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SUSPENSION

TABLE OF CONTENTS

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ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1FRONT SUSPENSION - 4x2 . . . . . . . . . . . . . . . . . . 6

FRONT SUSPENSION - 4x4 . . . . . . . . . . . . . . . . . 1 4REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . 23

ALIGNMENT

TABLE OF CONTENTS

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DESCRIPTION AND OPERATION

WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . 1DIAGNOSIS AND TESTING

PRE-ALIGNMENT INSPECTION. . . . . . . . . . . . . . . 2SERVICE PROCEDURES

SUSPENSION HEIGHT- 4x4. . . . . . . . . . . . . . . . . . 3

WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . 4

SPECIFICATIONSALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5


WHEEL ALIGNMENT

DESCRIPTIONWheel alignment involves the correct positioning of

the wheels in relation to the vehicle. The positioning

i s a c com p li s h ed t h r o ug h s u s pe n si on a n d s t e er i n g

l in k a g e a d ju s t men t s . An a l i gn m en t i s con s id er ed

essential for efficient steering, good directional stabil-

i t y a n d t o m i n i m iz e t i r e w e a r . Th e m o s t i m por t a n t

m ea s u r em en t s of a n a l i gn m en t a r e ca s t e r, ca m b er

and toe (Fig. 1).

CAUTION: Never attempt to modify suspension orsteering components by heating or bending.

NOTE: Periodic lubrication of the front suspension/

steering system components may be required. Rub-ber bushings must never be lubricated. Refer toGroup 0, Lubrication And Maintenance for the rec-ommended maintenance schedule.

OPERATION

CASTER i s t h e f or w a r d or r ea r w a r d t i l t of t h esteering knuckle from vertical . Tilt ing t he t op of the

knuckle forwa rd provides negative cast er. Tilt ing t he

top of the knuckle rearward provides positive caster.P os i t iv e ca s t e r p r om ot e s d i r ect i on a l s t a bi l it y. Th i s

a n g l e e n a bl es t h e f r on t w h e el s t o r e t u r n t o a s t r a i g h t

a h e a d p o s i t i o n a f t e r t u r n s .

CAMBER i s t h e i n w a r d o r o u t w a r d t i l t o f t h ewh eel relat ive to t he center of the vehicle. Tilt ing t he

t o p o f t h e w h e e l i n w a r d p r ov i de s n e g a t i v e ca m be r.

Tilting t he t op of the wheel outwa rd provides positive

ca m b er. I n cor r ect ca m b er w i l l ca u s e w e a r on t h e

inside or outside edge of the t ire.

TOE i s t h e d i ff er en ce b et w e en t h e l ea d i n gi n si de ed g es a n d t r a i li n g i n si de ed g es of t h e f r on t

tires. Wheel t oe position out of specificat ion causes

u n st a b l e s t eer i ng , u n ev en t i r e w e a r a n d s t eer i ngwh eel off- center. The wheel toe position is the finalfront wheel al ignment adjustment.

THRUST ANGLE i s t h e a n g l e o f t h e r e a r a x l er e la t i ve t o t h e ce n t er l in e of t h e v eh i cl e. I n c or r e ct

thrust angle can cause off-center steering and exces-

sive t ire wear. This angle is not adjustable, damaged

component(s) must be replaced t o correct the thrust

angle.

AN SU SPEN SI ON 2 - 1

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DIAGNOSIS AND TESTING

PRE-ALIGNMENT INSPECTIONB e f or e s t a r t i n g w h e el a l i gn m en t , t h e f ol low i n g

inspection an d necessary corrections must be com-

p le t ed . R ef er t o S u s pen s ion a n d S t e er i ng S y s t em

Di a g n o si s C h a r t f or a d d i t i on a l i n for m a t i o n .(1) I n s p ect t i r es f or s i ze , a i r p r es s u r e a n d t r e a d

w e a r .

(2) Inspect front wheel bearings for wear.

(3) Inspect front wheels for excessive radial or lat-

e r a l r u n o u t a n d ba l a n c e .

(4) I n s pe ct b a l l s t u ds , l in k a g e p iv ot p oi n t s a n d

steering gear for looseness, roughness or binding.

(5) I n s p ect s u s pe n si on com p on e n t s f or w e a r a n d

noise.

(6) On 4x4 vehicles check suspension height.

(7) Road test the vehicle.

SUSPENSION AND STEERING SYSTEM DIAGNOSIS

CONDITION POSSIBLE CAUSES CORRECTION

FRONT END NOISE 1. Loose or worn wheel bearing. 1. Replace wheel bearing.

2. Loose or worn steering orsuspension components.

2. Tighten or replace components asnecessary.

3. Lower ball joint (4x4). 3. Gease joint and perform diagnosis and

testing.

EXCESSIVE PLAY INSTEERING

1. Loose or worn wheel bearing. 1. Replace wheel bearing.

2. Loose or worn steering or

suspension components.

2. Tighten or replace components as

necessary.

3. Loose or worn steering gear. 3. Adjust or replace steering gear.

FRONT WHEELS SHIMMY 1. Loose or worn wheel bearing. 1. Replace wheel bearing.

2. Loose or worn steering or

suspension components.

2. Tighten or replace components as

necessary.

3. Tires worn or out of balance. 3. Replace or balance tires.

4. Alignment. 4. Align vehicle to specifications.

VEHICLE INSTABILITY 1. Loose or worn wheel bearing. 1. Replace wheel bearing.



3. Tire pressure. 3. Adjust tire pressure.


Fig. 1 Wheel Alignment Measurements1 FRONT OF VEHICLE

2 STEERING AXIS INCLINATION

3 PIVOT POINT

4 TOE-IN

2 - 2 SU SPEN SI ON AN

DESCRIPTION AND OPERATION (Continued)

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EXCESSIVE STEERINGEFFORT

1. Loose or worn steering gear. 1. Adjust or replace steering gear.

2. Column coupler binding. 2. Replace coupler.



VEHICLE PULLS TO ONESIDE





4. Radial tire lead. 4. Rotate or replace tire as necessary.

5. Brake pull. 5. Repair brake as necessary.

6. Weak or broken spring. 6. Replace spring.

7. Ride height 4WD only. 7. Measure and adjust ride height.

SERVICE PROCEDURES

SUSPENSION HEIGHT- 4x4The vehicle suspension height must be mea sured

a n d a d ju st e d i f n e ce ss a r y bef or e p er f or m i n g w h e e l

alignment on a 4x4 vehicle. Also when front suspen-

s i on com p on e n t s h a v e be r e pl a ce d . Th i s m e a s u r e

m u s t be p er f or m e d w i t h t h e v eh i cl e s u pp or t i n g i t s

o w n w e i g h t a n d t a k e n o n bo t h s i d e s o f t h e v e h i c l e .

HEIGHT MEASUREMENT

(1) I n s p ect t i r es f or t h e cor r e ct s i ze a n d a i r p r es -

sure.(2) J ounce the front of th e vehicle.

(3) M e a s u r e a n d r e cor d t h e d i s t a n ce bet w e e n t h e

g r o u n d a n d t h e c e n t e r o f t h e l o w e r s u s p e n s i o n a r m

rear mounting bolt head (Fig. 2).

(4) M e a s u r e a n d r e cor d t h e d i s t a n ce bet w e e n t h e

ground and the center of the front wheel (Fig. 2).

(5) S u bt r a c t t h e f ir s t m e a s u r em e n t f r om t h e s ec-

on d m e a s u r em e n t . Th e d i ff er e n ce bet w e e n t h e t w o

measurement should be 47 mm (1.85 inches) 3.25

mm (0.125 inches).

HEIGHT ADJUSTMENT

To a d ju s t t h e v eh i cl e h e i g h t t u r n t h e t o r si on ba ra d ju s t me nt b ol t C L O C K WI S E t o r a i s e t h e v eh i cl e

and COUNTER CLOCKWISE to lower the vehicle.

CAUTION: ALWAYS raise the vehicle to the correctsuspension height, NEVER lower the vehicle toobtain the correct suspension height. If the vehiclesuspension height is too high, lower the vehicle

below the height specification. Then raise the vehi-cle to the correct suspension height specification.

This will insure the vehicle maintains the propersuspension height.

NOTE: If a height adjustment has been made, per-form height measurement again on both sides of

the vehicle.

Fig. 2 Height Measurement


DIAGNOSIS AND TESTING (Continued)

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WHEEL ALIGNMENT

NOTE: 4x4 suspension height measurement must

be performed before alignment.

CAMBER AND CASTER ADJUSTMENT

C a m ber a n d ca s t er a n g le a d ju st m en t s i nv ol ve

ch a n g i n g t h e p os i t ion of t h e u p pe r s u s pe n si on a r m

pivot bar (Fig. 3).

NOTE: On 4x2 vehicles use Alignment Tool 8393 foralignment. The tool attaches to the pivot bar on the

upper control arm.

CASTER

Moving the rear position of the pivot bar in or out,

wil l change the caster angle significantly and camber

a n g l e on l y s li gh t l y. To m a i n t a i n t h e ca m b er a n g l e

while adjusting caster, move the rear of the pivot bar

i n or ou t . Th en m ov e t h e f ron t of t h e pi vot b a r

sl ightly in the opposite direction.

Fo r e x a m p le , t o i n c r ea s e a p os i t iv e c a s t e r a n g l e ,

m ov e t h e r ea r pos it ion of t h e piv ot b a r i nw a r d

(toward the engine). Move the front of pivot bar out-

w a r d (a w a y f r o m t h e e n g i n e ) s l i g h t l y u n t i l t h e o r i g i -

n a l c a m be r a n g l e i s o bt a i n e d .

CAMBER

Move the front of the pivot bar in or out. This wil l

ch a n g e t h e ca m b er a n g l e s ig n if ica n t l y a n d ca s t e r

an gle sl ightly.

Af t er a d ju s t me nt i s m a d e t i gh t e n t h e p iv ot b a r

nuts to proper torque specification.

TOE ADJUSTMENT

Th e w h e el t oe p os it i on a d ju s t me nt i s t h e f in a l

adjustment.

(1) S t a r t t h e en gi ne a n d t u rn w h eel s b ot h w a y s

bef or e s t r a i g h t e n in g t h e w h e e ls . Se cu r e t h e s t e er i n g

w h e el w i t h t h e f r on t w h e el s i n t h e s t r a i gh t -a h e a d

position.

(2) Loosen the t ie rod jam nuts.

NOTE: Each front wheel should be adjusted for

one-half of the total toe position specification. Thiswill ensure the steering wheel will be centered

when the wheels are positioned straight-ahead.

(3) Adjust the w heel toe position by t urning t he t ie

rod as necessary (Fig. 4).

(4) Ti g h t en t h e t i e r o d ja m n u t t o 7 5 N m (55 f t .lbs.).

(5) Verify the specifications.

(6) Turn off engin e.

Fig. 3 Caster & Camber Adjustment-Typical1 PIVOT BAR

2 + CASTER

3 + CAMBER

4 UPPER ARM SUSPENSION

Fig. 4 Toe Adjustment1 JAM NUT

2 TIE ROD

3 TIE ROD END


SERVICE PROCEDURES (Continued)

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SPECIFICATIONS

ALIGNMENT

VEHICLE WHEEL BASE CASTER ( 0.50) CAMBER ( 0.50) TOTAL TOE (

0.06)

4x2111.9 2.99 0.25 0.10

130.9 3.13 0.25 0.10

4x4111.9 3.16 0.25 0.10

130.9 3.27 0.25 0.10

MAXIMUM RT to LT DIFFERENCE 0.50 0.50 0.06

DAKOTA RT

VEHICLE WHEEL BASE CASTER ( 0.50) CAMBER ( 0.50) TOTAL TOE ( 0.06)

4x2111.9 3.67 0.34 0.10

130.9 3.81 0.34 0.10

MAXIMUM RT to LT DIFFERENCE 0.50 0.50 0.06

NOTE: All alignment specifications are in degrees.


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FRONT SUSPENSION - 4x2

TABLE OF CONTENTS

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DESCRIPTION AND OPERATIONFRONT SUSPENSION - 4X2 . . . . . . . . . . . . . . . . . 6

SHOCK ABSORBERS . . . . . . . . . . . . . . . . . . . . . . 6COIL SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . . . 7SUSPENSION ARMS . . . . . . . . . . . . . . . . . . . . . . . 7STABILIZER BAR. . . . . . . . . . . . . . . . . . . . . . . . . . 7

DIAGNOSIS AND TESTINGLOWER BALL JOINT . . . . . . . . . . . . . . . . . . . . . . . 7UPPER BALL JOINT . . . . . . . . . . . . . . . . . . . . . . . 8SHOCK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . 8

REMOVAL AND INSTALLATIONSHOCK ABSORBER. . . . . . . . . . . . . . . . . . . . . . . . 8

COIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . . . 9

LOWER SUSPENSION ARM . . . . . . . . . . . . . . . . 10UPPER SUSPENSION ARM . . . . . . . . . . . . . . . . . 10STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . 11HUB/BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . 11WHEEL MOUNTING STUDS. . . . . . . . . . . . . . . . . 12

SPECIFICATIONSTORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 12

SPECIAL TOOLSFRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . 13


FRONT SUSPENSION - 4X2

DESCRIPTION

Th e f r on t s u sp en s ion i s d es ig n ed t o a l l ow e a ch

w h e el t o a d a p t t o d if fe re nt r oa d s u rf a ce s i n de pe n-

d e n t l y . T h e w h e e l s a r e m o u n t e d t o h u b be a r i n g s o n

the cast iron steering knuckle spindles. The double-

r o w h u b be a r i n g s a r e s e a l e d a n d l u br i c a t e d f o r l i f e .

The steering knuckles turn (pivot) on ball joints riv-eted to the outboard portion of the suspension arms.

The ball joints are lubricated for l i fe.

The 4x2 front suspension is comprised of (Fig. 1) :

CAUTION: Components attached with a nut and

cotter pin must be torqued to specification. Then ifthe slot in the nut does not line up with the cotterpin hole, tighten nut until it is aligned. Never loosenthe nut to align the cotter pin hole.

CAUTION: Suspension components with rubber/

urethane bushings (except stabilizer bar) should betightened with the vehicle at normal ride height. It isimportant to have the springs supporting the weightof the vehicle when the fasteners are torqued. If

springs are not at their normal ride position, vehicleride comfort could be affected and premature bush-ing wear may occur.

Shock absorbers

Coil springs

Suspension arms

St a bi l i z e r ba r

J ounce/Rebound B umpers

Steering Knuckle

SHOCK ABSORBERS

DESCRIPTION

The top of the low-pressure gas charged shock are

b ol t ed t o t h e f r a m e. Th e b ot t om of t h e s h ock a r e

bolted to the lower suspension arm.

OPERATION

The shock absorbers dam pen jounce a nd rebound

of the vehicle over various road conditions.

Fig. 1 Front Suspension - 4X21 UPPER SUSPENSION ARM

2 STEERING KNUCKLE

3 COIL SPRING

4 LOWER SUSPENSION ARM

5 STABILIZER BAR


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COIL SPRINGS

DESCRIPTION

The springs mount between t he lower suspension

a r m s a n d f r a m e r a i l s p r i n g s e a t s . A r u bbe r i s o l a t o r

seats on top off the spring to help prevent noise.

OPERATION

Th e coi l s p r i n g s c on t r o l r i d e q u a l i t y a n d m a i n t a i n

proper ride h eight.

STEERING KNUCKLE

DESCRIPTION

The knuckle is a single casting with legs machined

for the upper and lower ball joints. The knuckle also

has machined mounting locations for the front brake

c a l i p e r s a n d h u b be a r i n g .

OPERATIONThe steering knuckle pivot between the upper and

l ow e r b a l l joi n t . S t e er i ng l in k a g e a t t a c h ed t o t h e

knuckle al lows the vehicle to be steered.

SUSPENSION ARMS

DESCRIPTION

The upper suspension arm bolts on frame brackets

t h r ou g h t h e a r m p iv ot s h a f t . Th e f r a m e b r a c ke t s

h a ve s lot t ed h oles w h ich a l low t h e a r ms t o b e

a d ju st e d f o r c a s t e r a n d ca m be r. P i v ot s h a f t bu s h in g s

are not replaceable.The lower suspension arms bolt to the lower frame

brackets and pivot through bushings, these bushings

are not replaceable.

The suspension arms have lube for l i fe riveted ball

studs. The suspension arm travel (jounce) is l imited

t h r ou gh t h e u se of u ret h a n e b um per s. R eb ou n d

travel is l imited by the shock absorber.

STABILIZER BAR

DESCRIPTION

T h e ba r e x t e n d s a c r o s s t h e f r o n t u n d e r s i d e o f t h e

ch a s s is a n d m ou n t s on t h e f r a m e r a i l s. L i nk s con -n e c t e d t h e ba r t o t h e l o w e r s u s p e n s i o n a r m s . St a bi -

l iz er b a r m ou n t s a r e i sol a t e d b y r u bb er b us h in g s.

L i n k s a r e i s ol a t e d w i t h r u bbe r g r o m m et s .

OPERATION

The st abil izer bar is used to minimize vehicle front

sway during turns. The spring steel bar helps to con-

t r o l t h e v eh i cl e bo d y i n r e la t i o n sh i p t o t h e s u s pe n -

sion.


LOWER BALL JOINT(1) Raise t he front of t he vehicle. Pla ce safety floor

s t a n d s u n d e r bo t h l o w e r s u s p e n s i o n a r m s a s f a r o u t -

b oa r d a s p os si bl e. L ow e r t h e v eh i cl e t o a l l ow t h e

stands to support some or al l of the vehicle weight.

NOTE: The upper suspension arms must not con-tact the rebound bumpers.

(2) Remove the t ire and wheel assemblies.

(3) Mount a dial indicat or solidly under t he lower

suspension arm.

(4) P os i t ion i n d ica t or p lu n g er a g a i n s t t h e bot t o m

of the steering knuckle lower ball joint boss.

NOTE: The dial indicator plunger must be perpen-dicular to the machined surface of the steering

knuckle lower ball joint boss (Fig. 2).

(5) P os it i on a p ry b a r ov er t h e t op of t h e u pp ersuspension arm and under the pivot bar of the upper

s u s p e n s i o n a r m . P r y d o w n o n t h e u p p e r s u s p e n s i o n

a r m a n d t h e n z e r o t h e d i a l i n d i c a t o r .

(6) Reposition the pry bar under t he upper suspen-

s i o n a r m a n d o n t o p o f t h e f r a m e r a i l . P r y u p o n t h e

u p p e r s u s p e n s i o n a r m a n d r e c o r d t h e d i a l i n d i c a t o r

reading.

(7) I f t h e t r a v el e xce ed s 1. 52 m m (0. 060 i n .),

replace the lower suspension arm.

Fig. 2 Lower Ball Joint Boss1 BALL JOINT BOSS

2 STEERING KNUCKLE

3 DIAL INDICATOR



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UPPER BALL JOINT(1) P os i t ion a f loor ja c k u n d er t h e l ow e r s u s pe n -

s ion a r m. R a is e t h e w h eel a n d a l low t h e t ir e t o

lightly contact the floor (vehicle weight relieved from

the t ire).

(2) Mount a dial indicator solidly on th e upper sus-

pension arm.(3) P o si t ion t h e i nd ica t or pl un ger a g a i ns t t h e

upper ball joint boss of the steering knuckle.

(4) G r a s p t h e t o p of t h e t i r e a n d a p p ly f o r ce i n a n d

out. Look for movement at the ball joint between the

upper suspension arm and steering knuckle.

(5) I f l a t e ra l m ov em en t i s g r ea t e r t h a n 1. 52 m m

(0.060 in.), replace upper suspension arm.

SHOCK DIAGNOSISA knocking or ra tt l ing noise from a shock absorber

m a y b e ca u s ed b y m ov em en t b et w e en m ou n t in g

b u sh i ng s a n d m et a l b r a ck et s or a t t a ch i ng com po-

nents. These noises can usually be stopped by t ight-en in g t h e a t t a ch in g n ut s. I f t h e n ois e per sis ts ,

i n s p e c t f o r d a m a g e d a n d w o r n bu s h i n g s , a n d a t t a c h -

i n g c o m p o n e n t s . R e p a i r a s n e c e s s a r y i f a n y o f t h e s e

conditions exist.

A squeaking noise from the shock absorber may be

ca u s e d by t h e h y d r a u l i c va l v i n g a n d m a y be i n t er m i t -

t e n t . Th i s c on d i t i on i s n o t r e pa i r a bl e a n d t h e s h ock

absorber must be replaced.

Th e s h ock a bs or ber s a r e n ot r e fi ll a bl e o r a d ju st -

a b l e. I f a m a l fu n ct i on occu r s, t h e s h ock a b s or b er

must be replaced. To test a shock a bsorber, hold it in

an upright position and force the piston in and out of

the cylinder four or five times. The action throughout

each stroke should be smooth and even.

Th e s h ock a bs or ber bu s h in g s d o n o t r e q u ir e a n y

t y p e o f l u br ica t i on . Do n o t a t t e m pt t o s t o p bu s h i n g

n oi se b y l ub r ica t i n g t h em . G r e a s e a n d m i ne ra l oi l-

ba s e l u br i ca n t s w i l l d e t e r ior a t e t h e bu s h in g .

REMOVAL AND INSTALLATION

SHOCK ABSORBER

REM OVAL

(1) R em ov e t h e u pp er s h ock n u t , r et a i n er a n d

grommet from the shock absorber stud (Fig. 3).

(2) Raise and support the vehicle.

(3) Remove th e lower mounting bolts a nd remove

s h ock a bs or ber t h r o ug h t h e l ow e r s u s pe n si on a r m

(Fig. 3).

INSTALLATION

NOTE: Upper shock nut must be replaced or use

Mopar Lock N Seal or Loctite 242 on existing nut.

(1) I n s t a l l t h e l ow e r r e t a i n er (lower retainer isstamped with a L) a n d g r om m et on t h e s hockabsorber stud and extend the shock. Insert the shock

a b sor ber t h r ou gh t h e l ow e r s us pen si on a r m a n d

upper mounting hole.

(2) I n s t a l l t h e l ow e r m o u n t i n g bol t s a n d t i g h t en t o

28 Nm (21 ft. lbs.).

(3) Remove support and lower the vehicle.

(4) Instal l the upper grommet and retainer (upperretainer is stamped with a U) on t h e s hocka bs o r be r s t u d . I n s t a l l a n e w n u t o r u s e M o p a r L o c k

N S eal or Locti te 242 on existing nut and t ighten to26 Nm (19 ft. lbs.).

COIL SPRING

REMOVAL


(2) Remove wheel and t ire assembly.

(3 ) R e m o v e t h e s t a bi l i z e r ba r l i n k f r o m t h e l o w e r

suspension arm.

(4) Remove the shock absorber.

(5) Install Spring Compressor DD-1278 up through

t h e l ow e r s u sp en s ion a r m , coi l s pr i ng a n d u pp er

shock mounting hole (Fig. 4).

(6) Tighten the tool lower nut to compress the coil

spring.

(7) R e m ov e t h e l ow e r ba l l joi n t n u t a n d s ep a r a t e

t h e b a ll join t fr om t h e k nu ck le w it h R em over

C-4150A (Fig. 5).

(8) L oos en t h e s pr i ng com pr es sor l ow e r n u t t o

relieve spring tension.

(9) R e m ov e t h e t o ol a n d p u ll d ow n on t h e l ow e r

suspension arm to remove the spring.

Fig. 3 Front Shock Absorber1 RETAINER

2 GROMMET

3 SHOCK ABSORBER



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INSTALLATION

NOTE: The ramped or open end of the coil springis the bottom of the spring.

(1) Ta p e t h e i sol a t or p a d t o t h e t op of t h e coi l

s pr i n g . P os i t ion t h e s pr i n g i n t h e l ow e r s u s pe n si on

a r m p o c k e t . B e s u r e t h a t t h e c o i l s p r i n g i s s e a t e d i n

the pocket.


t h e l ow e r s u s pe n si on a r m , coi l s pr i n g u p pe r s h ock

mounting hole.

(3) Ti gh t en t h e t ool n u t t o com pr es s t h e coi l

spring.

(4) Instal l the lower ball joint into the knuckle and

tighten the nut to 127 Nm (94 ft . lbs.). Instal l cotter

pin.

(5) Remove the spring compressor tool.

(6 ) I n s t a l l t h e s t a bi l i z e r ba r l i n k t o t h e l o w e r s u s -

pension arm and t ighten nut to 47 Nm (35 ft . lbs.).(7) Instal l the shock absorber.

(8) I n s t a l l t h e w h e e l a n d t i r e a s s em bl y.


STEERING KNUCKLE

REMOVAL


(2) Remove the wheel and t ire assembly.

(3) R e m ov e d i sc br a k e ca l i pe r, r ot o r, s h i el d a n d

ABS speed sensor, refer to Group 5 Brakes.

(4) R em ov e t i e -r od f r om s t e er i n g k n u ck le a r m ,

refer to Group 19 Steering.(5) Remove th e hub/bearin g.

(6) Remove the shock absorber.


t h e l ow e r s u sp en s ion a r m , coi l s pr i ng a n d u pp er

shock mounting hole (Fig. 4).

(8) Tighten the tool lower nut to compress the coil

spring.

(9) R e m ov e t h e l ow e r ba l l joi n t n u t a n d s ep a r a t e


C-4150A (Fig. 5).

(10) Remove the upper ball joint nut and separate


MB -991113 (F ig. 6).

CAUTION: When install Remover MB-991113 to sep-arate the ball joint, be careful not to damage theball joint seal.

(11) Remove steering knuckle.

Fig. 4 Spring Compressor1 COIL SPRING


3 SPRING COMPRESSOR

Fig. 5 Lower Ball Joint1 LOWER BALL JOINT

2 REMOVER

3 STEERING KNUCKLE


REMOVAL AND INSTALLATION (Continued)

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INSTALLATION

(1) Position steering knuckle on upper an d lower

ball joints a nd inst al l nut s. Tighten lower nut to 127

Nm (94 ft. lbs.). Tighten upper nut to 81 Nm (60 ft.

l bs.) a n d i n s t a l l n e w cot t e r p in s .

(2) Remove the spring compressor.

(3) Instal l the shock absorber.

(4) Insta l l the hub/bearing.

(5) I n s t a l l AB S s pe ed s en s or , br a k e d u s t s h i el d ,

r ot o r a n d ca l i p er, r e fe r t o G r ou p 5 B r a k es .

(6) Instal l t ie rod to steering knuckle arm, refer toGroup 19 Steering.

(7) I n s t a l l t h e w h e el a n d t i r e a s s em bl y.

(8) Remove support and lower the vehicle

LOWER SUSPENSION ARM

REM OVAL

(1) Raise and support vehicle.


(3) Remove disc brake caliper and rotor from steer-

i n g k n u c kl e, r e fe r t o G r ou p 5 B r a k es .

(4) Remove shock absorber.

(5) Remove stabil izer bar l ink from the lower sus-pension arm.

(6) Remove the coil spring.

(7) Remove lower suspension arm mounting bolts

(Fi g . 7 ) fr om t h e f r a m e m o u n t s a n d r e m ov e t h e a r m .

INSTALLATION

CAUTION: Frame mounting bolts must be installed

to their original location and orientation to avoiddamaging the steering rack boots.

(1) L oos ely a t t a ch s us pen sion a r m t o fr a memounts.

(2) Instal l the coil spring.

(3) Instal l the shock absorber.

(4 ) I n s t a l l s t a bi l i z e r ba r l i n k t o t h e l o w e r s u s p e n -

s i o n a r m a n d t i g h t e n n u t t o 4 7 N m (3 5 f t . l bs .)

(5) Instal l brake rotor and caliper, refer to Group 5

B r a k e s .

(6) I n s t a l l w h e e l a n d t i r e a s s em bly.


(8) Ti g h t en t h e f r on t s u s pe n si on a r m m ou n t i n g

nut to 175 Nm (130 ft . lbs.) and the rear nut to 108

Nm (80 ft. lbs.).

UPPER SUSPENSION ARM

REMOVAL



(3) Remove brake hose bracket from the arm.

(4) P os it i on a h y d ra u l ic j a ck u n d er t h e a r m a n d

raise the jack to unload the rebound bumper.

(5) R em ov e cot t e r p in a n d n u t f r om u pp er b a l l

joint.

(6) Separa te upper ba ll joint from steering knuckle

with Remover MB-991113 (Fig. 6).

CAUTION: When installing Remover MB-991113 toseparate the ball joint, be careful not to damage theball joint seal.

(7) R em ov e s u s pe n si on a r m p iv ot ba r m ou n t i n g

nuts and remove suspension arm (Fig. 8).

INSTALLATION

NOTE: Before installation, insure pivot bar adjust-ment bolts are in their original location (Fig. 8).

Fig. 6 Upper Ball Joint1 UPPER BALL JOINT

2 REMOVER

3 KNUCKLE

Fig. 7 Lower Suspension Arm1 LOWER SUSPENSION ARM

2 FRAME MOUNTS

2 - 1 0 S USP ENSI ON AN


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(1) P os i t ion s u s pe n si on a r m p iv ot ba r on a d ju st -

ment bolts. Instal l nuts and t ighten to 210 Nm (155

ft. lbs.).

(2) Position steering knuckle on upper ball joint.

Ti g h t en t h e u p pe r ba l l joi n t n u t t o 81 N m (60 f t .

l bs .) a n d i n s t a l l a n e w c o t t e r p i n .(3) I n s t a l l t h e w h e el a n d t i r e a s s em bl y.

(4) Remove support and lower vehicle.

(5) Align front end to specifications.

STABILIZER BAR

REM OVAL


(2) Remove the upper l ink nut, retainer and grom-

met from each l ink.

(3) Remove the lower l ink nut from the lower sus-

pension arm on each side (Fig. 9).

(4) R e m ov e t h e s t a b il iz er b a r r et a i n er b ol t s a n dr em ov e t h e r et a i ner s a n d s t a bi li zer b a r f rom t h e

vehicle.

(5) Remove the bushings from the stabil izer bar.

INSTALLATION

(1) I n s t a l l t h e bu sh i n g s o n t h e s t a bi li z er ba r .

(2) I ns t a ll t h e s t a bi li zer b a r on t h e f ra m e a n d

i n s t a l l t h e r e t a i n e r s a n d t h e bo l t s .

(3) Tighten the bolts to 60 Nm (45 ft . lbs.).

NOTE: Ensure the bar is center with equal spacingon both sides.

(4) I n s t a l l t h e l i n k l o w e r r e t a i n e r a n d g r om m e t o n

the l inks.

(5) I n st a l l t h e l in ks i nt o t h e s t a bi li zer b a r a n d

lower suspension arm on each side.

(6) Instal l the lower l ink mounting nut and t ighten

to 47 Nm (35 ft. lbs.).

NOTE: Ensure both link end caps are facingstraight forward.

(7) I n s t a l l t h e u pp er l in k g r om m et , r et a i n er a n d

nut and t ighten to 37 Nm (27 ft . lbs.).


HUB/BEARING

REMOVAL



(3) R e m ov e br a k e ca l i p er, r ot o r, a n d AB S w h e e l

speed sensor i f equipped, refer to Group 5 Brakes.(4) R e m ov e h u b/bea r i n g s pi n d le n u t a n d d i sca r d

nut (Fig. 10).

CAUTION: The hub/bearing spindle nut can not bere-used.

(5) Slide hub/bearin g off spindle.

INSTALLATION

(1) Slide hub/bearin g on spindle.

Fig. 8 Upper Suspension Arm1 UPPER SUSPENSION ARM

2 STEERING KNUCKLE


Fig. 9 Stabilizer Bar1 RETAINER

2 GROMMET

3 STABILIZER LINK

4 STABILIZER BAR

AN S USPENSI ON 2 - 1 1


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(2) Instal l new s pi nd le n u t a n d t i gh t en t o 251Nm (185 ft. lbs.).

(3) I n st a l l b r a k e r ot or, ca l i pe r, a n d AB S w h e el

speed sensor i f equipped, refer to Group 5 Brakes.

(4) I n s t a l l w h e el a n d t i r e a s s em bl y.


WHEEL MOUNTING STUDS

CAUTION: Do not use a hammer to remove wheelstuds.

REM OVAL



(3) R em ov e b r a k e ca l i pe r, ca l i pe r a d a p t e r a n d

rotor, refer to Group 5 Brakes for procedure.

(4) Remove stud from hub with Remover C-4150A

(Fig. 11).

INSTALLATION

(1 ) I n s t a l l n e w s t u d i n t o h u b f l a n g e .

(2) I n s t a l l t h r ee w a s h e r s on t o s t u d, t h en i n st a l l

lu g n u t w it h t h e f la t s id e of t h e n u t a g a in st t h ew a s h e r s .

(3) Ti gh t e n l ug n u t u n t il t h e s t u d i s p ul le d i n t o

t h e h ub f la n g e. Ver if y t h a t t h e s t ud i s p roper ly

s e a t e d i n t o t h e f l a n g e .

(4 ) R e m o v e l u g n u t a n d w a s h e r s .

(5) Instal l the brake rotor, cal iper adapter, and cal-

iper, refer to Group 5 Brakes for procedure.

(6) I n s t a l l w h e el a n d t i r e a s se mb ly, u s e n e w l ug

n u t o n s t u d o r s t u d s t h a t w e r e r e p l a c e d .


SPECIFICATIONS

TORQUE CHART

DESCRIPTION TORQUE

Shock Absorber

U p p er Nu t . . . . . . . . . . . . . . . 26 Nm (19 f t . l bs .)

L ow e r B ol t s . . . . . . . . . . . . . . 28 Nm (21 f t . l bs .)

Lower Suspension Arm

Front Nut . . . . . . . . . . . . . . 175 Nm (130 ft . lbs.)

R e a r Nu t . . . . . . . . . . . . . . . 108 Nm (80 f t . l bs .)

B a l l J oi n t Nu t . . . . . . . . . . . 127 Nm (94 f t . l bs .)

Upper Suspension Arm

P i v ot S h a f t Nu t s . . . . . . . . 167 Nm (130 ft . l bs .)

P ivot S ha ft to Fra me Nuts . 210 Nm (155 ft . lbs.)

B a l l J oi n t Nu t . . . . . . . . . . . . 81 Nm (60 f t . l bs .)

Stabilizer Bar

Link U pper Nut . . . . . . . . . . . 37 Nm (27 ft . lbs.)

L i n k B a l l St u d Nu t . . . . . . . . 47 Nm (35 ft . l bs .)

R e t a i n er B ol t s . . . . . . . . . . . . 60 Nm (45 f t . l bs .)

Hub/Bearing

Spindle Nut . . . . . . . . . . . . . . 251 Nm (185 ft . lbs.)

Fig. 10 Hub/Bearing1 KNUCKLE

2 HUB/BEARING

3 SPINDLE NUT

Fig. 11 Wheel Stud Removal1 REMOVER

2 WHEEL STUD



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SPECIAL TOOLS

FRONT SUSPENSION

Compressor, Coil Spring DD-1278

Remover Ball Joint MB-991113

Remover Ball Joint C-4150A

Puller Tie Rod C-3894-A


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TABLE OF CONTENTS

page page

DESCRIPTION AND OPERATIONFRONT SUSPENSION - 4x4. . . . . . . . . . . . . . . . . 14

SHOCK ABSORBERS . . . . . . . . . . . . . . . . . . . . . 14TORSION BARS. . . . . . . . . . . . . . . . . . . . . . . . . . 15STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . . 15SUSPENSION ARMS . . . . . . . . . . . . . . . . . . . . . . 15STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . 15

DIAGNOSIS AND TESTINGLOWER BALL JOINT . . . . . . . . . . . . . . . . . . . . . . 15UPPER BALL JOINT. . . . . . . . . . . . . . . . . . . . . . . 15SHOCK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 16

SERVICE PROCEDURESLUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

REMOVAL AND INSTALLATIONSHOCK ABSORBER. . . . . . . . . . . . . . . . . . . . . . . 16

TORSION BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . 17STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . . 17LOWER SUSPENSION ARM . . . . . . . . . . . . . . . . 18UPPER SUSPENSION ARM . . . . . . . . . . . . . . . . . 19STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . 20

HUB/BEARING. . . . . . . . . . . . . . . . . . . . . . . . . . . 21WHEEL MOUNTING STUDS. . . . . . . . . . . . . . . . . 21


SPECIAL TOOLSFRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . 22



DESCRIPTION

Th e f r on t s u sp en s ion i s d es ig n ed t o a l l ow e a ch

w h e el t o a d a p t t o d if fe re nt r oa d s u rf a ce s i n de pe n-

d e n t ly. Th e w h e el s a r e m ou n t e d t o h u b/bea r i n g s

units bolted to cast steering knuckle. The double-row

h u b be a r i n g s a r e s e a l e d a n d l u br i c a t e d f o r l i f e . T h e

s t e er i n g k n u ck l es t u r n (p iv ot ) on ba l l joi n t s . Th eupper ball joint is r iveted to the outboard portion of

the suspension arm and lubricated for l i fe. The lower

ba l l joi n t i s p r es s ed i n t o t h e l ow e r s u s pe n si on a r m

and requires lubrication.

The 4x4 front suspension is comprised of (Fig. 1) :

Shock absorbers

Torsion-ba r sprin gs

Suspension arms

Steering knuckles

St a bi l i z e r ba r

J ounce/Rebou nd bum pers

CAUTION: Components attached with a nut andcotter pin must be torqued to specification. Then if

the slot in the nut does not line up with the cotterpin hole, tighten nut until it is aligned. Never loosenthe nut to align the cotter pin hole.

CAUTION: Suspension components with rubber/

urethane bushings (except stabilizer bar) should betightened with the vehicle at normal ride height. It isimportant to have the springs supporting the weightof the vehicle when the fasteners are torqued. If

springs are not at their normal ride position, vehicleride comfort could be affected and premature bush-ing wear may occur.

SHOCK ABSORBERS

DESCRIPTION

The top of the low-pressure gas charged shock are

b ol t ed t o t h e f r a m e. Th e b ot t om of t h e s h ock a r e

bolted to the lower suspension arm.

Fig. 1 Front Suspension - 4x41 UPPER SUSPENSION ARM

2 SHOCK ABSORBER

3 STABILIZER BAR


5 TORSION BAR


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OPERATION

The shock a bsorbers da mpen jounce an d rebound

of the vehicle over various road conditions.

TORSION BARS

DESCRIPTIONThe front of the bar mounts to the back side of the

l ow e r s u sp en s ion a r m . Th e r ea r e nd of t h e b a r i s

m ou n t ed i n a a n ch or t h a t r es t s i n t h e f r a m e c r os s-

member.

OPERATION

Th e t o r si on ba r s a r e u s ed t o con t r o l r i d e h e ig h t

a n d r id e q u a li t y. Th e v eh icl e h ei gh t i s a d ju st ed

t h r o u g h a n a n c h o r a d ju s t m e n t bo l t t h a t i n c r e a s e s o r

d e c r e a s e s t h e a n g l e o f t h e t o r s i o n ba r . I n c r e a s i n g o r

d ecr ea s i n g t h e b a r a n g l e c ha n g es t h e a n g l e of t h e

suspension arms.

STEERING KNUCKLE

DESCRIPTION

The knuckle is a single casting with legs machined

for the upper and lower ball joints. The knuckle also

has machined mounting locations for the front brake

c a l i p e r s a n d h u b be a r i n g .

OPERATION

The steering knuckle pivot between the upper and

l ow e r b a l l joi n t . S t e er i ng l in k a g e a t t a c h ed t o t h e

knuckle al lows the vehicle to be steered.

SUSPENSION ARMS

DESCRIPTION

The upper suspension arm bolts on frame brackets

t h r ou g h t h e a r m p iv ot s h a f t . Th e f r a m e b r a c ke t s

h a ve s lot t ed h oles w h ich a l low t h e a r ms t o b e

a d ju st e d f o r c a s t e r a n d ca m be r. P i v ot s h a f t bu s h in g s


The lower suspension arms bolt to the lower frame

brackets and pivot through bushings, these bushings


The suspension arms have lube for l i fe riveted ballstuds. The suspension arm travel (jounce) is l imited

t h r ou gh t h e u se of u ret h a n e b um per s. R eb ou n d

travel is l imited by the shock absorber.

STABILIZER BAR

DESCRIPTION

T h e ba r e x t e n d s a c r o s s t h e f r o n t u n d e r s i d e o f t h e

chassis and connects to the frame crossmember. The

e n d s o f t h e ba r m o u n t t o t h e l o w e r s u s p e n s i o n a r m .

All mounting points of the stabil izer bar are isolated

by bushings.

OPERATION

The st abil izer ba r is used to minimize vehicle front

s w a y d u r in g t u r n s. Th e b a r h el ps t o m a i n t a i n a f la t

a t t i t u d e t o t h e r o a d s u r f a c e .


LOWER BALL JOINT

NOTE: If the ball joint is equipped with a lubrica-tion fitting, grease the joint then road test the vehi-

cle before performing test.

(1) Raise t he front of t he vehicle. Pla ce safety floor

s t a n d s u n d e r bo t h l o w e r s u s p e n s i o n a r m s a s f a r o u t -

b oa r d a s p os si bl e. L ow e r t h e v eh i cl e t o a l l ow t h e

stands to support some or al l of the vehicle weight.

NOTE: The upper suspension arms must not con-tact the rebound bumpers.

(2) Remove the t ire and wheel assemblies.

(3) Mount a dial indicator solidly to the underside

of the lower suspension arm.

(4) P os i t ion i n d ica t or p lu n g er a g a i n s t t h e bot t o m

surface of the steering knuckle lower ball joint boss.

NOTE: The dial indicator plunger must be perpen-dicular to the machined surface of the steering

knuckle lower ball joint boss (Fig. 2).

(5) P os it i on a p ry b a r ov er t h e t op of t h e u pp er

suspension arm and under the pivot bar of the upper

s u s p e n s i o n a r m . P r y d o w n o n t h e u p p e r s u s p e n s i o n

a r m a n d t h e n z e r o t h e d i a l i n d i c a t o r .

(6) Reposition the pry bar under t he upper suspen-

sion ar m and on t op of th e jounce/rebound bracket.

P r y u p o n t h e u p p e r s u s p e n s i o n a r m a n d r e c o r d t h e

dial indicator reading.

(7) I f t h e t r a v el e xce ed s 1. 52 m m (0. 060 i n .),

replace the lower control arm.

UPPER BALL JOINT(1) P os i t ion a f loor ja c k u n d er t h e l ow e r s u s pe n -

s ion a r m. R a is e t h e w h eel a n d a l low t h e t i re t o

lightly contact the floor (vehicle weight relieved from

the t ire).

(2) Mount a dial indicator solidly on th e upper sus-

pension arm.

(3) Position the indicator plunger against the back

s id e of t h e u pper b a ll joi nt b os s of t h e s t eer in g

knuckle (Fig. 3).



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(4) G r a s p t h e t op of t h e t i re a n d pu ll ou t w a r d,

t h e n z er o t h e d i a l i n d ica t or .

(5) G r a s p t h e t o p of t h e t i r e a n d p us h i n w a r d a n d

record the dial indicator reading.

(6) I f l a t e ra l m ov em en t i s g r ea t e r t h a n 1. 52 m m

(0.060 in.), replace upper suspension arm.

SHOCK DIAGNOSISA knocking or rat t l ing noise from a shock a bsorber

m a y b e ca u s ed b y m ov em en t b et w e en m ou n ti ng


nents. These noises can usually be stopped by t ight-

en in g t h e a t t a ch in g n ut s. I f t h e n oi se per si st s,

i n s p e c t f o r d a m a g e d a n d w o r n bu s h i n g s , a n d a t t a c h -i n g c o m p o n e n t s . R e p a i r a s n e c e s s a r y i f a n y o f t h e s e

conditions exist.











Th e s h ock a bs or ber bu sh i n g s d o n o t r e q u ir e a n yt y p e o f l u br ica t i o n . Do n ot a t t e m pt t o s t o p bu s h i n g

n oi se b y l ub r ica t i n g t h e m. G r e a s e a n d m i ne ra l oi l-

ba s e l u br i ca n t s w i l l d e t e r i or a t e t h e bu s hi n g .

SERVICE PROCEDURES

LUBRICATIONPeriodic lubrication of the suspension system may

be required. Refer to G roup 0, Lubrication And Main-

tenance for the recommended maintenance schedule.


SHOCK ABSORBER

REMOVAL


(2) Remove the upper shock absorber nut, retainer

and grommet (Fig. 4).

(3) R e mov e t h e l ow e r bol t a n d r e mov e t h e s h ock

absorber.

INSTALLATION


Mopar Lock N Seal or Loctite 242 on existing nut.(1) I n s t a l l t h e l ow e r r e t a i n er (lower retainer is

stamped with a L) a n d g r om m et on t h e s hockabsorber stud. Insert the shock absorber through the

frame bracket hole.

(2) I n s t a l l t h e l ow e r b ol t a n d t i gh t en t h e b ol t t o

108 Nm (80 ft. lbs.).

Fig. 2 Lower Ball Joint Boss1 BALL JOINT BOSS

2 STEERING KNUCKLE

3 DIAL INDICATOR

Fig. 3 Upper Ball Joint Boss

1 DIAL INDICATOR2 BALL JOINT BOSS



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(3) I n s t a l l t h e u pp er g r om m et , r et a i n er (upperretainer is stamped with a U) a n d n e w n u t o r u s eMopar Lock N Seal or Locti te 242 on existing nut,

on t h e s h ock a bs or ber s t u d . Ti g h t en n u t t o 2 6 N m

(19 ft. lbs.).

TORSION BAR

CAUTION: The left and right side torsion bars areNOT interchangeable. The bars are identified and

stamped R or L, for right or left. The bars do nothave a front or rear end and can be installed witheither end facing forward.

REM OVAL

(1) R a i s e a n d s u pp or t t h e v eh i cl e w i t h t h e f r on t

suspension han ging.(2) Turn the adjustment bolt counterclockwise to

release spring load (Fig. 5).

NOTE: Count and record the number of turns forinstallation reference.

(3) Remove the adjustment bolt from swivel .

(4) Remove torsion bar and anchor. Remove anchor

from torsion bar.

(5) R e m ov e a l l f or e ig n m a t e r i a l f r om t o r si on ba r

m ou n t i n g i n a n c h or a n d s u s pe n si on a r m .

(6) Inspect adjustment bolt , bearing and swivel for

d a m a g e .

INSTALLATION

(1) Insert torsion bar ends into anchor and suspen-

s i o n a r m .

(2) P o s it i on a n ch or a n d b ea r i n g i n f r a m e cr os s-

m em b er. I n s t a l l a d ju s t men t b ol t t h r ou g h b ea r i n g,

a n c h o r a n d i n t o t h e s w i v e l .

(3) Turn adjustment bolt clockwise the recordeda m o u n t o f t u r n s .

(4) Lower vehicle a nd adjust the front suspension

height. Refer to Suspension Height service procedure.

STEERING KNUCKLE

REMOVAL



(3) R e m ov e br a k e ca l i p er, r ot o r, s h i el d a n d AB S

w h e el s pe ed s en s or i f e q ui pp ed . R ef er t o G r o up 5

B r a k e s .

(4) Remove front driveshaft , refer to Group 3 Dif-

ferential and Driveline.

(5 ) R e m o v e t i e r o d e n d c o t t e r p i n a n d n u t . Se p a -

r a t e t h e t i e r od f rom t h e k nu ck le w i t h R em ov er

MB -991113 (F ig. 6).

(6) S u ppor t t h e l ow e r s us pen si on a r m w i t h a

h yd ra u lic ja ck a n d r a is e t h e ja ck t o u nloa d t h e

rebound bumper.

(7) Remove the upper ball joint cotter pin and nut.

S epa r a t e t h e b a ll joi nt f rom t h e k nu ckle w it h

Remover MB-991113 (Fig. 7).

Fig. 4 Shock Absorber1 NUT

2 RETAINER

3 GROMMET

4 SHOCK

Fig. 5 Torsion Bar

1 SWIVEL2 ANCHOR

3 BEARING

4 ADJUSTMENT BOLT

5 TORSION BAR




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(8) Remove the lower ball joint cotter pin and nut.

S epa r a t e t h e b a ll join t fr om t h e k nu ck le w it h

Remover C-4150A (Fig. 8) and remove the knuckle.

(9) R em ov e t h e h u b/b ea r i n g f r om t h e s t ee ri n g

knuckle.

INSTALLATION

(1) I nsta l l t he h ub/bearing to t he st eering knuckle

and t ighten the bolts to 166 Nm (123 ft . lbs.).

NOTE: When installing hub/bearing with ABS

brakes, position the speed sensor opening towardsthe front of the vehicle.

CAUTION: The ball joint stud tapers must beCLEAN and DRY before installing the knuckle.

Clean the stud tapers with mineral spirits to removedirt and grease.

(2) I n s t a l l t h e k n u ck l e o nt o t h e u p pe r a n d l ow e r

ball joint.

(3) I n st a l l t h e u pp er a n d l ow e r b a l l joi n t n u t s.Ti g h t en t h e u p pe r ba l l joi n t n u t t o 81 N m (60 f t .

lbs.) and the lower ball joint nut to 183 Nm (135 ft .

l bs.) t h e n i n s t a l l cot t e r p in s . G r e a s e t h e l ow e r ba l l

joint.

(4) Remove the hydraulic jack from the lower sus-

pension arm.

( 5 ) I n s t a l l t h e t i e r o d e n d a n d t i g h t e n t h e n u t t o

88 Nm (65 ft . lbs.). Instal l the cotter pin.

(6) I n s t a l l t h e f r on t d r iv es h a f t , r ef er t o G r o up 3

Differential and Driveline.

(7) Instal l the ABS wheel speed sensor i f equipped

and brake shield, rotor and caliper. Refer to Group 5

B r a k e s .(8) I n s t a l l t h e w h e e l a n d t i r e a s s em bl y.


LOWER SUSPENSION ARM

REMOVAL


(2) Remove the wheel and t ire assembly.

(3) Remove front driveshaft , refer to Group 3 Dif-

ferentia l & Driveline.

(4) Remove torsion bar.

Fig. 6 Tie Rod End1 STEERING KNUCKLE

2 REMOVER

3 TIE ROD END

Fig. 7 Upper Ball Joint1 UPPER BALL STUD

2 REMOVER

Fig. 8 Lower Ball Joint1 REMOVER

2 LOWER BALL STUD



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(5) Remove shock absorber lower bolt.

(6) Remove st abil izer bar.

(7) Remove the cotter pin and nut from lower ball

joi n t . Se pa r a t e ba l l joi n t f r om t h e s t e er i n g k n u ck l e

with Remover C-4150A (Fig. 9).

(8) R e m ov e s u s pe n si on a r m p iv ot bol t s a n d s u s -

pension arm from frame rai l brackets (Fig. 10).(9) Inspect lower ball joint seal a nd replace i f dam-

aged. Pry off old seal with screw driver i f necessary.

INSTALLATION

(1 ) I n s t a l l n e w l o w e r ba l l jo i n t s e a l by t a p p i n g o n

a r o u n d t h e s e a l f l a n g e l i g h t l y w i t h a h a m m e r .

(2) Position the lower suspension arm at the frame

r a il b ra cket s. I n st a ll t h e piv ot b olt s a n d n ut s.

Tighten the nuts finger-tight.

CAUTION: The ball joint stud taper must be CLEAN

and DRY before installing the knuckle. Clean thestud taper with mineral spirits to remove dirt andgrease.

(3) I ns er t t h e b a l l joi n t i n t o s t eer i ng k n uck le.

Instal l and t ighten the retaining nut to 183 Nm (135

f t . l bs .) a n d i n s t a l l a n e w c o t t e r p i n .

(4) Instal l the torsion bar.

(5) Instal l shock absorber lower bolt and t ighten to

108 Nm (80 ft. lbs.).

(6) I n s t a l l t h e f r on t d r iv es h a f t . R ef er t o G r o up 3

Differentia l & Driveline.

(7) I n s t a l l t h e w h e e l a n d t i r e a s s em bl y.


(9) I n s t a l l t h e s t a bi l iz er ba r .

(10) Tighten the lower suspension front pivot nut

to 108 Nm (80 ft. lbs.). Tighten rear pivot bolt to 190

Nm (140 ft. lbs.).

(11) Adjust the front suspension height.

UPPER SUSPENSION ARM

REMOVAL



(3) Remove brake hose bra ckets from suspension

a r m , r e f e r t o Gr o u p 5 B r a k e s .

(4) P osition hydra ulic jack under lower suspension

a r m a n d r a i s e ja ck t o u n l oa d r e bou n d bu m pe r.

(5) Remove shock absorber.

(6) Remove the cotter pin and nut from upper ball

joint.(7) S ep a r a t e u pp er b a l l joi n t f r om t h e s t ee ri n g

knuckle with Remover MB-991113 (Fig. 11).


(8) R em ov e s u s pe n si on a r m p iv ot ba r bol t s a n d

remove suspension arm (Fig. 12).

INSTALLATION

(1) Position suspension arm pivot bar on mounting

bracket. Inst al l bolts a nd t ighten (tempora rily) to 136Nm (100 ft. lbs.).

(2) I n ser t b a ll joi nt i n s t eer in g k nu ck le a n d

t i g ht e n b a l l joi n t n u t t o 81 N m (60 f t . l bs .) t h e n

i n s t a l l a n e w c o t t e r p i n .

(3) Insta l l shock absorber.


Mopar Lock N Seal or Loctite 242 on existing nut.(4) Remove hydraulic jack.

Fig. 9 Lower Ball Joint1 REMOVER

2 LOWER BALL STUD

Fig. 10 Lower Suspension Arm1 PIVOT BOLTS




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(5) Attach brake hose brackets to suspension arm,

r e f e r t o Gr o u p 5 B r a k e s .

(6) Ti g h t en u p pe r s u s pe n si on a r m p iv ot bol t s t o

224 Nm (165 ft. lbs.).

(7) I n s t a l l t h e w h e el a n d t i r e a s s em bl y.(8) Remove support and lower vehicle.

(9) Align front suspension.

STABILIZER BAR

NOTE: To service the stabilizer bar the vehiclemust be on a drive on hoist. The vehicle suspen-sion must be at curb height for stabilizer bar instal-lation.

REMOVAL

(1) R e mov e t h e s t a bi l iz er ba r r e t a i n er bol t s f r om

the lower suspension arms (Fig. 13) and remove the

retainers.

(2 ) R e m o v e t h e s t a bi l i z e r ba r r e t a i n e r n u t s , bo l t s

and retainers from the frame crossmember (Fig. 13)

a n d r e m o v e t h e ba r .(3) If necessary, remove the bushings from the sta-

bil izer bar.

INSTALLATION(1 ) I f r e m o v e d , i n s t a l l t h e bu s h i n g s o n t h e s t a bi -

l izer bar.

(2 ) P o s i t i o n t h e s t a bi l i z e r ba r o n t h e f r a m e c r o s s -

m em b er b r a ck et s a n d i n st a l l t h e r e t a i n er s a n d n u t s

and bolts finger-tight (Fig. 13).

NOTE: Check the alignment of the bar to ensurethere is no interference with the either frame rail orchassis component. Spacing should be equal onboth sides.

(3 ) I n s t a l l t h e s t a bi l i z e r ba r t o t h e l o w e r s u s p e n -

s i o n a r m .

(4) I n s t a l l t h e r e t a i n e r s a n d bol t s t o t h e l ow e r s u s -

pension arm and t ighten to 34 Nm (25 ft . lbs.).

(5) Ti gh t en t h e f r a m e r et a i n er n u t s t o 190 N m

(140 ft. lbs.).

(6) Ti g h t en t h e f r a m e r e t a i n er bol t s t o 108 N m

(80 ft. lbs.).

Fig. 11 Separate Upper Ball Joint1 UPPER BALL STUD

2 REMOVER

Fig. 12 Upper Suspension Arm1 PIVOT BAR BOLT

2 UPPER SUSPENSION ARM

Fig. 13 Stabilizer Bar1 LOWER SUSPENSION ARM

2 FLAG NUT

3 STABILIZER BAR

4 RETAINER



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HUB/BEARING

REM OVAL



(3) Remove axle nut.

(4) Remove ABS wheel speed sensor i f equipped,r e f e r t o Gr o u p 5 B r a k e s .

(5) R e m ov e t h e br a k e ca l i p er a n d r ot o r, r e fe r t o

Gr o u p 5 B r a k e s .

(6) Remove hub/bearing mounting bolts from the

steering knuckle (Fig. 14).

(7) S l id h u b/bea r i n g ou t of t h e s t e er i n g k n u ck l e

a n d o f f t h e a x l e .

INSTALLATION

(1) I n st a l l t h e h u b/b ea r i ng i nt o t h e s t eer in g

k n uck le a n d t i gh t en t h e b ol t s t o 166 N m (123 f t .

lbs.).

(2) Instal l the brake rotor and caliper.

(3) Instal l ABS wheel speed sensor i f equipped.

(4) Instal l axle nut and t ighten to 235 Nm (173 ft .

lbs.).

(5) I n s t a l l w h e el a n d t i r e a s s em bl y.


WHEEL MOUNTING STUDS

CAUTION: Do not use a hammer to remove wheel

studs.

REMOVAL



(3) R em ov e b r a k e ca l i pe r, ca l i pe r a d a p t e r a n d

rotor, refer to Group 5 Brakes for procedure.

(4) Remove stud from hub with Remover C-4150A

(Fig. 15).

INSTALLATION

(1 ) I n s t a l l n e w s t u d i n t o h u b f l a n g e .

(2) I n s t a l l t h r ee w a s h e r s on t o s t u d, t h en i n st a l l

l ug n ut w it h t h e f la t s id e of t h e n u t a g a in st t h e

w a s h e r s .

(3) Ti gh t en l ug n u t u n t il t h e s t u d i s p ul le d i n t o

t h e h u b f la n g e. Ver if y t h a t t h e s t ud i s pr op er ly

s e a t e d i n t o t h e f l a n g e .

(4 ) R e m o v e l u g n u t a n d w a s h e r s .

(5) Instal l the brake rotor, cal iper adapter, and cal-

iper, refer to Group 5 Brakes for procedure.

(6) I n s t a l l w h e el a n d t i r e a s sem b ly, u s e n e w l ug

n u t o n s t u d o r s t u d s t h a t w e r e r e p l a c e d .


Fig. 14 Hub/Bearing1 HUB BEARING

2 STEERING KNUCKLE

Fig. 15 Wheel Stud Removal1 REMOVER

2 WHEEL STUD



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SPECIFICATIONS

TORQUE CHART

DESCRIPTION TORQUE

Shock Absorber

U p p er Nu t . . . . . . . . . . . . . . . 26 Nm (19 f t . l bs .)

Lower B olt . . . . . . . . . . . . . . 108 Nm (80 ft . lbs.)

Lower Suspension Arm

Fr on t B ol t . . . . . . . . . . . . . . 108 Nm (80 f t . l bs .)

Rear B olt . . . . . . . . . . . . . . 190 Nm (140 ft . lbs.)

B a l l J oi n t Nu t . . . . . . . . . . 183 Nm (135 f t . l bs .)

Upper Suspension Arm

P i v ot S h a f t Nu t s . . . . . . . . . 129 Nm (95 ft . l bs .)

P ivot S haft to Fra me Bolts . 224 Nm (165 ft . lbs.)

B a l l J oi n t Nu t . . . . . . . . . . . . 81 Nm (60 f t . l bs .)

Stabilizer Bar

Fr a m e R e t a i n e r B o lt . . . . . . 108 Nm (80 ft . l bs .)

Fra me Retainer Nut . . . . . . 190 Nm (140 ft . lbs.)Control Arm Reta iner Bolts . . 34 Nm (25 ft . lbs.)

Hub/Bearing

B olts . . . . . . . . . . . . . . . . . . 166 Nm (123 ft . lbs.)

SPECIAL TOOLS

FRONT SUSPENSION

Puller Tie Rod C-3894-A

Remover MB-991113

Remover C-4150A


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REAR SUSPENSION

TABLE OF CONTENTS

page page

DESCRIPTION AND OPERATIONREAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . 23

SHOCK ABSORBERS . . . . . . . . . . . . . . . . . . . . . 23STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . 23LEAF SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 23

DIAGNOSIS AND TESTINGSPRING AND SHOCK . . . . . . . . . . . . . . . . . . . . . 24

REMOVAL AND INSTALLATIONSHOCK ABSORBER. . . . . . . . . . . . . . . . . . . . . . . 24

STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . 24LEAF SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 25



REAR SUSPENSION

DESCRIPTION

The rear suspension is comprised of:

Drive Axle

Shock Absorbers

Stabil izer Bar (optional)

L e a f Sp r i n g s

CAUTION: A vehicle should always be loaded sothe vehicle weight center-line is located immedi-ately forward of the rear axle. Correct vehicle load-

ing provides proper front tire-to-road contact. Thisresults in maximum vehicle handling stability and

safety. Incorrect vehicle weight distribution cancause excessive tire tread wear, spring fatigue or

failure, and erratic steering.

CAUTION: Suspension components with rubber/urethane bushings should be tightened with thevehicle at normal ride height. It is important to have

the springs supporting the weight of the vehiclewhen the fasteners are torqued. This will maintainvehicle ride comfort and prevent premature bushingwear.

SHOCK ABSORBERS

DESCRIPTION

Th e t o p o f t h e s h ock a bs or ber s a r e bol t e d t o t h e

bod y cr os s m em ber. Th e bot t o m of t h e s h ock s a r e

b ol t ed t o t h e a x l e b r a c ket s . Th e a x l e b r a c ke t s a r e

s t a g g e r e d o n e a h e a d o f t h e a x l e a n d o n e be f i n d .

OPERATION

R i d e c on t r o l i s a c com p li s h ed t h r o ug h t h e u s e of

dual-action shock absorbers. The shocks dampen the

jounce and rebound as the vehicle travels over vari-ous road conditions.

STABILIZER BAR

DESCRIPTION

Th e s t a bi l iz er ba r (op t i on a l ) e xt e n d s a c r os s t h e

u n d e r s i d e o f t h e v e h i c l e a n d i s bo l t e d t o t h e t o p o f

t h e a x l e . L i n k s a t t h e e n d o f t h e b a r a r e b o l t e d t o

frame brackets.

OPERATION

The stabil izer bar is used to minimize vehicle body

roll . The spring steel bar helps to control the vehiclebody in relationship to the suspension.

LEAF SPRINGS

DESCRIPTION

The 4x2 rear suspension system uses a 4-leaf t wo

s t a g e or 5-l ea f s i n gl e s t a g e s p r in g s a n d a s ol id d r i ve

a x l e. Th e 4x 4 r e a r s u s pe n si on s y s t em u s es on l y a

4-leaf two stage spring and solid drive axle. The for-

w a r d e n d o f t h e s pr i n g s a r e m o u n t ed t o t h e bod y r a i l

h a n g e r s t h r ou g h r u bbe r bu s h i n g s. Th e r e a r w a r d e n d

o f t h e s p r i n g s a r e a t t a c h e d t o t h e bo d y by t h e u s e o f

shackles. The spring and shackles use rubber bush-

ings. The bushing help to isolate road noise.

OPERATION

The springs control ride quali ty and maintain vehi-

cl e r i de h ei gh t . Th e s h a ck le s a l l ow t h e s pr i ng s t o

change t heir length as the vehicle moves over various

road conditions.


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SPRING AND SHOCKA knocking or ra tt l ing noise from a shock absorber

m a y b e ca u s ed b y m ov em en t b et w e en m ou n t in g


nents. These noises can usually be stopped by t ight-en in g t h e a t t a ch in g n ut s. I f t h e n ois e per sis ts ,

i n s p e c t f o r d a m a g e d a n d w o r n bu s h i n g s , a n d a t t a c h -

i n g c o m p o n e n t s . R e p a i r a s n e c e s s a r y i f a n y o f t h e s e

conditions exist.











The spring eye a nd shock a bsorber bushings do not

r eq u ir e a n y t y p e of l ub r ica t i on . D o n ot a t t e m pt t o

s t op s pr in g b us hi ng n oi se b y l ub ri ca t i ng t h em .Gr e a s e a n d m i n er a l oi l -ba s e l u br i ca n t s w i l l d e t er i o-

r a t e t h e bu s h in g r u bbe r.

If the vehicle is used for severe, off-road operation,

the springs should be examined periodically. Check

for broken and shifted leafs, loose and missing cl ips,

a n d br o k e n c e n t e r bo l t s . R e f e r t o Sp r i n g a n d Sh o c k

Absorber Diagnosis chart for additional information.

SPRING AND SHOCK ABSORBER


SPRING SAGS 1. Broken leaf. 1. Replace spring.

2. Spring fatigue. 2. Replace spring.

SPRING NOISE 1. Loose spring clamp bolts. 1. Tighten to specification.

2. Worn bushings. 2. Replace bushings.

3. Worn or missing spring tip inserts. 3. Replace spring tip inserts.

SHOCK NOISE 1. Loose mounting fastener. 1. Tighten to specification.

2. Worn bushings. 2. Replace shock.

3. Leaking shock. 3. Replace shock.


SHOCK ABSORBER

REM OVAL

(1) Raise vehicle and support rear axle.

(2) Remove shock absorber lower nut and bolt from

the axle bracket (Fig. 1).

(3) R em ov e s h ock a b s or b er u pp er n u t a n d b ol tf rom t h e f ra m e b ra cket a n d r em ov e t h e s hock

absorber.

INSTALLATION

(1) Insta l l shock a bsorber a nd upper mounting bolt

an d nut. Tighten n ut to 95 Nm (70 ft . lbs.).

(2) I n s t a l l s h ock a bs or ber i n t o t h e a x l e br a c ke t .

I n s t a l l t h e b o l t a n d n u t a n d t i g h t e n n u t t o 9 5 N m

(70 ft. lbs.).

(3) Remove axle support and lower vehicle.

STABILIZER BAR

REMOVAL


(2) R e m ov e n u t s a n d b ol t s f r om t h e l in k s a t t h e

stabil izer bar.

(3) Remove stabil izer bar retainer bolts and retain-

ers (Fig. 2).

(4) R em ov e s t a bi li zer b a r a n d r epl a ce w or n ,cracked or distorted bushings.

(5) R e m ov e l i n k s u p pe r m ou n t i n g n u t s a n d bol t s

and remove l inks.

INSTALLATION

(1) I n st a l l t h e s t a bi li zer b a r a n d cen t er i t w i t h

e q ua l s pa c in g on b ot h s id es . I n s t a l l s t a b il iz er b a r

retainers and t ighten bolts to 54 Nm (40 ft . lbs.).

(2 ) I n s t a l l l i n k i n t o f r a m e br a c k e t s a n d t h e s t a bi -

l i z e r ba r . I n s t a l l m o u n t i n g n u t s a n d bo l t s .



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(4) Ti g h t en s t a bi l iz er l in k n u t s t o 54 N m (40 f t .

lbs.).

LEAF SPRINGS

CAUTION: The rear of the vehicle must be lifted

only with a jack or hoist. The lift must be placedunder the frame rail crossmember located aft of therear axle. Use care to avoid bending the side rail

flange.

REMOVAL

(1 ) R a i s e t h e v e h i c l e a t t h e f r a m e .

(2) Use a hydraulic jack to relieve the axle weight.

(3) Remove the wheel and t ire assemblies.

(4 ) R e m o v e t h e n u t s , t h e U - bo l t s a n d s p r i n g p l a t e

from the axle (Fig. 3) and (Fig. 4).

(5) Remove the nut and bolt from the spring front

eye.

(6) Rem ov e t h e n u t a n d b ol t t h a t a t t a ch es t h e

s p ri n g s h a ck l e t o t h e r e a r f r a m e br a ck et .

(7) Remove the spring from the vehicle.(8) Remove the shackle from the spring.

Fig. 1 Shock Absorber1 SHOCK ABSORBER

2 MOUNTING BOLT

3 MOUNTING BOLT

Fig. 2 Stabilizer Bar Mounting1 STABILIZER BAR

2 LINK

3 RETAINER

Fig. 3 Leaf Spring - 4x2

1 JOUNCE BUMPER2 SHACKLE

3 PLATE

4 LEAF SPRING



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INSTALLATION

(1 ) I n s t a l l t h e s p r i n g s h a c k l e o n t h e s p r i n g f i n g e r

t i g h t .

(2) P o s it i on t h e s p r i n g o n t h e r e a r a x l e p a d . M a k es u re t h e s pr i ng ce nt e r b ol t i s i n ser t ed i n t h e p a d

locating hole.

(3) Align front spring eye with the bolt hole in the

f r o n t f r a m e br a c k e t . I n s t a l l t h e s p r i n g e y e bo l t a n d

n u t a n d t i g h t e n t h e s p r i n g e y e n u t f i n g e r - t i g h t .

(4) Align spring sha ckle eye w ith the bolt hole in

t h e r e a r f r a m e b r a c k e t . I n s t a l l t h e b o l t a n d n u t a n d

tighten the spring shackle eye nut finger-tight.

(5) I n st a l l t h e s pr i ng s ea t (4x 4 on l y), U -b ol t s,

s p r i n g p l a t e a n d n u t s .

(6) Ti g h t en t h e U -bol t n u t s t o 149 N m (110 f t .

lbs.).(7) I n s t a l l t h e w h e e l a n d t i r e a s s em bl ie s.

(8) R em ov e t h e s u pp or t s t a n d s f r om u n d er t h e

f r a m e r a i l s . L o w e r t h e v e h i c l e u n t i l t h e s p r i n g s a r e

supporting the weight of the vehicle.

(9) Ti g h t en t h e s pr i n g e y e p iv ot bol t n u t a n d a l l

shackle nuts to 163 Nm (120 ft . lbs.).

SPECIFICATIONS

TORQUE CHART

DESCRIPTION TORQUEShock Absorber

L ow e r B ol t . . . . . . . . . . . . . . . 95 N m (70 f t . l bs.)

U p p er B ol t . . . . . . . . . . . . . . . 95 N m (70 f t . l bs.)

Stabilizer Bar

Fr a m e B r a c k et Nu t s . . . . . . . 54 Nm (40 ft . l bs .)

L i n k Nu t s . . . . . . . . . . . . . . . 54 Nm (40 ft . l bs .)

R e t a i n er B ol t s . . . . . . . . . . . . 54 Nm (40 f t . l bs .)

Spring U-Bolt Nuts

2WD . . . . . . . . . . . . . . . . . . 149 Nm (110 ft . lbs.)

4WD . . . . . . . . . . . . . . . . . . 149 Nm (110 ft . lbs.)

Spring

Sp r i n g E y e Nu t . . . . . . . . . 163 Nm (120 f t . l bs .)Spring Sha ckle Nuts . . . . . 163 Nm (120 ft . lbs.)

J ounce Bumper

B o l t s . . . . . . . . . . . . . . . . . . . 61 Nm (45 ft . l bs .)

Fig. 4 Leaf Spring - 4x41 SHACKLE

2 JOUNCE BUMPER

3 SEAT

4 PLATE

5 LEAF SPRING



Documents

ER1_2.PDF