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Fig. 1 Strut Damper Removal

INSPECTION

Inspect for evidence of fluid running from the upper end of the reservoir. (Actual leakage will be a stream of fluid running down the side and dripping off lower end of unit). A slight amount of seepage between the strut rod and strut shaft seal is not unusual and does not affect performance of the strut assembly.

INSTALLATION

(1)Install unit into fender reinforcement and in-

stall retaining nuts and washer assemblies (Fig. 1). Tighten the 3 nuts to 27 NIm (20 ft. lbs.) torque.

(2)Position steering knuckle neck into strut assembly. Position washer plate and install cam and knuckle bolts (Fig. 1).

(3)Attach brake hose retainer to damper, tighten the screw to 13 NIm (10 ft. lbs.) torque (Fig. 1).

(4)Index strut to original outline on the knuckle neck, or align mark on cam bolt with the mark that was put on the strut to steering knuckle bracket (Fig. 1).

(5)Place a 4 inch (or larger) C clamp on the strut and knuckle as shown in (Fig. 2). Tighten the clamp just enough to eliminate any looseness between the knuckle and the strut. Check alignment of the index

marks and tighten the bolts to 100 NIm (75 ft. lbs.) plus 1/4 turn beyond specified torque. Remove the (C) clamp.

Fig. 2 Strut Damper Installation

(6) Install wheel and tire assembly. Tighten the wheel nuts to 129 NIm (95 ft. lbs.) torque.

DISASSEMBLY (STRUT DAMPER)

(1) Compress front coil spring with Spring Compressor, Special Tool C-4838 (Fig. 3).

Fig. 3 Compressing Coil Spring

(2)Hold end of strut shaft from rotating with wrench, while loosening strut shaft nut. Remove nut from shaft (Fig. 4).

(3)Remove the upper strut mount from the strut assembly.

(4)Remove coil spring from the strut assembly.

Mark spring for installation back on the same side of the vehicle (Fig. 8).

CAUTION: see Suspension Coil Springs before releasing coil from Tool C-4838.

(5) Inspect strut damper, mount assembly (Fig. 5) for:

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Fig. 4 Loosening Strut Assembly Shaft Nut

Fig. 5 Mount Assembly

(a)Severe deterioration of rubber isolator; retainers for cracks and distortion and bond failure of retainers and rubber isolators.

(b)Bearings for binding.

(c)Shock Absorber for flat spots over full stroke also see, Shock Absorbers, (strut damper).

ASSEMBLE (STRUT DAMPER)

(1)Mount the strut assembly in a vertical position.

(2)Place the compressed spring onto the strut assembly, so the end of the coil is seated in the seat recess in lower spring mount (Fig. 6).

(3)Install the dust shield, isolator (if so equipped) jounce bumper, spacer (as required), and spring seat onto the top of the strut shaft (Fig. 5).

(4)Position top spring seat alignment tab correctly with respect to bottom bracket (Fig. 6).

(5)Install the rebound retainer and shaft nut (Fig.

5).

SUSPENSION/DRIVESHAFTS 2 - 9

Fig. 6 Spring Seat Alignment Notch Position to Bracket

(6) Tighten the strut shaft nut using, Strut Rod Socket And Holder, Special Tool L-4558. Torque strut shaft nut to 75 NIm (55 ft. lbs.) plus 1/4 turn (Fig. 7).

WARNING: THIS STEP MUST BE DONE BEFORE SPRING COMPRESSOR, SPECIAL TOOL C-4838 IS RELEASED FROM THE COIL SPRING.

Fig. 7 Tighten Strut Rod Nut with Tool

(7)Verify coil spring is aligned correctly with respect to bottom bracket (Fig. 6).

(8)Release Spring Compressor Tool C-4838.

SUSPENSION COIL SPRINGS

Springs are rated separately for each side of vehicle depending on optional equipment and type of service. During service procedures where both springs are removed, mark springs (Chalk, Tape, etc.) (Fig. 8) to ensure installation in original position. If the coils springs require replacement. Be sure that the springs needing replacement, are replaced with springs meeting the correct load rating for the vehicle and its specific options.

During service procedures requiring the removal or installation of a coil spring with Spring

Fig. 8 Identifying Coil Springs

SPRING RETAINER UPPER

Ensure that upper spring retainer is positioned properly, see; step (5), Assemble (Strut Damper).

SPRING SEAT LOWER

During assembly of the coil spring to strut damper. Ensure that lower coil spring end is seated in strut damper spring seat recess refer to (Fig. 6) in assemble (Strut Damper) section.

SHOCK ABSORBERS (Strut Damper)

INSPECTION

Inspect for evidence of fluid leaking from around the strut assembly shaft seal at the upper end of the reservoir. (Actual leakage will be a stream of fluid running down the side and dripping off lower end of unit. A slight amount of seepage around the strut rod is not unusual and does not affect performance.

LOWER CONTROL ARM

The lower control arm if damaged, is serviced only as a complete component. Do not attempt to repair or straighten a broken or bent lower control arm.

The serviceable components of the lower control arm are, the ball joint assembly, and both pivot bushings. The service procedure to replace these components is detailed in the specific component sections of this group.

REMOVAL (ASSEMBLY)

(1)Raise vehicle. See Hoisting in Lubrication, Group 0 of this service manual.

(2)Remove the ball joint stud to steering knuckle clamp nut and bolt (Fig. 1).

Fig. 1 Control Arm To Steering Knuckle Attachment

(3)Remove the sway bar to lower control arm retainer on both sides of the vehicle (Fig. 2). Then rotate the sway bar down away from the lower control arms.

(4)Separate the steering knuckle from the ball joint stud (Fig. 1).

(5)Remove the front and rear control arm pivot bushing to crossmember attaching nuts and bolts (Fig. 2). Then remove the lower control arm from the crossmember.

CAUTION: Pulling steering knuckle out from vehicle after releasing from ball joint can separate inner C/V joint. See Driveshafts.

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Inspect lower control arm for distortion. Check bushings for severe deterioration.

INSTALLATION (ASSEMBLY)

(1)Position the lower control arm into the crossmember. Install front and rear pivot bushing to crossmember attaching bolts. Then loosely assemble nuts to bolts (Fig. 2).

(2)Install ball joint stud into steering knuckle and

install clamp bolt (Fig. 1). Tighten clamp bolt to 145 NIm (105 ft. lbs.).

(3)Position sway bar and bushings against the lower control arms. Install sway bar to control arm

retainers. Install retainer bolts and tighten nuts to 70 NIm (50 ft. lbs.).

(4)Lower vehicle so the suspension is supporting vehicles weight (control arm at design height).

Tighten the lower control arm to crossmember attaching bolts to 169 NIm (125 ft. lbs.) torque.

LOWER CONTROL ARM PIVOT BUSHINGS

When performing the replacement procedure on the lower control arm pivot bushings, the following sequence must be followed. When removing the pivot bushings from the lower control arm, the large bushing must be removed first then the small bushing. When installing the pivot bushings into the lower control arm, the small bushing must be installed first then the large bushing. This sequence must be used when removal and replacement of bushings is done using Bushing Remover/Installer, Special Tool 6602.

LARGE BUSHING

REMOVE

(1)Position and clamp lower control arm in a vise.

(2)Assemble the washer, thrust bearing and large bushing disk, Special tool 6602-5 onto the threaded rod from Bushing Remover/Installer, Special Tool 6602 (Fig. 3).

SUSPENSION/DRIVESHAFTS 2 - 11

(3) Install the tools assembled in step 2 above into the large bushing of the lower control arm (Fig. 4). Then assemble the remaining Special Tools, Cup 6602-2, thrust bearing, washer and long nut onto the threaded rod (Fig. 4) from Bushing Remover/Installer, Special Tool 6602.

Fig. 4 Tool Assembled For Bushing Removal

(4) Hold the long nut stationary. Using a deep socket turn the long threaded rod until the large pivot bushing is pushed out of the lower control arm.

SMALL BUSHING

REMOVE

(1)Remove the special tools from the lower control arm that were used for the removal of the large pivot bushing.

(2)Remove the large Bushing Disc, Special Tool 6602-5 from the threaded rod. Leave the thrust bearing and washer on the threaded rod. Install the small Bushing Disc, Special Tool 6602-3 on the threaded rod and against thrust bearing (Fig. 5).

Fig. 5 Bushing Removal Tools

Fig. 6 Tool Assembled For Bushing Removal

(4) Hold the threaded rod stationary and turn the long nut until the small pivot bushing is pulled out of the lower control arm.

SMALL BUSHING

INSTALL

(1)Remove the special tools from the lower control arm that were used for the removal of the small pivot bushing.

(2)On the threaded rod from Remover/Installer, Special Tool 6602 assemble the following pieces. Washer, thrust bearing, small bushing disc Special Tool 6602-3, small lower control arm pivot bushing and small bushing sizer, Special Tool 6602 (Fig. 7).

(3)Install the pieces assembled in step 2 through the small and large pivot bushing holes in the lower control arm. At the large pivot bushing hole in the lower control arm, assemble Cup, Special Tool 6602-2, thrust bearing, washer and nut (Fig. 8). Cup, Special Tool 6602-2 is to be installed on threaded rod with cup facing out and undercut in large bushing hole of lower control arm (Fig. 8). Lubricate the installer cone and new bushing using Mopart, Silicone Spray Lube or equivalent.

(4)Hold the threaded rod stationary and turn the long nut until the small pivot bushing is fully installed into the lower control arm. Be sure that the flanges of the bushing are fully expanded around the control arm bushing holes.

Fig. 7 Bushing Installing Tools Assembled

Fig. 8 Bushing And Tool Position For Installation In

Control Arm

LARGE BUSHING

INSTALL

(1)Remove the special tools from the lower control arm that were used for installing the small pivot bushing.

(2)On the threaded rod from Remover/Installer, Special Tool 6602 assemble the following pieces. Washer, thrust bearing, Cup Special Tool 6602-2 (Fig. 9).

(3)Install the pieces assembled in step 2 through the hole in the small pivot bushing and the large pivot bushing hole in the lower control arm. At the large pivot bushing hole in the lower control arm assemble the following special tool pieces. Large Bushing Sizer, Special Tool 6602-4, large lower control arm pivot bushing, large bushing disc Special Tool 6602-5, thrust bearing, washer and nut (Fig. 10). Lubricate the installer cone and new bushing using Mopart Silicone Spray Lube or equivalent.

(4)Hold the threaded rod stationary and turn the long nut until the bushing is fully installed into the