(4) Install a NEW steering knuckle to ball jointstud, clamping bolt and nut (Fig. 21). Tighten theclamping bolt and nut to a torque of 145 Nm (105 ft.lbs.).

(5) Install tie rod end into steering knuckle. Startattaching nut onto stud of tie rod end. While holdingstud of tie rod end stationary using a 11/32 socket,(Fig. 17) tighten tie rod end to steering knuckleattaching nut. Then using a crowfoot and 11/32socket (Fig. 26), tighten the tie rod end attaching nutto a torque of 54 Nm (40 ft. lbs.).

(6) Install braking disc on hub and bearing assem-bly (Fig. 16).

(7) Install disc brake caliper assembly on steeringknuckle. Caliper is installed by first sliding bottom ofcaliper under abutment on steering knuckle, andthen rotating top of caliper against top abutment(Fig. 14).

(8) Install disc brake caliper assembly to steeringknuckle attaching bolts (Fig. 13). Tighten the discbrake caliper assembly attaching bolts to a torque of35 Nm (30 ft. lbs.).

(9) Clean all foreign matter from the threads ofthe outer C/V joint stub axle. Install the washer and

Fig. 25 Correctly Installed Eccentric Attaching Bolt

NS/GS

REMOVAL AND INSTALLATION (Continued)stub axle to hub/bearing assembly nut on stub axleand securely tighten nut.(10) Install wheel speed sensor and mounting bolt(Fig. 19) on steering knuckle. Tighten the speed sen-sor attaching bolt to a torque of 7 Nm (60 in. lbs.).

(11) Install front wheel and tire assembly. Installand tighten the wheel mounting stud nuts in propersequence until all nuts are torqued to half therequired specification. Then repeat the tighteningsequence to the full specified torque of 135 Nm (100ft. lbs.).

(12) Lower vehicle.(13) With the vehicles brakes applied to keep hub

from turning, tighten the hub nut to a torque of 203Nm (150 ft. lbs.) (Fig. 27).

(14) Install the spring wave washer on the end ofthe stub axle.

(15) Install the hub nut lock, and a new cotter pin(Fig. 11). Wrap cotter pin prongs tightly around thehub nut lock as shown in (Fig. 11).

(16) Set front Toe on vehicle to required specifica-tion. Use procedure listed under Wheel Alignment, in

Fig. 26 Torquing Tie Rod End Attaching Nut

Fig. 27 Torquing Front Stub Axle To Hub Nut

STEERINGKNUCKLE WHEEL STOP LOWER CON-TROL ARMROTORCLAMPING NUT/BOLT LOWER CON-TROL ARMBALLJOINTSTEERING KNUCKLEROTORthe Front Suspension Service Procedures section ofthis service manual.

LOWER CONTROL ARM

REMOVE(1) Raise vehicle on jack stands or centered on a

frame contact type hoist. See Hoisting in the Lubri-cation and Maintenance section of this manual, forthe required lifting procedure to be used for thisvehicle.

(2) Remove wheel and tire assembly from the sideof vehicle requiring service to the lower control arm.

(3) Remove the wheel stop (Fig. 28) from the steer-ing knuckle. When installing the pinch bolt whenassembling the steering knuckle to the balljoint, the pinch bolt must be installed from therear facing the front on the vehicle (Fig. 28).

(4) Remove the nut and bolt clamping the steeringknuckle to the ball joint stud. (Fig. 29)

Fig. 28 Wheel Stop Location On Steering Knuckle

Fig. 29 Control Arm To Steering Knuckle

2 - 20 SUSPENSION

REMOVAL AND INSTALLATION (Continued)AttachmentNOTE: The attaching bolts for the cradle plate areof two different thread sizes. Nine of the bolts are aM-14 thread and one of the bolts is a M-12 thread.Refer to (Fig. 30) for the cradle plate attaching boltlocations.

(5) Remove the 10 bolts (Fig. 30) attaching the cra-dle plate to the front suspension cradle. Then removethe cradle plate from the cradle.

CAUTION: Pulling steering knuckle out from vehi-cle after releasing from ball joint can separate innerC/V joint. See Driveshafts.

(6) Using a pry bar, separate steering knucklefrom ball joint stud (Fig. 31). Use caution whenseparating ball joint stud from steeringknuckle, so ball joint seal does not get cut.

Fig. 30 Front Suspension Cradle Plate AndMounting Bolts

FRONT SUSPENSION CRA-DLECRADLE PLATE ATTACHINGBOLT M12 (1)CRADLE PLATE TO CRADLEATTACHING BOLTS M14 (9)

Fig. 31 Separating Ball Joint Stud From SteeringKnuckle

STEERING KNUCKLE BALL JOINT STUDBALL JOINT SEALLOWER CONTROL ARMPRY BAR

NS/GS

FRONT SUSPENSION CRA-DLE CONTROL ARM PIVOTBUSHING BOLTCONTROL ARM REARBUSHING RETAINERLOWER CONTROL ARM SUSPENSIONCRADLEBUSHINGRETAINERLOWER CONTROL ARM FRAME RAILFRONT SUSPENSION CRA-DLEMOUNTINGBOLTMOUNTINGBOLT PRY BAR TRANSAXLELOWER CONTROL ARM PIVOTBOLTFRONT SUSPENSION CRA-DLE(7) Loosen but do not remove the pivot bolt (Fig.32) attaching the front bushing of the lower controlarm to the front suspension cradle.

(8) Remove retainer (Fig. 33) attaching rear bush-ing of lower control arm to front suspension cradle.

CAUTION: Make location reference marks wherethe front suspension cradle is mounted against thefront frame rails before loosening and lowering thecradle. This is required so the cradle can be re-in-stalled in the design location to achieve properfront suspension alignment.

(9) Loosen but not fully removing the 2 left sidesuspension cradle to frame rail attaching bolts (Fig.34).

NOTE: When removing the left lower control arm

Fig. 32 Lower Control Arm Bushing To Cradle PivotBolt

Fig. 33 Control Arm Bushing To Suspension CradleRetainer

NS/GS

REMOVAL AND INSTALLATION (Continued)from the vehicle, the front suspension cradle needsto be lowered for the pivot bolt to clear the tran-saxle.

(10) Lower the left front corner of the suspensioncradle until pivot bolt will clear end of transaxle (Fig.35). Remove the pivot bolt and the lower control armfrom the cradle.

INSTALL

NOTE: If the left lower control arm is beinginstalled on the vehicle the front suspension cradleneeds to be lowered for the pivot bolt to clear thetransaxle.

(1) Position lower control arm assembly into frontsuspension cradle. If installing the left lower con-trol arm, pry down on the left front corner ofthe suspension cradle until the pivot bolt clearsthe end of the transaxle (Fig. 35). Install pivot

Fig. 34 Suspension Cradle To Frame Rail MountingBolts

Fig. 35 Lowering Front Suspension Cradle

SUSPENSION 2 - 21bolt attaching front bushing of lower control arm to

(5) Install lower control arm ball joint stud into

LOWER CONTROL ARMBUSHING PIVOT BOLT

LOWER CONTROL ARMFRONT SUSPENSION CRADLE LOWER CONTROLARMBUSHING

RETAINERGROOVEFRONT SUSPENSION CRA-DLERAISEDRIBREAR BUSHING LOWER CONTROL ARMS BALLJOINTJACK STANDSBALLJOINT

NS/GSfront suspension cradle (Fig. 36). Do not tighten ortorque pivot bolt at this time.

(2) Install retainer (Fig. 37) attaching rear bush-ing of lower control arm to front suspension cradle.When installing retainer, be sure raised rib onrear bushing (Fig. 37) is positioned in thegroove on the retainer. Do not torque attachingbolts at this time.

NOTE: If reference marks were not put on theframe rails prior to lowering the suspension cradle,Refer to group 13 Frame And Bumpers for the cra-dle positioning procedure.

(3) Raise the front suspension cradle against thefront frame rails. Align the cradle with the referencemarks on the frame rails.

(4) Tighten the 4 mounting bolts for the front sus-

Fig. 36 Lower Control Arm Bushing Pivot BoltCorrectly Installed

Fig. 37 Installing Lower Control Arm Rear BushingRetainer

2 - 22 SUSPENSION

REMOVAL AND INSTALLATION (Continued)pension cradle to a torque of 163 Nm (120 ft. lbs.).steering knuckle. Then install the bolt and nut,clamping the steering knuckle to the ball joint stud(Fig. 29). Tighten the clamping bolt to a torque of145 Nm (105 ft. lbs.).

(6) Install the cradle plate on front suspension cra-dle and then install the 10 cradle plate to cradleattaching bolts (Fig. 30). Tighten the 9 M-14 attach-ing bolts (Fig. 30) to a torque of 165 Nm (123 ft.lbs.). Tighten the 1 M-12 attaching bolt (Fig. 30) to atorque of 108 Nm (80 ft. lbs.).

CAUTION: When locating jack stands under lowercontrol arm, do not place the jack stands under theball joints (Fig. 38).

(7) Position jack stands under the lower controlarms as close to the ball joints as possible (Fig. 38).Lower the vehicle onto the jack stands, until the jackstands are supporting the total weight of the vehicle(Fig. 38).

(8) Tighten front lower control arm pivot bolt (Fig.36) to a torque of 183 Nm (135 ft. lbs.) first, thentighten rear lower control arm bushing retainerattaching bolts (Fig. 33) to a torque of 68 Nm (50 ft.lbs.).

(9) Install the wheel/tire assembly on the vehicle.(10) Install and tighten the wheel mounting stud

nuts in proper sequence until all nuts are torqued tohalf specification. Then repeat the tighteningsequence to the full specified torque of 135 Nm (100ft. lbs.).

(11) Remove jack stands and lower vehicle to theground.

Fig. 38 Jack Stands Supporting Vehicle Weight

LOWER CONTROL ARM BALL JOINT STUDSEAL BOOTSCREW DRIVERBALL JOINT ASSEM-BLYARBOR PRESS SPECIAL TOOL 6919BALL JOINTSPECIAL TOOL6758LOWER CONTROL ARM NOTCH BALL JOINT STUDBALL JOINTLOWER CONTROLARMARBORPRESS SPECIAL TOOL69084BALL JOINTLOWER CONTROLARM

NS/GS SUSPENSION 2 - 23BALL JOINT

REMOVE(1) Using a screw driver or other suitable tool, pry

the seal boot off of the ball joint assembly (Fig. 39)

(2) Position receiving cup, Special Tool 6758 tosupport lower control arm when removing ball jointassembly (Fig. 40). Install Remover, Special Tool6919 on top of the ball joint assembly (Fig. 40).

(3) Using the arbor press, press the ball jointassembly completely out of the lower control arm.

INSTALL

NOTE: When installing ball joint in lower controlarm, position the ball joint in control arm so notchin ball joint stud is in the direction shown (Fig. 41).This will ease assembly of the ball joint to thesteering when installing pinch bolt.

Fig. 39 Ball Joint Seal Boot Removal

Fig. 40 Ball Joint Removal From Lower Control Arm

REMOVAL AND INSTALLATION (Continued)(1) By hand, position ball joint into ball joint boreof lower control arm. Be sure ball joint is notcocked in the bore of the control arm, this willcause the ball joint to bind when being pressedinto control arm.

(2) Position control arm with installed ball joint, inan arbor press with Receiving Cup, Special Tool 6758supporting the lower control arm (Fig. 42). Then cen-ter Installer, Special Tool 69084 on the bottom ofthe ball joint (Fig. 42)

(3) Carefully align all pieces. Then press the balljoint into the lower control arm until it is completelyseated against surface of lower control arm. The balljoint is correctly installed when there is no gapbetween the ball joint and the lower control arm (Fig.43). Do not apply excessive force against theball joint or the lower control arm.

Fig. 41 Installation Position Of Ball Joint In ControlArm

Fig. 42 Installing Ball Joint In Control Arm

SPECIAL TOOL 69084 BALL JOINTBALL JOINT IS COR-RECTLY INSTALLEDWHEN NO GAP ISPRESENT HERELOWER CONTROLARMBALL JOINT SEAL BOOT BALL JOINT STUDLOWER CONTROL ARMSHIELD SHIELD SPECIAL TOOL 6758LOWER CONTROL ARMBALL JOINT SEAL BOOTCAUTION: When installing the ball joint seal on theball joint/lower control arm, the shield (Fig. 44) onthe ball joint seal must be positioned as shown.

(4) Install a NEW seal boot by hand as far as pos-sible on the ball joint. Installation of the seal boot isto be with the shield positioned as shown (Fig. 44).

CAUTION: Do not use an arbor press to install thesealing boot on the ball joint. Damage to the seal-ing boot will occur if excessive pressure is appliedto the sealing boot when it is being installed.

(5) Place Installer, Special Tool 6758 over seal bootand squarely align it with bottom edge of seal boot(Fig. 45). Apply hand pressure to Special Tool 6758until seal boot is pressed squarely against top surfaceof lower control arm.

CAUTION: A replacement ball joint is not prelubri-cated. Properly lubricate the replacement ball joint

Fig. 43 Correctly Installed Lower Ball Joint

Fig. 44 Ball Joint Seal Boot Installed Position

2 - 24 SUSPENSION

REMOVAL AND INSTALLATION (Continued)using Mopar MultiMile grease or an equivalent.Lubricate ball joint after seal boot is installed butprior to top of seal boot being pushed down belownotch in ball joint stud (Fig. 41). Air must vent outof the seal boot at notch when grease is pumpedinto ball joint, failure to do so will balloon and dam-age seal boot. Do not over grease the ball joint, thiswill prevent the seal boot from pushing down onthe stud of the ball joint.

CAUTION: After the ball joint is properly greased,clip the end of the grease fitting off below the hex.The ball joint seal boot is non-purgeable and furthergreasing is not required and can result in damageto the seal boot.

STABILIZER BAR

REMOVE(1) Raise vehicle on jack stands or centered on a

frame contact type hoist. See Hoisting in the Lubri-cation and Maintenance section of this manual, forthe required lifting procedure to be used for thisvehicle.

NOTE: The attaching bolts for the cradle plate areof two different thread sizes. Nine of the bolts are aM-14 thread and one of the bolts is a M-12 thread.Refer to (Fig. 46) for the cradle plate attaching boltlocations.

(2) Remove the 10 bolts (Fig. 46) attaching the cra-dle plate to the front suspension cradle. Then removethe cradle plate from the cradle.

NOTE: When removing nut from stud of stabilizerbar attaching link, do not allow the stud to rotate.Hold stud from rotating by inserting a Torx Plus 40IP bit in the end of the stud (Fig. 47).

Fig. 45 Installing Ball Joint Seal Boot

NS/GS

FRONT SUSPENSION CRA-DLECRADLE PLATE ATTACHINGBOLT M12 (1)CRADLE PLATE TO CRADLEATTACHING BOLTS M14 (9)STABILIZER BAR ATTACHINGLINKLOWER CONTROL ARMSTABILIZER BARSTABILIZER BAR ATTACHINGLINK STUDNUTDRIVESHAFT STEERINGGEAR

SWAY BARRAISED

BEADFRONT SUSPENSIONCRADLESWAY BAR BUSHING RETAINERSSWAY BAR ISOLA-TOR BUSHING SLIT IN SWAY BARBUSHINGSLIT SIDE OF BUSHING MUSTBE INSTALLED ON SWAY BARAS INDICATED. THIS WILL POSI-TION SLIT FACING TOWARD THEREAR OF VEHICLE WHEN SWAYBAR IS INSTALLED.SWAY BAR

SUSPENSION 2 - 25(3) Remove the nuts (Fig. 47) attaching the stabi-lizer bar attaching links to the stabilizer bar. Thenremove the attaching links from the stabilizer bar.

(4) Remove the stabilizer bar bushing retainersfrom the front suspension cradle (Fig. 48).

(5) Remove the stabilizer bar and bushings as anassembly from the front suspension cradle.

INSTALL(1) If the stabilizer bar to front suspension cradle

bushings require replacement at time of inspection,install new bushings before installing stabilizer bar.Bushings are replaced by opening slit on bushingsand peeling them off stabilizer bar. Install new bush-ings on stabilizer bar by spreading bushing at slitand forcing them on the stabilizer bar. Bushingsmust be installed on stabilizer bar so slit inbushing will be facing toward the rear of vehi-cle with the square corner toward the ground,

Fig. 46 Cradle Plate And Mounting Bolts

Fig. 47 Stabilizer Bar Link Attachment To StabilizerBar

NS/GS

REMOVAL AND INSTALLATION (Continued)when the stabilizer bar is installed on the vehi-cle (Fig. 49).

(2) Position stabilizer bar into front suspensioncradle so stabilizer bar bushings are aligned withdepressions in cradle. Install stabilizer bar bushingretainers onto crossmember aligning raised bead onretainer with cutouts in bushings (Fig. 50). Do nottighten Stabilizer bar bushing retainers at thistime.

(3) Check position of the stabilizer bar in the frontsuspension cradle. The center of the curved section ofthe stabilizer bar must be aligned with the raisedline in the center of the front suspension cradle (Fig.51).

(4) Align holes in stabilizer bar with attaching linkassemblies. Install the stabilizer bar attaching linksinto the stabilizer bar and install the attaching nuts(Fig. 47).

Fig. 48 Front Stabilizer Bar Bushing Retainers

Fig. 49 Correctly Installed Stabilizer Bar To CradleBushing

SWAY BAR SWAY BAR BUSH-INGBUSHINGSPLITFRONT SUS-PENSION CRA-DLEBUSHINGCUT-OUTBUSHINGRETAINER RAISED BEADRAISED BEAD SWAYBARWHEN INSTALLING SWAY BARTHE RAISED BEAD ON THE SUS-PENSION CRADLE MUST BE INTHE CENTER OF RADIUS INSWAY BARFRONT SUSPENSION CRA-DLE HUB/BEARING NUT LOCKCOTTERPINSTUB AXLEHUB/BEARINGASSEMBLY WAVE WASHERSTUB AXLE

2 - 26 SUSPENSION NS/GS

REMOVAL AND INSTALLATION (Continued)NOTE: When torquing nut on stud of stabilizer barattaching link, do not allow the stud to rotate. Holdstud from rotating by inserting a Torx Plus 40 IP bitin the end of the the stud (Fig. 47).

(5) Tighten the stabilizer bar attaching link nuts(Fig. 47) to a torque of 88 Nm (65 ft. lbs.).

(6) Tighten the stabilizer bar bushing retainer tocradle attaching bolts (Fig. 48) to 68 Nm (50 ft. lbs.)torque.

(7) Install the cradle plate on front suspension cra-dle and then install the 10 cradle plate to cradleattaching bolts (Fig. 46). Tighten the 9 M-14 attach-ing bolts (Fig. 46) to a torque of 165 Nm (123 ft.lbs.). Tighten the 1 M-12 attaching bolt (Fig. 46) to atorque of 108 Nm (80 ft. lbs.).

(8) Lower vehicle.

Fig. 50 Stabilizer Bar Bushing Retainer Installation

Fig. 51 Stabilizer Bar Correctly PositionedIn CradleHUB AND BEARING ASSEMBLY

REMOVE

NOTE: Replacement of the Unit III front hub/bearingassembly can be normally done without having toremove the steering knuckle from the vehicle. In theevent that the hub/bearing is frozen in the steeringknuckle and cannot be removed by hand it will haveto be pressed out of the steering knuckle. Thesteering knuckle will require removal from the vehi-cle to allow the hub/bearing assembly to bepressed out of the steering knuckle. Refer to FrontSteering Knuckle in this section of the service man-ual for the required removal and installation proce-dure.

(1) Remove the cotter pin, and nut lock from thestub axle (Fig. 52).

(2) Remove the spring wave washer (Fig. 53) fromthe end of the stub axle.

Fig. 52 Cotter Pin And Nut LockFig. 53 Nut Lock Wave Washer

DISC BRAKE CALI-PER ASSEMBLY

STEERING KNUCKLEDISC BRAKECALIPERMOUNTINGBOLTSDRIVESHAFT CALIPERASSEMBLY ROTORSTEERINGKNUCKLEMACHINEDABUT-MENT STEERINGKNUCKLEBRAKE FLEXHOSECALIPERASSEMBLYWIRE HANGERSTRUT ASSEM-BLY RETAININGNUT TIE RODENDSTUB AXLEWASHERHUB/BEARINGASSEMBLYSTEERINGKNUCKLE

NS/GS SUSPENSION 2 - 27CAUTION: Wheel bearing damage will result ifafter loosening hub nut, vehicle is rolled on theground or the weight of the vehicle is allowed to besupported by the tires.

(3) With the aid of a helper applying the brakes tokeep the front hub from turning, loosen but do notremove the hub nut. The hub and driveshaft aresplined together through the knuckle (bearing)and retained by the hub nut.

(4) Raise vehicle on jack stands or centered on aframe contact type hoist. See Hoisting in the Lubri-cation and Maintenance section of this manual, forthe required lifting procedure to be used for thisvehicle.

(5) Remove wheel lug nuts, and front tire andwheel assembly.

(6) Remove front disc brake caliper to steeringknuckle attaching bolts. (Fig. 54).

(7) Remove disc brake caliper assembly from steer-ing knuckle. Caliper is removed by first rotating topof caliper away from steering knuckle, and thenremoving bottom of caliper out from under machinedabutment. (Fig. 55)

(8) Support disc brake caliper assembly using awire hook, (Fig. 56) do not hang caliper assemblyby hydraulic hose.

(9) Remove the braking disc from the front hub/bearing assembly.

(10) Remove the retaining nut and the washer(Fig. 57) from the end of the stub axle.

(11) Remove the four hub and bearing assemblymounting bolts from the rear of steering knuckle(Fig. 58).

(12) Remove the hub and bearing assembly fromthe steering knuckle (Fig. 59).

Fig. 54 Front Disc Brake Caliper Mounting Bolts

REMOVAL AND INSTALLATION (Continued)Fig. 55 Brake Caliper Assembly Removal/Installation

Fig. 56 Supporting Brake Caliper

Fig. 57 Hub/Bearing To Stub Axle Retaining Nut AndWasher

FRONT HUBSTEERINGKNUCKLEHUB/BEARING MOUNT-ING BOLTS (4)DRIVESHAFT STUB AXLEHUB/BEARINGASSEMBLYSTEERINGKNUCKLEBEARINGSEAL BEARING SEALSTUB AXLETHESE SURFACESMUST BE CLEAN ANDFREE OF NICKSBEFORE INSTALLINGBEARING ASSEMBLYSTEERINGKNUCKLE RETAININGNUT TIE RODENDSTUB AXLEWASHERHUB/BEARINGASSEMBLYSTEERINGKNUCKLEINSTALL

CAUTION: Hub and bearing assembly mountingsurfaces on the steering knuckle and halfshaft (Fig.60) must be smooth and completely free of foreignmaterial or nicks prior to installing hub and bearingassembly.

CAUTION: When installing hub and bearingassembly into steering knuckle, be careful not todamage the bearing seal (Fig. 60) on the outer C/Vjoint.

(1) Install hub/bearing assembly onto stub axleand into steering knuckle until squarely seated onthe face of the steering knuckle.

(2) Install the 4 hub/bearing assembly to steeringknuckle attaching bolts (Fig. 58). Equally tighten all4 mounting bolts in a criss-cross pattern until hub/

Fig. 58 Hub/Bearing Assembly Mounting Bolts

Fig. 59 Hub and Bearing Assembly Removal FromSteering Knuckle

2 - 28 SUSPENSION

REMOVAL AND INSTALLATION (Continued)bearing assembly is squarely seated against front ofsteering knuckle. Then tighten the 4 hub and bearingassembly mounting bolts to a torque of 65 Nm (45ft.lbs.)

(3) Install the hub/bearing assembly to stub shaftwasher and retaining nut (Fig. 61). Tighten, but donot torque the hub nut at this time.

(4) Install the braking disk on the hub and bearingassembly.

(5) Install front brake caliper back over brakingdisc and align with caliper mounting holes on steer-ing knuckle (Fig. 55). Caliper is installed by firstinstalling bottom of caliper under machined abut-ment on bottom of steering knuckle and then rotat-ing top of caliper toward steering knuckle. Install thedisc brake caliper to steering knuckle attaching bolts(Fig. 54) and tighten to a torque of 19 Nm (168 in.lbs.).

Fig. 60 Hub And Bearing Assembly MountingSurfaces

Fig. 61 Hub/Bearing To Stub Axle Washer AndRetaining Nut

NS/GS(6) Install wheel and tire assembly on vehicle.Tighten the wheel mounting stud nuts in proper

DISC BRAKE CALI-PER ASSEMBLY

STEERING KNUCKLEDISC BRAKECALIPERMOUNTINGBOLTSDRIVESHAFT HUBSTEERINGKNUCKLEBRAKINGDISC(ROTOR) WHEELMOUNTINGSTUDsequence until all nuts are torqued to half specifica-tion. Then repeat the tightening sequence to the fullspecified torque of 129 Nm (95 ft. lbs.).

(7) Lower vehicle to the ground.

CAUTION: When tightening hub/bearing assemblyto stub shaft retaining nut, do not exceed the max-imum torque of 244 Nm (180 ft. lbs.).

(8) With vehicle brakes applied to keep vehiclefrom moving, torque stub shaft to hub/bearing assem-bly retaining nut to 244 Nm (180 ft. lbs.).

(9) Check the Toe setting on the vehicle and resetif not within specifications.

FRONT WHEEL MOUNTING STUDS

REMOVE

CAUTION: If a wheel attaching stud needs to bereplaced in the hub and bearing assembly the studsCAN NOT be hammered out of the hub flange. If astud is removed by hammering it out of the bearingflange, damage to the hub and bearing assemblywill occur leading to premature bearing failure.

The following procedure and special tools shownMUST BE used when replacing wheel attachingstuds.

The hub and bearing assembly does not requireremoval from the steering knuckle to replace wheelattaching studs in the hub and bearing assembly.

(1) Raise vehicle on jackstands or centered on aframe contact type hoist. See Hoisting in the Lubri-cation and Maintenance section of this manual forthe required lifting procedure to be used for thisvehicle.

(2) Remove the front wheel and tire assembly fromthe vehicle.

(3) Remove the front caliper assembly from thefront steering knuckle assembly. (Fig. 62) Refer toFront Disc Brake Service in the Brake Section of thisservice manual for caliper removal procedure.

(4) Remove front rotor from hub, by pulling itstraight off wheel mounting studs. (Fig. 63)

(5) Install a lug nut on the wheel stud to beremoved from the hub and bearing assembly, so thethreads on the stud are even with end of lug nut.Install Remover, Special Tool C-4150A on hub andbearing assembly flange and wheel stud (Fig. 64).

(6) Tightening down on special tool will pushwheel stud out of the hub and bearing assemblyflange. When shoulder of wheel stud is past flangeremove special tool from hub and bearing assembly.Remove lug nut from stud and remove wheel stud

NS/GS

REMOVAL AND INSTALLATION (Continued)from flange.INSTALL(1) Install replacement wheel stud into flange of

hub and bearing assembly. Install washers on wheelstud, then install a wheel lug nut on stud with flatside of lug nut against washers (Fig. 65).

(2) Tighten the wheel lug nut, pulling the wheelstud into the flange of the hub and bearing assembly.When the head of the stud is fully seated against thebearing flange, remove lug nut and washers fromwheel stud.

(3) Install the braking disk back on the hub andbearing assembly. (Fig. 63)

(4) Install front brake caliper back over brakingdisc and align with caliper mounting holes on steer-

Fig. 62 Disc Brake Caliper Mounting

Fig. 63 Removing Braking Disc

SUSPENSION 2 - 29ing knuckle (Fig. 62). Refer to Front Disc Brake Ser-vice in the Brake Section of this service manual for

LUG NUTHUB / BEARINGASSEMBLYSPECIALTOOL C-4150ASTEERINGKNUCKLE WHEEL STUD WASHERSHUB / BEARINGASSEMBLYWHEEL LUGNUTSTEERING KNUCKLEcaliper installation procedure. Install the caliperadapter to steering knuckle attaching bolts andtorque to 19 Nm (168 in. lbs.).

(5) Install wheel and tire assembly on vehicle.Tighten the wheel mounting stud nuts in propersequence until all nuts are torqued to half specifica-tion. Then repeat the tightening sequence to the fullspecified torque of 129 Nm (95 ft. lbs.).

(6) Lower vehicle to the ground.

REAR WHEEL MOUNTING STUDS

REMOVE

CAUTION: If a wheel attaching stud needs to bereplaced in the hub and bearing assembly the studsCAN NOT be hammered out of the hub flange. If astud is removed by hammering it out of the bearingflange, damage to the hub and bearing assembly

Fig. 64 Wheel Stud Removal From Hub/BearingAssembly

Fig. 65 Installing Wheel Stud Into Hub And Bearing

2 - 30 SUSPENSION

REMOVAL AND INSTALLATION (Continued)will occur leading to premature hub and bearingfailure.The following procedure and special tools shownMUST be used when replacing wheel attachingstuds.

The hub and bearing assembly does not requireremoval from the rear axle for replacement of thewheel attaching studs.

(1) Raise vehicle on jackstands or centered on aframe contact type hoist. See Hoisting in the Lubri-cation and Maintenance section of this manual, forthe required lifting procedure to be used for thisvehicle.

(2) Remove the rear wheel and tire assembly.(3) Remove the rear brake drum.(4) Install a lug nut on the wheel stud to be

removed from the hub and bearing assembly (Fig. 66)so the threads on stud are even with end of lug nut.Install Remover, Special Tool C-4150A on hub andbearing assembly flange and wheel stud (Fig. 66).

(5) Tightening down on special tool will pushwheel stud out of the hub and bearing assemblyflange. Remove lug nut from stud and remove wheelstud from flange.

INSTALL(1) Install replacement wheel stud into flange of

hub and bearing assembly. Install washers on wheelstud, then install a wheel lug nut on stud with flatside of lug nut against washers (Fig. 67).

(2) Tighten the wheel lug nut, pulling the wheelstud into the flange of the hub and bearing assembly.When the head of the stud is fully seated against thebearing flange, remove lug nut and washers fromwheel stud.

(3) Install the rear brake drum on the hub andbearing assembly.

(4) Install wheel and tire assembly on vehicle.

Fig. 66 Removing Wheel Stud From Hub AndBearing

HUB/BEARINGASSEMBLY LUGNUT WHEEL STUDSPECIAL TOOL C-4150A

NS/GSTighten the wheel mounting stud nuts in propersequence until all nuts are torqued to half specifica-

LUGNUT HUB/BEARINGASSEMBLYWASHERSWHEEL STUDSTRUT ASSEM-BLYSTRUT CLEVIS BRACKET VISEtion. Then repeat the tightening sequence to the fullspecified torque of 129 Nm (95 ft. lbs.).

(5) Lower vehicle to the ground.

DISASSEMBLY AND ASSEMBLY

Mc PHERSON STRUT

DISASSEMBLYThe Mc Pherson Strut must be remove from the

vehicle for it to be disassembled and assembled.Refer to Mc Pherson Strut in the Removal AndInstallation Section in this group of the service man-ual for the required procedure to remove and installthe Mc Pherson Strut.

(1) Clamp strut assembly in vise, with strut in avertical position. Do not clamp reservoir of strutassembly in vise, only clamp strut assemblyusing strut clevis bracket (Fig. 68).

Fig. 67 Installing Wheel Stud Into Hub And Bearing

Fig. 68 Strut Assembly Correctly InstalledIn Vise

NS/GS

REMOVAL AND INSTALLATION (Continued)(2) Mark coil spring and strut assembly right orleft, according to which side of vehicle strut wasremoved from, and which strut coil spring wasremoved from.

WARNING: DO NOT REMOVE STRUT ROD NUT,BEFORE STRUT ASSEMBLY COIL SPRING IS COM-PRESSED, REMOVING SPRING TENSION FROMUPPER SPRING SEAT AND BEARING ASSEMBLY.

WARNING: WHEN COMPRESSING COIL SPRINGFOR REMOVAL FROM STRUT ASSEMBLY, THEUPPER SPRING SEAT AND SECOND COIL OF THECOIL SPRING MUST BE CAPTURED BY THE JAWSOF THE COIL SPRING COMPRESSOR (Fig. 69).

(3) Compress strut assembly coil spring, using Pro-fessional Service Spring Compressor, GP2020S2.5or an equivalent (Fig. 69). Use the A60 top shoe tograb upper spring seat and A40 bottom shoe to grabcoil spring (Fig. 69).

(4) Install Socket, Strut Nut, Special Tool 6864 onthe strut shaft retaining nut (Fig. 70). Then install a10 mm socket on the hex of the strut damper shaft(Fig. 70). While holding strut shaft from turning,remove the strut shaft retaining nut.

(5) Remove the upper strut mount (Fig. 71) fromthe strut assembly.

(6) Release the coil spring from the spring com-pressor. Then remove the spring compressor from thecoil spring (Fig. 72).

(7) Remove the upper spring seat and the pivotbearing as an assembly from the coil spring (Fig. 72).Then remove the coil spring from the strut assembly.Mark left and right springs for installationback on correct side of vehicle.

(8) Remove the dust shield and the jounce bumper(Fig. 73) as an assembly from strut shaft. The dustshield can not be removed from the jounce bumper

Fig. 69 Compressing Strut Assembly Coil Spring

A60 TOP SHOE UPPERSPRING SEATSTRUT ASSEM-BLYA40 BOTTOM SHOESPECIAL TOOLGP-202052.5

SUSPENSION 2 - 31until after it is removed from strut shaft.

SPECIAL TOOL6864 10MMSOCKETSTRUT MOUNTUPPER STRUT MOUNT UPPER SPRING SEATCOIL SPRINGSPECIAL TOOLGP-202052.5UPPER SHOE OF SPRINGCOMPRESSORSTRUT SHAFT PIVOT BEARINGCOIL SPRINGUPPER SEATCOILSPRING JOUNCE BUMPER STRUT SHAFTDUST SHIELDSTRUT ASSEMBLY SPRINGSEAT STRUT ASSEMBLYCOIL SPRING ISOLA-TORRETAININGTABS (2)

2 - 32 SUSPENSION(9) Remove the jounce bumper from the dust

Fig. 70 Strut Shaft Retaining Nut Removal Tools

Fig. 71 Strut Assembly Upper Mount

Fig. 72 Strut Assembly Pivot Bearing And SpringSeat

DISASSEMBLY AND ASSEMBLY (Continued)shield. Jounce bumper is removed from dust shieldby collapsing dust shield until jounce bumper can begrabbed onto and then pulled out of the dust boot.

(10) Remove the spring isolator from the strutassembly lower spring seat (Fig. 74).

(11) Inspect strut damper for any condition ofshaft binding over full stroke of the shaft.

(12) Inspect the strut mount and the upper springseat assembly for the following:

Mount for cracks and distortion and retainingstuds for any sign of damage.

Severe deterioration of rubber isolator, Binding strut assembly pivot bearing. If pivot

bearing is replaced it is to be installed with thelarger diameter end of bearing facing up.

Inspect dust shield for rips and/or deterioration. Inspect jounce bumper for cracks and signs of

deterioration.(13) Replace any components of the strut assembly

found to be worn or defective during the inspection,before re-assembling the strut.

Fig. 73 Dust Shield Jounce Bumper

Fig. 74 Strut Assembly Lower Spring Seat Isolator

NS/GS

STRUT SHAFT JOUNCE BUMPERSTRUTSPRING SEAT DUST BOOTSTRUT SHAFTJOUNCE BUMPERSTRUTNOTCH UPPER SPRINGSEATCOIL SPRINGCLEVISBRACKETEND OF BOTTOM COILPOSITIONED HERESPRING ISOLATOR

)ASSEMBLY(1) Clamp strut assembly in vise, with strut in a

vertical position. Do not clamp reservoir of strutassembly in vise, only clamp the strut assemblyin vise using clevis bracket (Fig. 68).

(2) Install the spring isolator on the strut lowerspring seat (Fig. 74). When installing the spring iso-lator, be sure the 2 retaining tabs on the spring iso-lator (Fig. 74) are installed in the 2 holes in thespring seat. When properly installed, the oversizeholes in the spring seat should line up with the holesin the spring isolator.

WARNING: IF A REPLACEMENT COIL SPRING ISTO BE INSTALLED ON THE STRUT ASSEMBLY, THEFIRST FULL TOP AND BOTTOM COIL OF THESPRING MUST BE CAPTURED BY THE JAWS OFTHE COIL SPRING COMPRESSOR.

(3) Install the jounce bumper (Fig. 75) on the shaftof the strut assembly. Jounce bumper is to beinstalled with the small end of the jounce bumperpointing down (Fig. 75).

(4) Install the dust shield (Fig. 76) on the strutassembly. After dust shield is installed on strut,collapse dust shield down on top of jouncebumper until jounce bumper snaps into dustshield. Then return the dust shield to its fullyextended length.

(5) Install coil spring onto strut. Spring is to beinstalled with the end of the bottom coil aligned withthe clevis bracket on the strut assembly (Fig. 77).

(6) Install the upper spring seat on the coil spring(Fig. 77). Spring seat must be installed with thenotch in the spring seat (Fig. 77) aligned with theclevis bracket on the strut assembly.

(7) Compress strut assembly coil spring, using Pro-

Fig. 75 Correctly Installed Jounce Bumper

NS/GS

DISASSEMBLY AND ASSEMBLY (Continuedfessional Service Spring Compressor, GP2020S2.5or an equivalent (Fig. 72). Use the A60 top shoe tograb upper spring seat and A40 bottom shoe to grabcoil spring (Fig. 72).

(8) Install the strut assembly pivot bearing on thetop of the upper spring seat (Fig. 78). Bearing mustbe installed on spring seat with the smallerdiameter side of the pivot bearing toward thespring seat (Fig. 78). Also, be sure the pivotbearing is sitting flat on the spring seat.

(9) Install the strut mount on the upper springseat of the strut assembly. Then loosely install thenut on strut shaft.

WARNING: THE FOLLOWING 2 STEPS MUST BECOMPLETELY DONE BEFORE SPRING COMPRES-SOR IS RELEASED FROM THE COIL SPRING.

(10) Install Socket, Strut Nut, Special Tool 6864 onthe strut shaft retaining nut (Fig. 70). Then install a10 mm socket on the hex of the strut damper shaft

Fig. 76 Installing Dust Boot

Fig. 77 Coil Spring And Spring Seat CorrectlyInstalled

SUSPENSION 2 - 33(Fig. 70). While holding strut shaft from turning,

PIVOT BEARING STRUT SHAFTSMALLER DIAMETER OFPIVOT BEARINGUPPER SPRING SEATLOWER CONTROL ARM BALL JOINT STUDSEAL BOOTSCREW DRIVERBALL JOINT ASSEM-BLY BALL JOINT SEAL BOOT BALL JOINT STUDLOWER CONTROL ARMSHIELD

2 - 34 SUSPENSION NS/GS

)torque strut shaft retaining nut to 94 Nm (70 ft.lbs.).

(11) Loosen Spring Compressor, Special ToolGP-2020S2.5 until top coil of spring is fully seatedagainst upper spring seat. Then relieve all tensionfrom spring compressor and remove spring compres-sor from strut assembly spring.

(12) Install the strut assembly back in the vehicle.Refer to Mc Pherson Strut in the Removal AndInstallation Section in this group of the service man-ual for the required procedure to install the Mc Pher-son Strut.

BALL JOINT SEAL BOOT

REMOVE(1) Using a screw driver or other suitable tool, pry

the seal boot off of the ball joint assembly (Fig. 79)

Fig. 78 Installing Pivot Bearing On Upper SpringSeat

Fig. 79 Ball Joint Seal Boot Removal

DISASSEMBLY AND ASSEMBLY (ContinuedINSTALL

CAUTION: When installing the ball joint seal on theball joint/lower control arm, the shield (Fig. 80) onthe ball joint seal must be positioned as shown.

(1) Install a NEW seal boot by hand as far as pos-sible on the ball joint. Installation of the seal boot isto be with the shield positioned as shown (Fig. 80).

CAUTION: Do not use an arbor press to install thesealing boot on the ball joint. Damage to the seal-ing boot will occur if excessive pressure is appliedto the sealing boot when it is being installed.

(2) Place Installer, Special Tool 6758 over seal bootand squarely align it with bottom edge of seal boot(Fig. 81). Apply hand pressure to Special Tool 6758until seal boot is pressed squarely against top surfaceof lower control arm.

CAUTION: A replacement ball joint is not prelubri-cated. Properly lubricate the replacement ball jointusing Mopar MultiMile grease or an equivalent.Lubricate ball joint after seal boot is installed butprior to top of seal boot being pushed down belownotch in ball joint stud. Air must vent out of theseal boot at notch when grease is pumped into balljoint, failure to do so will balloon and damage sealboot. Do not over grease the ball joint, this will pre-vent the seal boot from pushing down on the studof the ball joint.

CAUTION: After the ball joint is properly greased,clip the end of the grease fitting off below the hex.The ball joint seal boot is non-purgeable and furthergreasing is not required and can result in damageto the seal boot.

Fig. 80 Ball Joint Seal Boot Installed Position

SHIELD SPECIAL TOOL 6758LOWER CONTROL ARMBALL JOINT SEAL BOOTTHRUSTBEARING SPECIAL TOOL69081 LOWER CONTROLARMNUTSPECIALTOOL 69082FRONT BUSH-INGSPECIAL TOOL69083THREADEDROD LOWER CONTROL ARM LOWER CONTROL ARMREAR BUSHINGRUBBERBLOCKSLOWER CONTROLARM FRONT BUSH-INGTHRUST WASHER SPECIAL TOOL 69085LOWER CONTROL ARMFRONT BUSH-INGNUTSPECIAL TOOL69084SPECIAL TOOL69089THREADEDROD

)LOWER CONTROL ARM FRONT BUSHING

REMOVE(1) Remove the lower control arm from the front

suspension cradle. Refer to Lower Control Arm in theRemoval And Installation Section in this section ofthe service manual for the required procedure.

(2) Securely mount the lower control arm in a vise.(3) Assemble for removal of the front bushing, the

Bushing Receiver, Special Tool 69082, BushingRemover, Special Tool 69081, Nut, Special Tool69083 thrust washer, threaded rod and small nut,as shown in (Fig. 82) on the lower control arm andfront bushing.

(4) To remove front bushing from lower controlarm, hold the threaded rod stationary and tightenthe Nut, Special Tool 69083 (Fig. 82). This will forcethe front bushing out of the lower control arm and

Fig. 81 Installing Ball Joint Seal Boot

Fig. 82 Tools Assembled For Removal Of FrontBushing

NS/GS

DISASSEMBLY AND ASSEMBLY (Continuedinto Bushing Receiver, Special Tool 69082 (Fig. 82).INSTALL(1) Securely mount the lower control arm in a vise.

NOTE: The lower control arm front bushing is adirectional bushing. It must be installed in the lowercontrol arm positioned as shown in (Fig. 83).

(2) Position the front bushing in the lower controlarm so that the 2 rubber blocks on the bushing arepositioned horizontally as shown in (Fig. 83).

(3) Assemble for installation of the front bushing,the Bushing Receiver, Special Tool 69085, BushingInstaller, Special Tool 69084, Nut, Special Tool69083 thrust washer, threaded rod and small nut,as shown in (Fig. 84) on the lower control arm andfront bushing.

(4) To install the front bushing in lower control

Fig. 83 Installation Position Of Lower Control ArmFront Bushing

Fig. 84 Tools Assembled For Installation Of FrontBushing

SUSPENSION 2 - 35arm, hold the threaded rod stationary and tighten

WHEN BUSHING IS CORRECTLYINSTALLED NO GAP IS TO BE VISIBLEBETWEEN BUSHING AND CONTROL ARMHERESPECIAL TOOL69084BUSHINGLOWER CON-TROL ARMSPECIAL TOOL69085 LOWER CONTROL ARMREAR BUSHINGSLIT CUT IN BUSHINGLOWER CONTROLARMROUND SURFACE OF BUSH-ING LOWER CONTROL ARMLOWER CONTROL ARMREAR BUSHINGUPSET