Chrysler Crossfire 2005, 2005 Crossfire SRT6 Service Manual

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GROUP TAB LOCATOR

Introduction
Lubrication & Maintenance

0

Suspension

2

Differential & Driveline

3

Brakes

5

Clutch

6

Cooling

7

Audio/Video
Chime/Buzzer
Electronic Control Modules
Engine Systems
Heated Systems
Horn
Ignition Control
Instrument Cluster
Lamps
Message Systems
Power Systems
Restraints
Speed Control
Vehicle Theft Security
Wipers/Washers
Wiring
Engine

9

Exhaust System
Frame & Bumpers
Fuel System
Steering
Transmission
Tires/Wheels
Body
Heating & Air Conditioning
Emissions Control
Component and System Index
DTC Index

Service Manual Comment Forms (Rear of Manual)

ZH INTRODUCTION 1

INTRODUCTION

TABLE OF CONTENTS

page page

VEHICLE IDENTIFICATION NUMBER

DESCRIPTION ..........................1

VEHICLE SAFETY CERTIFICATION LABEL

DESCRIPTION ..........................2

VECI LABEL

DESCRIPTION ..........................2

INTERNATIONAL SYMBOLS

DESCRIPTION ..........................3

FASTENER IDENTIFICATION

DESCRIPTION ..........................3

FASTENER USAGE

DESCRIPTION

FASTENER USAGE .....................6

THREADED HOLE REPAIR ...............6

METRIC SYSTEM

DESCRIPTION ..........................6

TORQUE REFERENCES

DESCRIPTION ..........................8

VEHICLE IDENTIFICATION NUMBER

DESCRIPTION

The Vehicle Identification Number (VIN) is located on the upper left corner of the dash panel, inside the windshield
opening. The VIN consists of 17 characters in a combination of letters and numbers that provide specific information
about the vehicle. Refer to the VIN Code Breakdown table for decoding information.

CROSSFIRE VIN CODE BREAKDOWN

POSITION INTERPRETATION CODE = DESCRIPTION

1 Country of Origin 1 = Manufactured By DaimlerChrysler Corporation
2 Make C = Chrysler
3 Vehicle Type 3 = Passenger Car
4 Other A = Restraint System Active Front And Side Air Bags
5 Car Line N = Crossfire (LHD)

P = Crossfire (RHD)

6 Series 6 = “S” Series

6 - International Transmission C = 6 Speed Manual (DED)

E = 5 Speed Automatic (DGU)
7 Body Style 9 = Specialty Coupe
8 Engines L = 3.2L V6 SOHC 18 Valve

N = 3.2L V6 Supercharged
9 Check Digit See explanation in this section

10 Model Year 5 = Model Year
11 Plant X = Osnabruck Germany

12 through 17 Sequence Number 6 Digit Sequential Number Assigned By Assembly Plant.

2 INTRODUCTION ZH

VEHICLE SAFETY CERTIFICATION LABEL

DESCRIPTION

A vehicle safety certification label is attached to every
DaimlerChrysler Corporation vehicle. The label certi­fies that the vehicle conforms to all applicable Federal
Motor Vehicle Safety Standards. The label is located
on the driver door shut-face.

All communications or inquiries regarding the vehicle
should include the Date of Manufacture, and the Vehi­cle Identification Number.

The Vehicle Safety Certification label contains the fol­lowing:

• Vehicle Identification Number (VIN)

• Date of Manufacture (month and year)

• Gross Vehicle Weight Rating (GVWR)

• Gross Axle Weight Rating (GAWR) Front

• Gross Axle Weight Rating (GAWR) Rear

• Month Day Hour (MDH)

VECI LABEL

DESCRIPTION

All models are equipped with a Vehicle Emission Con­trol Information (VECI) Label. DaimlerChrysler Corpo­ration permanently attaches the label in the engine
compartment. It cannot be removed without defacing
the information and destroying the label. The label
contains the vehicle’s emission specifications and vac­uum hose routings. All hoses must be connected and
routed according to the label.

The VECI label contains the following:

• Engine family and displacement

• Evaporative family

• Emission control system schematic

• Certification application

• Spark plug type and gap

ZH INTRODUCTION 3

INTERNATIONAL SYMBOLS

DESCRIPTION

The graphic symbols illustrated in the following International Control and Display Symbols Chart are used to identify
various instrument controls. The symbols correspond to the controls and displays that are located on the instrument
panel.

FASTENER IDENTIFICATION

DESCRIPTION

The SAE bolt strength grades range from grade 2 to grade 8. The higher the grade number, the greater the bolt
strength. Identification is determined by the line marks on the top of each bolt head. The actual bolt strength grade
corresponds to the number of line marks plus 2. The most commonly used metric bolt strength classes are 9.8 and

10.9. The metric strength class identification number is imprinted on the head of the bolt. The higher the class
number, the greater the bolt strength. Some metric nuts are imprinted with a single-digit strength class on the nut
face. Refer to the Fastener Identification and Fastener Strength Charts.

4 INTRODUCTION ZH

ZH INTRODUCTION 5

6 INTRODUCTION ZH

FASTENER USAGE

DESCRIPTION
FASTENER USAGE

WARNING: USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PERSONAL
INJURY.

Fasteners and torque specifications references in this Service Manual are identified in metric and SAE format.
During any maintenance or repair procedures, it is important to salvage all fasteners (nuts, bolts, etc.) for reassem-

bly. If the fastener is not salvageable, a fastener of equivalent specification must be used.

THREADED HOLE REPAIR

Most stripped threaded holes can be repaired using a HelicoilT. Follow the vehicle or HelicoilT recommendations for
application and repair procedures.

METRIC SYSTEM

DESCRIPTION

The metric system is based on quantities of one, ten, one hundred, one thousand and one million.
The following chart will assist in converting metric units to equivalent English and SAE units, or vise versa.

CONVERSION FORMULAS AND EQUIVALENT VALUES

MULTIPLY BY TO GET MULTIPLY BY TO GET

in-lbs x 0.11298 = Newton Meters (N·m) N·m x 8.851 = in-lbs
ft-lbs x 1.3558 = Newton Meters (N·m) N·m x 0.7376 = ft-lbs
Inches Hg (60° F) x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg
psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches
Feet x 0.3048 = Meters (M) M x 3.281 = Feet
Yards x 0.9144 = Meters M x 1.0936 = Yards
mph x 1.6093 = Kilometers/Hr. (Km/h) Km/h x 0.6214 = mph
Feet/Sec x 0.3048 = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec
mph x 0.4470 = Meters/Sec (M/S) M/S x 2.237 = mph
Kilometers/Hr. (Km/h) x 0.27778 = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr.

(Km/h)

COMMON METRIC EQUIVALENTS

1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters
1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter
1 Mile = 1.6 Kilometers

Refer to the Metric Conversion Chart to convert torque values listed in metric Newton- meters (N·m). Also, use the
chart to convert between millimeters (mm) and inches (in.).

ZH INTRODUCTION 7

8 INTRODUCTION ZH

TORQUE REFERENCES

DESCRIPTION

Individual torque charts appear within many of the groups. Refer to the Standard Torque Specifications Chart for
torque references not listed in the individual torque charts.

ZH LUBRICATION & MAINTENANCE 0 - 1

LUBRICATION & MAINTENANCE

TABLE OF CONTENTS

page page

INTERNATIONAL SYMBOLS

DESCRIPTION ..........................1

PARTS & LUBRICANT RECOMMENDATION

STANDARD PROCEDURE - PARTS AND

LUBRICANT RECOMMENDATIONS .........2

FLUID TYPES

DESCRIPTION

DESCRIPTION - ENGINE OIL AND

LUBRICANTS..........................2

DESCRIPTION - COOLANT ...............3

DESCRIPTION - TRANSMISSION FLUID .....4

DESCRIPTION -

DESCRIPTION - BRAKE FLUID ............5

DESCRIPTION - POWER STEERING FLUID . . 5

DESCRIPTION - FUEL REQUIREMENTS .....5

FLUID CAPACITIES

SPECIFICATIONS - FLUID CAPACITIES .......5

FLUID FILL/CHECK LOCATIONS

DESCRIPTION ..........................5

DIFFERENTIAL LUBRICANT

..5

INTERNATIONAL SYMBOLS

DESCRIPTION

DaimlerChrysler Corporation uses international sym­bols to identify engine compartment lubricant and fluid
inspection and fill locations.

LUBRICATION POINTS

DESCRIPTION ..........................6

MAINTENANCE SCHEDULES

DESCRIPTION

DESCRIPTION - FLEXIBLE SERVICE

SYSTEM (FSS) ........................6

DESCRIPTION - MAINTENANCE

SCHEDULES ..........................8

HOISTING

STANDARD PROCEDURE - HOISTING .......10

JUMP STARTING

STANDARD PROCEDURE -

EMERGENCY TOW HOOKS

DESCRIPTION .........................12

TOWING

STANDARD PROCEDURE - TOWING ........12

JUMP STARTING

..11

0 - 2 LUBRICATION & MAINTENANCE ZH

PARTS & LUBRICANT RECOMMENDATION

STANDARD PROCEDURE - PARTS AND LUBRICANT RECOMMENDATIONS

Lubricating grease is rated for quality and usage by
the NLGI. All approved products have the NLGI sym­bol on the label. At the bottom NLGI symbol is the
usage and quality identification letters. Wheel bearing
lubricant is identified by the letter “G”. Chassis lubri­cant is identified by the latter “L”. The letter following
the usage letter indicates the quality of the lubricant.
The associated symbols indicate the highest quality.

When service is required, DaimlerChrysler Corporation
recommends that only MoparT brand parts, lubricants
and chemicals be used. Mopar provides the best engi­neered products for servicing DaimlerChrysler Corpo­ration vehicles.

FLUID TYPES

DESCRIPTION
DESCRIPTION - ENGINE OIL AND LUBRICANTS

WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTER­NAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH
SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS,
HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CON­TACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR
AREA.

When service is required, DaimlerChrysler Corporation recommends that only MoparT brand parts, lubricants and
chemicals be used. MoparT provides the best engineered products for servicing DaimlerChrysler Corporation vehi­cles.

Only lubricants bearing designations defined by the following organization should be used.

• Society of Automotive Engineers (SAE)

• American Petroleum Institute (API)

• National Lubricating Grease Institute (NLGI)

ZH LUBRICATION & MAINTENANCE 0 - 3

Use synthetic engine oils, approved to MB 229.3 or
MB 229.5, such as Mopar part number 05127394AA.
Synthetic SAE 0W-40 or SAE 5W-40 engine oils
approved to API SL and/or GF-3 may be substituted.
The FSS mat not alert for an oil change at the proper
interval if an unapproved product is used; engine dam­age and reduced engine life may result.

ENERGY CONSERVING OIL

An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CONSERVING
is located on the label of an engine oil container.

LUBRICANTS AND GREASES

Lubricating grease is rated for quality and usage by the NLGI. All approved products have the NLGI symbol on the
label. At the bottom of the NLGI symbol is the usage and quality identification letters. Wheel bearing lubricant is
identified by the letter “G”. Chassis lubricant is identified by the letter “L”. The letter following the usage letter indi­cates the quality of the lubricant.

SPECIALIZED LUBRICANTS AND OILS

Some maintenance or repair procedures may require the use of specialized lubricants or oils. Consult the appro­priate sections in this manual for the correct application of these lubricants.

DESCRIPTION - COOLANT

WARNING: ANTIFREEZE IS AN ETHYLENE-GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR
INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE
TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED
CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE­GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CON­TACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR
AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT
UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE
COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT.

CAUTION: Use of Propylene-Glycol based coolants is not recommended, as they provide less freeze pro­tection and less corrosion protection.

Use coolant approved to MB 325.0, such as Mopar part number 05066386AA, or an equivalent Extended Life Cool­ant with the Hybrid Organic Additive Technology (HOAT) inhibitor system.

The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder
head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/
fin radiator can transfer the heat to the air.

The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection.
MoparT Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MB 325.0), or the equivalent ethylene-glycol based cool­ant with organic corrosion inhibitors is recommended. This coolant offers the best engine cooling without corrosion
when mixed with 50% ethylene-glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses
color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution.

0 - 4 LUBRICATION & MAINTENANCE ZH

CAUTION: MoparT Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MB 325.0) may not be mixed with any
other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT), may result in
engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protec­tion.

COOLANT PERFORMANCE

The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle operating conditions.
The coolant performance of various mixtures follows:

Pure Water: Water can absorb more heat than a mixture of water and ethylene-glycol. This is for purpose of heat
transfer only. Water also freezes at a higher temperature and allows corrosion.

100 percent Ethylene-Glycol: The corrosion inhibiting additives in ethylene-glycol need the presence of water to
dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as
high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature
can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F).

50/50 Ethylene-Glycol and Water: Is the recommended mixture, it provides protection against freezing to -37°C
(-35°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If per­centage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided with a
68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will
freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because
specific heat of antifreeze is lower than that of water.

CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause prob­lems associated with 100 percent ethylene-glycol.

COOLANT SELECTION AND ADDITIVES

The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only
MoparT Antifreeze/Coolant, 5 Year/100,000 Mile Formula is recommended. This coolant offers the best engine cool­ing without corrosion when mixed with 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color
or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution.

CAUTION: Do not use coolant additives that claim to improve engine cooling.

DESCRIPTION - TRANSMISSION FLUID

Automatic Transmission Fluid

Note: Refer to the maintenance schedules for the recommended maintenance (fluid/filter change) intervals
for this transmission.

Note: For fluid level checking procedures, (Refer to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC - NAG1/
FLUID - STANDARD PROCEDURE) .

Use ATF approved to MB 236.10, MB 236.12, such as Mopar part number 05127382AA. Synthetic Dexron IIIT Auto­matic Transmission Fluid may be substituted.

FLUID ADDITIVES

DaimlerChrysler strongly recommends against the addition of any fluids to the transmission, other than those auto­matic transmission fluids listed above. Exceptions to this policy are the use of special dyes to aid in detecting fluid
leaks.

Various “special” additives and supplements exist that claim to improve shift feel and/or quality. These additives and
others also claim to improve converter clutch operation and inhibit overheating, oxidation, varnish, and sludge.
These claims have not been supported to the satisfaction of DaimlerChrysler and these additives must not be
used. The use of transmission “sealers” should also be avoided, since they may adversely affect the integrity of
transmission seals.

ZH LUBRICATION & MAINTENANCE 0 - 5

Manual Transmission Fluid

No service is required or recommended for the manual transmission. If required, use fluid approved to MB 236.2.
SAE 5W-20 meeting API SL or GF-3 Engine Oil, such as Mopar part number 04761872AB, may be subsituted.

DESCRIPTION - DIFFERENTIAL LUBRICANT

Note: Refer to the Owner’s Manual for the recommended differential lubricant change intervals for this axle.

Use synthetic SAE 75W-85 axle lubricant that meets MB 231.1, such as Mopar 05126035AA. An SAE 80W-90
GL-5/MIL-2105-E Synthetic Axle Lubricant may be substituted. Reduced axle durability may result if an unapproved
product is used.

DESCRIPTION - BRAKE FLUID

Use brake fluid approved to MB 331.0, such as Mopar part number 0454925AC, or a DOT 4 brake fluid with: min­imum dry boiling point (ERBP) 500°F, minimum wet boiling point (WERBP) 356°F, maximum viscosity 1500 mm2/s,
conforming to FMVSS 116 and ISO 4925.

DESCRIPTION - POWER STEERING FLUID

No service required or recommended. Filled at the factory with Pentosin CHF 11S. Use Pentosin CHF 11S, Mopar
part number 05127381AA. Steering noise and reduced component life may result if an unapproved fluid is used.

DESCRIPTION - FUEL REQUIREMENTS

Crossfire engines require the use of unleaded fuel to reduce exhaust emissions. Use premium unleaded gasoline
having a minimum octane rating of 91 (R+M)/2. Higher octane premium unleaded gasoline can be used if desired.

FLUID CAPACITIES

SPECIFICATIONS - FLUID CAPACITIES

FLUID CAPACITY

Automatic Transmission Fluid 8.0 L (8.5 qts.)
Brake System 0.5 L (0.5 qts.)
Cooling System*

3.2L 11.2 L (11.8 qts.)

3.2L SRT 14.5 L (15.3 qts.)
Engine Oil W/ Filter 8.0 L (8.5 qts.)
Fuel 60.0 L (15.8 gal.)
Fuel Tank Reserve 8.0 L (2.1 gal.)
Manual Transmission Fluid 1.8 L (1.9 qts.)
Power Steering 1.0 L (1.1 qts.)
Rear Axle 1.3 L (1.4 qts.)
Windshield Washer Reservoir 7.0 L (7.4 qts.)

* Includes heater and coolant recovery bottle filled to MAX level.

FLUID FILL/CHECK LOCATIONS

DESCRIPTION

The fluid fill/check locations are noted, and located in each of the applicable Service Information sections.

0 - 6 LUBRICATION & MAINTENANCE ZH

LUBRICATION POINTS

DESCRIPTION

Lubrication points are noted, and located in each of the applicable Service Information sections.

MAINTENANCE SCHEDULES

DESCRIPTION
DESCRIPTION - FLEXIBLE SERVICE SYSTEM (FSS)

The Flexible Service System (FSS) is a demand-acti­vated engine oil service system. The FSS will illumi­nate a symbol (2) in the instrument cluster to indicate
to the driver when a particular service is due. After a
level has dropped below a warning threshold, the
remaining distance or the remaining time and the tool
symbol (2) are displayed in the panel of the odometer.

The FSS is supplied the time intervals from the digital clock in the instrument cluster. The remaining information is
supplied by the Powertrain Control Module (PCM) and the Controller Antilock Brake (CAB) via the Controller Area
Network (CAN) data bus. The data required for FSS from the CAN includes the following:

• The four wheel speed sensors from the CAB.

• Coolant temperature from the PCM.

• Engine speed from the PCM.

• Load torque from the PCM.

TRIP ODOMETER, FSS INDICATOR

This display in the instrument cluster shows the distance traveled since last reset.
To reset:

• Press the button to the left of the display once (with the key in the ON/RUN position).

• Press the button twice (with the key removed or in the OFF/ACC position).

MAIN ODOMETER

This shows the total distance the vehicle has traveled.
The FSS permits a flexible service schedule that is directly related to the operating conditions of the vehicle.
There are two symbols which will appear in the main odometer display field prior to the next suggested service.

ZH LUBRICATION & MAINTENANCE 0 - 7

This symbol represents Service A.

The second symbol represents Service B.

Depending on operating conditions throughout the
year, the next service is calculated and displayed next
to the this symbol in days remaining before the next
service is required.

0 - 8 LUBRICATION & MAINTENANCE ZH

The next service may be calculated and displayed
next to this symbol as distance remaining before the
next service is required.

The counter can also be reset by any individual after the indicated service has been performed.
Perform the following to reset the counter:

1. Turn the ignition key to the ON/RUN position.

2. Within one second press the knob/button to the left of the display twice.

3. The present status for days remaining or distance traveled is displayed. Within ten seconds turn the key to
OFF.

4. Press and hold the knob/button to the left of the display, while turning the key to ON/RUN again. The present
status for days remaining or distance traveled is displayed once more. Continue to hold the knob/button to the left
of the display.

5. Release the knob/button to the left of the display. After approximately ten seconds, a tone sounds and the

display shows 7,000 miles (11,000 km) for approximately ten seconds.
If the FSS counter was inadvertently reset, the counter must be reset.
The message is displayed for approximately ten seconds when turning the key to the ON/RUN position, or while

driving when reaching the service warning threshold. It can be cancelled manually by pressing the knob/button to
the left of the display.

Once the suggested term has passed, the message, plus either the symbol for Service A or the symbol for Service
B preceded by a “–” (minus symbol) blinks for approximately thirty seconds and a tone sounds every time when
turning the key to the ON/RUN position.

The FSS display can also be called up for approximately ten seconds with the display illuminated by pressing the
knob/button to the left of the display twice within one second.

Note: When disconnecting the battery for one or more days at a time, such days will not be counted. Any
such days not counted by the FSS can be added.

The interval between services is determined by the type of vehicle operation. Driving at extreme speeds, and cold
starts combined with short distance driving in which the engine does not reach normal operating temperature,
reduce the interval between services.

DESCRIPTION - MAINTENANCE SCHEDULES

SCOPE OF WORK FOR “A” SCHEDULE MAINTENANCE SERVICE

Oil Change

• Change the oil and replace the oil filter

Maintenance

• Lubricate the hood hinges, hood latch, and secondary hood latch

• Reset the FSS Display

ZH LUBRICATION & MAINTENANCE 0 - 9

Function Check

• Horn, hazard warning flashers, turn signals, and indicator lamps

• Headlamps and exterior lighting

• Windshield wipers and washer system

Inspection

• Check front and rear brake pads for lining thickness

• Check tires for damage and general condition

• Check tire inflation pressures and correct if necessary

Fluid Levels

Check fluid levels for the following systems and correct if necessary. Should there be a loss of fluid that cannot be
explained by regular use, trace and eliminate the cause.

• Engine cooling system (check corrosion inhibitor/antifreeze)

• Hydraulic brake system

• Power steering system

• Windshield washer system

SCOPE OF WORK FOR “B” SCHEDULE MAINTENANCE SERVICE

Oil Change

• Change oil and replace filter

Maintenance

• Rotate tires

• Replace dust filter

• Lubricate hood hinges, latch, and secondary latch

• Reset FSS Display

Function Check

• Horn, hazard warning flashers, turn signals, and indicator lamps

• Headlamps and exterior lighting

• Windshield wipers and washer system

• Check seat belts for damage and proper function

• Test hydraulic brakes and check parking brake function

Inspection

• Check front and rear brake pads for lining thickness

• Check condition of front and rear brake discs

• Check tires for damage and general condition

• Check tire inflation pressures and correct if necessary

• Check major underbody components for leakage or damage (if there are signs of leakage, determine cause

and repair)

• Check condition of front axle ball joints and rubber boots

• Check condition of steering components and rubber boots

Check underhood components for leakage or damage (if there are signs of leakage determine cause and repair)

•

• Check condition of accessory drive belt

• Check headlamp aiming, adjust if necessary

• Check windshield wiper blades, replace if necessary

Fluid Levels

Check fluid levels for the following systems and correct if necessary. Should there be a loss of fluid that cannot be
explained by regular use, trace and eliminate the cause.

• Engine cooling system (check corrosion inhibitor/antifreeze)

• Hydraulic brake system

• Power steering system

• Windshield washer system

0 - 10 LUBRICATION & MAINTENANCE ZH

HOISTING

STANDARD PROCEDURE - HOISTING

WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN
THE ENGINE, TRANSMISSION OR REAR SUSPENSION IS REMOVED FROM A VEHICLE, THE CENTER OF
GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE. PROPERLY SUPPORT OR
SECURE VEHICLE TO HOISTING DEVICE WHEN THESE CONDITIONS EXIST.

CAUTION: Do not position hoisting device on suspension components, damage to vehicle can result.

The vehicle can be lifted with:

• A twin-post, chassis hoist.

• A ramp-type, drive-on hoist.

FLOOR JACK

When properly positioned, a floor jack can be used to lift the vehicle. Support the vehicle in the raised position with
jack stands at the front and rear ends of the frame rails.

CAUTION: Do not lift vehicle with a floor jack positioned under:

• An axle shaft.

• A body side sill.

• A steering linkage component.

• A drive shaft.

• The engine or transmission oil pan.

• A front suspension arm.

ZH LUBRICATION & MAINTENANCE 0 - 11

JUMP STARTING

STANDARD PROCEDURE - JUMP STARTING

WARNING: DO NOT JUMP START A FROZEN BATTERY, PERSONAL INJURY CAN RESULT.

WARNING: WHEN USING A HIGH OUTPUT BOOSTING DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO
EXCEED 16 VOLTS. REFER TO INSTRUCTIONS PROVIDED WITH DEVICE BEING USED.

WARNING: DO NOT JUMP START WHEN MAINTENANCE FREE BATTERY INDICATOR DOT IS YELLOW OR
BRIGHT COLOR.

WARNING: DO NOT JUMP START A VEHICLE WHEN THE BATTERY FLUID IS BELOW THE TOP OF LEAD
PLATES.

WARNING: DO NOT ALLOW JUMPER CABLE CLAMPS TO TOUCH EACH OTHER WHEN CONNECTED TO A
BOOSTER SOURCE.

WARNING: DO NOT USE OPEN FLAME NEAR BATTERY. REMOVE METALLIC JEWELRY WORN ON HANDS
OR WRISTS TO AVOID INJURY BY ACCIDENTAL ARCING OF BATTERY CURRENT.

CAUTION: When using another vehicle as a booster, do not allow vehicles to touch. Electrical systems can
be damaged on either vehicle.

TO JUMP START A DISABLED VEHICLE:

WARNING: SHIELD EYES AND FACE FROM BATTERIES AT ALL TIMES

CAUTION: If the cause of starting problem on disabled vehicle is severe, damage to booster vehicle charg­ing system can result.

1. Raise hood on disabled vehicle and visually inspect

engine compartment for:

• Battery cable clamp condition, clean if necessary.

• Frozen battery.

• Yellow or bright color test indicator, if equipped.

• Low battery fluid level.

• Generator drive belt condition and tension.

• Fuel fumes or leakage, correct if necessary.

2. When using another vehicle as a booster source,

park the booster vehicle within cable reach. Turn
off all accessories, set the parking brake, place the
automatic transmission in PARK or the manual
transmission in NEUTRAL and turn the ignition
OFF.

3. On disabled vehicle, place gear selector in park or

neutral and set park brake. Turn off all accessories.

4. Connect positive jumper cable (4) to positive (+)

terminal (5) of the disabled battery.

5. Connect other end of positive jumper cable (7) to positive terminal (+) booster battery.

6. Connect negative jumper cable to negative (-) terminal of the booster battery.

0 - 12 LUBRICATION & MAINTENANCE ZH

7. Make final connection of the negative (-) jumper cable (2) to the ENGINE GROUND (1) of disabled vehicle, away

from battery.

CAUTION: Do not crank the starter motor on the disabled vehicle for more than 15 seconds, the starter will
overheat and could fail.

8. Start the engine in the vehicle which has the booster battery, let the engine idle a few minutes.

9. Allow the battery in disabled vehicle to charge to at least 12.4 volts (75% charge) before attempting to start the

engine. If the engine does not start within 15 seconds, stop cranking engine and allow starter to cool (15 min­utes), before cranking again.

DISCONNECT JUMPER CABLES AS FOLLOWS:

1. Disconnect the negative (-) jumper cable from the engine ground on the disabled vehicle.

2. Disconnect the negative (-) jumper cable from the booster vehicle.

3. Disconnect positive (+) jumper cable from the battery positive (+) terminal on the disabled vehicle.

4. Disconnect positive (+) jumper cable from the battery positive (+) terminal on the booster vehicle.

EMERGENCY TOW HOOKS

DESCRIPTION

WARNING: REMAIN AT A SAFE DISTANCE FROM A VEHICLE THAT IS BEING TOWED VIA ITS TOW HOOKS.
THE TOW STRAPS/CHAINS COULD BREAK AND CAUSE SERIOUS INJURY.

The tow hooks should be used for EMERGENCY purposes only.
CAUTION: DO NOT USE EMERGENCY TOW HOOKS FOR TOW TRUCK HOOK-UP OR HIGHWAY TOWING.

TOWING

STANDARD PROCEDURE - TOWING

WARNINGS AND PRECAUTIONS

WARNING: DO NOT ALLOW TOWING ATTACHMENT DEVICES TO CONTACT THE FUEL TANK OR LINES,
FUEL LEAK CAN RESULT. DO NOT VENTURE UNDER A LIFTED VEHICLE IF NOT SUPPORTED PROPERLY
ON SAFETY STANDS. DO NOT ALLOW PASSENGERS TO RIDE IN A TOWED VEHICLE. USE A SAFETY
CHAIN THAT IS INDEPENDENT FROM THE TOWING ATTACHMENT DEVICE.

CAUTION: Do not damage brake lines, exhaust system, shock absorbers, sway bars, or any other under
vehicle components when attaching towing device to vehicle. Remove or secure loose or protruding objects
from a damaged vehicle before towing. Refer to state and local rules and regulations before towing a vehi­cle. Do not allow weight of towed vehicle to bear on lower fascia, grill or front structure.

CAUTION: To avoid damage to the front fascia and grille, the use of a flat bed towing device is recom­mended. DO NOT attempt to tow the vehicle from the front or the rear. Towing from the front is not possible
without sustaining damage to the nose/front fascia due to the extended distance between the wheels and
the pointed nose/front fascia. Towing from the rear is not possible without sustaining damage to the rear
fascia and the exhaust system.

ZH LUBRICATION & MAINTENANCE 0 - 13

TOWING RECOMMENDATIONS

Flat bed towing should be the only method used for the Chrysler Crossfire. The flat bed must have an approach
angle less then 13.3° or something must be used (such as wood slats) to raise the overall height of the vehicle
during loading.

GROUND CLEARANCE

CAUTION: If vehicle is towed with wheels removed, install lug nuts to retain brake rotors.

A towed vehicle should be raised until the lifted wheels are a minimum 100 mm (4 in.) from the ground. Be sure
there is at least 100 mm (4 in.) clearance between the tail pipe and the ground. If necessary, remove the wheels
from the lifted end of the vehicle and lower the vehicle closer to the ground, to increase the ground clearance at the
rear of the vehicle. Install lug nuts on wheel attaching studs to retain brake rotors.

ZH SUSPENSION 2 - 1

SUSPENSION

TABLE OF CONTENTS

page page

SUSPENSION

DIAGNOSIS AND TESTING - SUSPENSION

AND STEERING SYSTEM ................1

WHEEL ALIGNMENT ......................3

FRONT SUSPENSION .....................13

REAR SUSPENSION ......................44

SUSPENSION

DIAGNOSIS AND TESTING - SUSPENSION AND STEERING SYSTEM

CONDITION POSSIBLE CAUSES CORRECTION

FRONT END NOISE 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.

2. Loose or worn steering or
suspension components.

EXCESSIVE PLAY IN
STEERING

FRONT WHEELS SHIMMY 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.

1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.

2. Loose or worn steering or
suspension components.

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

2. Loose or worn steering or
suspension components.

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

4. Alignment. 4. Align vehicle to specifications.

5. Leaking steering dampener. 5. Replace steering dampener.

2. Tighten or replace components as
necessary.

2. Tighten or replace components as
necessary.

2. Tighten or replace components as
necessary.

VEHICLE INSTABILITY 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.

EXCESSIVE STEERING
EFFORT

VEHICLE PULLS TO ONE
SIDE DURING BRAKING

2. Loose or worn steering or
suspension components.

3. Tire pressure. 3. Adjust tire pressure.

4. Alignment. 4. Align vehicle to specifications.

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

2. Power steering fluid low. 2. Add fluid and repair leak.

3. Column coupler binding. 3. Replace coupler.

4. Tire pressure. 4. Adjust tire pressure.

5. Alignment. 5. Align vehicle to specifications.

1. Uneven tire pressure. 1. Adjust tire pressure.

2. Worn brake components. 2. Repair brakes as necessary.

3. Air in brake line. 3. Repair as necessary.

2. Tighten or replace components as
necessary.

2 - 2 SUSPENSION ZH

CONDITION POSSIBLE CAUSES CORRECTION

VEHICLE LEADS OR
DRIFTS FROM STRAIGHT
AHEAD DIRECTION ON
UNCROWNED ROAD

KNOCKING, RATTLING
OR SQUEAKING

IMPROPER TRACKING 1. Loose, worn or bent track bar. 1. Inspect, tighten or replace component as

1. Radial tire lead. 1. Cross front tires.

2. Brakes dragging. 2. Repair brake as necessary.

3. Weak or broken spring. 3. Replace spring.

4. Uneven tire pressure. 4. Adjust tire pressure.

5. Wheel Alignment. 5. Align vehicle.

6. Loose or worn steering or
suspension components.

7. Cross caster out of specification. 7. Align vehicle.

1. Worn shock bushings. 1. Replace shock.

2. Loose, worn or bent steering/
suspension components.

3. Worn shock valve. 3. Replace shock.

2. Loose, worn or bent steering/
suspension components.

6. Repair as necessary.

2. Inspect, tighten or replace components
as necessary.

necessary.

2. Inspect, tighten or replace components
as necessary.

ZH WHEEL ALIGNMENT 2 - 3

WHEEL ALIGNMENT

TABLE OF CONTENTS

page page

WHEEL ALIGNMENT

DESCRIPTION ..........................3

OPERATION ............................4

STANDARD PROCEDURE

STANDARD PROCEDURE - WHEEL

ALIGNMENT INSPECTION ................5

STANDARD PROCEDURE - CHASSIS

ALIGNMENT INSPECTION ................6

INSPECTING AND ADJUSTING VEHICLE

LEVEL AT FRONT AND REAR AXLES .......7

INSPECTING AND ADJUSTING VEHICLE

LEVEL AT FRONT AND REAR AXLES

WITH AN ELECTRONIC INCLINOMETER.....7

CHECKING AND ADJUSTING FRONT AXLE

CAMBER AND CASTER..................7

STANDARD PROCEDURE - CHECKING AND

ADJUSTING FRONT TOE-IN ..............9

STANDARD PROCEDURE - CHECKING

TOE-OUT ON TURNS ..................10

STANDARD PROCEDURE - CHECKING

REAR AXLE CAMBER ..................10

STANDARD PROCEDURE - CHECKING AND

ADJUSTING REAR AXLE TOE ............11

SPECIFICATIONS

SPECIFICATIONS - WHEEL ALIGNMENT . . . 12

SPECIFICATIONS - TORQUE ............12

WHEEL ALIGNMENT

DESCRIPTION

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

CAUTION: Components attached with a nut and cotter pin must be torqued to specification. Then if the slot
in the nut does not line up with the cotter pin hole, tighten nut until it is aligned. Never loosen the nut to
align the cotter pin hole.

Note: Periodic lubrication of the front suspension/steering system components may be required. Rubber
bushings must never be lubricated.

Note: Vehicles are delivered from the factory with pre-set caster, camber, and toe settings. When aligning a
vehicle with factory settings, Eccentric Repair Bolts must be installed in order to adjust caster or camber.
Toe is the only adjustment that can be made without installing the Eccentric Repair Bolts.

Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning is accom­plished through suspension and steering linkage adjustments. An alignment is considered essential for efficient
steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are
caster, camber and toe position.

2 - 4 WHEEL ALIGNMENT ZH

OPERATION

CASTER

Caster is the forward or rearward tilt of the steering
knuckle from vertical. Tilting the top of the knuckle
rearward provides positive caster. Tilting the top of the
knuckle forward provides negative caster. Caster is a
directional stability angle. This angle enables the front
wheels to return to a straight ahead position after
turns. (2) Indicates the spring location. (1) Is the
eccentric repair bolt for adjusting caster.

• +3 mm Range of adjustment ±25’ Caster.

CAMBER

Camber is the inward or outward tilt of the wheel rel­ative to the center of the vehicle. Tilting the top of the
wheel inward provides negative camber (NEG.). Tilting
the top of the wheel outward provides positive camber
(POS.). Incorrect camber will cause wear on the inside
or outside edge of the tire. (1) Indicates the spring
location. (2) Is the eccentric repair bolt for adjusting
camber.

• +3 mm Range of adjustment ±25’ Camber.

ZH WHEEL ALIGNMENT 2 - 5

WHEEL TOE POSITION

Toe is the difference between the leading inside edges
(1) and the trailing inside edges (2) of the front tires.
Incorrect wheel toe position is the most common
cause of unstable steering and uneven tire wear. The
wheel toe position is the final front wheel alignment
adjustment.

• Negative Toe (Toe Out):1>2.

• Positive Toe (Toe In):1<2.

TOE-OUT ON TURNS

Toe-out on turns is the relative positioning (1) of the
front wheels while steering through a turn. This com­pensates for each front wheel’s turning radius. As the
vehicle encounters a turn, the outboard wheel must
travel in a larger radius circle than the inboard wheel.
The steering system is designed to make each wheel
follow its particular radius circle. To accomplish this,
the front wheels must progressively toe outward as
the steering is turned from center. This eliminates tire
scrubbing and undue tire wear when steering a vehi­cle through a turn.

STEERING AXIS INCLINATION ANGLE

Is measured in degrees and is the angle that the steering knuckles are tilted. The inclination angle has a fixed
relationship with the camber angle. It will not change except when a spindle or ball stud is damaged or bent. The
angle is not adjustable, damaged component(s) must be replaced to correct the steering axis inclination angle.

STANDARD PROCEDURE
STANDARD PROCEDURE - WHEEL ALIGNMENT INSPECTION

1. Inspect the overall condition of the vehicle.

• The vehicle should be properly aligned and adjusted to a ready to drive condition in which it is most frequently
used. The chassis alignment inspection is carried out in reference to the vehicle level.

2. Use the measurement sheet for the chassis alignment inspection.

3. Inspect the tire condition.

2 - 6 WHEEL ALIGNMENT ZH

• Perform a visual inspection for wear pattern, tread depth and any damage to the tires.

4. Inspect the wheel condition

• Perform a visual inspection for any damage to the wheels.

5. Inspect the tire pressure.

• Compare the tire pressure from the door placcard to the current tire pressure, correct the tire pressures if
necessary.

6. Inspect the underside of the vehicle.

• Inspect for any damage, corrosion of chassis parts and supporting body parts, leaks from any components and
pipes.

7. Inspect the wheel bearing play.

Note: For the next step the vehicle must be sitting on its wheels.

8. Inspecting the condition of the steering mechanism.

• With the ignition OFF, inspect the steering wheel play. Permissible play around circumference of steering
wheel with steering in its center position is a maximum of .984 in. (25 mm).

• Inspect the play of the tie rods and the drag links.

• Inspect the track rod and drag link joints by pulling the tire back and forth with force or move steering

wheel from left to right and vice versa approx. 100 mm while having a second technician feel the
track rod and drag link joints.

Note: The right side of the drag link/tie rod is the pivot joint. This prevents any pivot movement in the drag
links. If any play exists replace the tie rod link or the drag link.

• Inspect the seals and condition of the rubber boots. If the rubber boot is not tight replace the tie rod link or
replace the drag link.

• Inspect the steering coupling. It must not have any play. If necessary, replace the steering coupling.

• Inspect the steering gear for play. If play exists, adjust the vehicle’s steering gear.

STANDARD PROCEDURE - CHASSIS ALIGNMENT INSPECTION

1. Observe the general information on chassis alignment inspection. (Refer to 2 - SUSPENSION/WHEEL ALIGN­MENT - STANDARD PROCEDURE).

2. Drive the vehicle onto an electronic measuring system.

3. Unlock the turntables and the sliding platforms.

4. Install a brake pedal winch on the brake pedal.

5. Attach the wheel sensors.

6. Perform the initial measurement process.

7. Inspect the vehicle level at the front and the rear axles and adjust if necessary. (Refer to 2 - SUSPENSION/
WHEEL ALIGNMENT - STANDARD PROCEDURE).

8. Inspect the vehicle level at the front and the rear axles with an electronic inclinometer and adjust if necessary.
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).

9. Inspect and adjust the rear axle toe. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCE­DURE).

10. Inspect and adjust the front axle camber and caster. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STAN-

DARD PROCEDURE).

11. Inspect the rear axle camber. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).

12. Inspect and adjust the front axle toe. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCE-

DURE).

13. Perform the final measurement of the vehicle.

14. Detach the sensors.

15. Remove the brake pedal winch.

16. Carefully drive the vehicle off the measuring system.

17. Lock the turntables.

ZH WHEEL ALIGNMENT 2 - 7

INSPECTING AND ADJUSTING VEHICLE LEVEL AT FRONT AND REAR AXLES

1. Observe the general information on chassis alignment inspection. (Refer to 2 - SUSPENSION/WHEEL ALIGN­MENT - STANDARD PROCEDURE).

2. Inspect the vehicle level at the front axle by performing the following:

• Insert measuring device between the retaining bolts of the lower control arm bearing.

• Position the contact arm of measuring device on the control arm and read off the plumb value of vehicle level,

viewed from the center of the vehicle. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PRO­CEDURE).

3. Inspect the vehicle level at the rear axle by performing the following:

• Loosen right rear frame brace and swivel to one side.

• Position contact arm on the rear axle shaft and read off the plumb value of the vehicle level, viewed from the

center of the vehicle. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).

Note: If the vehicle level at the front or rear axle is outside the tolerance, adjust the vehicle level by chang­ing the springs or spring rubber mounts.

4. Adjust the vehicle level at the front and rear axles.

INSPECTING AND ADJUSTING VEHICLE LEVEL AT FRONT AND REAR AXLES
WITH AN ELECTRONIC INCLINOMETER

1. Observe the general information on chassis alignment inspection. (Refer to 2 - SUSPENSION/WHEEL ALIGN­MENT - STANDARD PROCEDURE).

CAUTION: The measuring plate is magnetic. Information on data media, e.g. floppy disks, credit cards, etc.,
could be rendered unusable.

Note: Be sure to clean measurement points on the lower wishbone.

Note: Remove any metal shavings on the measuring plate.

2. Install the measuring plate in the recessed area in the lower control arm. The groove in the measuring plate
should be at an angle of 90° towards the direction of travel.

3. Inspect the vehicle level at the front axle via control arm inclination. (Refer to 2 - SUSPENSION/WHEEL ALIGN­MENT - STANDARD PROCEDURE).

4. Inspect the vehicle level at the rear axle via the rear axle shaft inclination. (Refer to 2 - SUSPENSION/WHEEL
ALIGNMENT - STANDARD PROCEDURE).

5. Adjust the vehicle level at the front and rear axles. If the vehicle level is outside the allowed tolerance at the front
or rear axle, perform the following:

• Adjust the vehicle level by changing the springs or the spring rubber mounts. (Refer to 2 - SUSPENSION/
WHEEL ALIGNMENT - STANDARD PROCEDURE).

CHECKING AND ADJUSTING FRONT AXLE CAMBER AND CASTER

CHECKING

1. Observe the general information on chassis alignment check. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT

- STANDARD PROCEDURE).

2. Check the vehicle level at the front and rear axles. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STAN­DARD PROCEDURE).

3. Check the vehicle level at the front and rear axles with an electronic inclinometer and adjust if necessary. (Refer
to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).

4. Check the camber and assign to tabular value. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - SPECIFICA­TIONS).

Note: Measure with the wheels turned to 20°.

2 - 8 WHEEL ALIGNMENT ZH

5. Check the caster and assign to tabular value. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - SPECIFICA­TIONS).

ADJUSTING

Note: Vehicles are delivered from the factory with pre-set caster, camber, and toe settings. When aligning a
vehicle with factory settings, Eccentric Repair Bolts must be installed in order to adjust caster or camber.
Toe is the only adjustment that can be made without installing the Eccentric Repair Bolts.

1. Raise and support the vehicle.

2. Cover all the attached parts remaining in the vehicle. (area to be repaired)

WARNING: RISK OF INJURY WITH TRAPPED OR CRUSHED FINGERS WHEN WORKING ON SPRINGS OR
SPRING-LOADED COMPONENTS.

CAUTION: Use only approved tensioning devices; additionally shield off hazardous area if necessary.

CAUTION: Inspect special tools for damage and proper operation (visual inspection). Wear protective
gloves.

Note: Inspect for prior installation of the eccentric
repair bolt.

3. For camber, compress the front spring (1). (Refer
to 2 - SUSPENSION/FRONT/SPRING ­REMOVAL).

4. Install the repair bolt (2). Screw on the nut from the
repair kit as far as it will go, but do not tighten it so
that the rubber mount on the wishbone can turn
when the suspension is compressed and
rebounded.

5. Release the front spring (1).

6. Lower the vehicle and settle the suspension by
pulling and pushing firmly several times.

Note: Inspect for prior installation of the eccentric
repair bolt.

7. For caster, compress the front spring (2). (Refer to
2 - SUSPENSION/FRONT/SPRING - REMOVAL).

8. Install the repair bolt (1). Screw on the nut from the
repair kit as far as it will go, but do not tighten it so
that the rubber mount on the wishbone can turn
when the suspension is compressed and
rebounded.

9. Release the front spring (2).

10. Lower the vehicle and settle the suspension by

pulling and pushing firmly several times.

ZH WHEEL ALIGNMENT 2 - 9

Note: The vehicle level must correlate with the dimension established on the initial measurement.

11. Recheck the vehicle level at the front axle after adjusting the camber and caster.

• Vehicle level at the front axle. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).

• With an electronic inclinometer. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCE-

DURE).

Note: After repairing, the adjusting screw must not be turned by the shims, and must be countered when
tightening the hexagon nut.

12. Tighten the nut from the repair kit to 120 N·m (88 ft. lbs.)

13. Adjust the rear axle toe. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).

14. Adjust the front axle toe. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).

STANDARD PROCEDURE - CHECKING AND ADJUSTING FRONT TOE-IN

1. Set the steering wheel in the center position.

Note: The steering gear is in the center position
when the separating joint of the steering coupling
and the marking notch on the steering gear are
above each other. Offset the steering wheel by a
maximum of one tooth, if necessary.

2. Check the center position of the steering gear and
steering wheel.

Note: The flexible mount of the control arms
results in a correspondingly large toe-in value
which reduces to the correct dimension in the
ready-to-drive condition

3. Install a steering wheel spreader on the inside of
the steering wheel in the forward direction of travel.

Note: After adjusting toe-in, check rubber boot on
inner joint for twisting.

4. Adjust the toe-in by rotating the tie rods. Tighten the lock nut to 50 N·m (37 ft. lbs.).

• Negative Toe (Toe Out)1>2.

• Positive Toe (Toe In)1<2.

2 - 10 WHEEL ALIGNMENT ZH

STANDARD PROCEDURE - CHECKING TOE-OUT ON TURNS

1. Check and adjust the toe-in at the front axle. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).

2. Check the toe-out on turns. To check steering geometry measure toe-out on turns. This is the difference in the
wheel angle between the wheel on the outside of a curve and the wheel on the inside of a curve when the wheel
on the inside of the curve is turned 20°. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PRO­CEDURE).

• Toe-in not adjusted with steering gear in straight ahead position resulting in unequal tie rod lengths.

• Steering knuckle, steering column or steering intermediate arm bent.

• On vehicles involved in an accident excessive deviations in the front end (longitudinal frame member, frame

cross member, wheelhouse, or the cowl/dash panel) which have a negative effect on the adjustment range for
camber and caster which can result in greater differences in the toe-out on turns between left and right.

STANDARD PROCEDURE - CHECKING REAR AXLE CAMBER

1. Check the vehicle level at the front and rear axles and adjust if necessary. (Refer to 2 - SUSPENSION/WHEEL
ALIGNMENT - STANDARD PROCEDURE).

2. Check the vehicle level at the front and rear axles with an electronic inclinometer and adjust if necessary. (Refer
to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).

ZH WHEEL ALIGNMENT 2 - 11

3. Check the rear axle camber. (POS+) = Positive
Camber, (NEG-) = Negative Camber. The camber
on the rear axle is not adjustable. If substantial
deviations in the rear axle camber are found, the
cause may be one of the following: (Refer to 2 ­SUSPENSION/WHEEL ALIGNMENT - SPECIFICA­TIONS).

• Too great a difference in the vehicle level
between the right and left-hand sides of vehicle.

• Camber strut bent.

• Accident damage to the frame floor. Level differ-

ences at the mounting points for the rear axle
carrier between the left and right sides of the
body. Experience shows that bending caused by
an accident also has an effect on the toe.

STANDARD PROCEDURE - CHECKING AND ADJUSTING REAR AXLE TOE

1. Check the vehicle level at the front and rear axles and adjust if necessary. (Refer to 2 - SUSPENSION/WHEEL
ALIGNMENT - STANDARD PROCEDURE).

2. Check the vehicle level at the front and rear axles with an electronic inclinometer and adjust if necessary. (Refer
to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE).

3. Adjust the toe with the cam bolt on the mounting of the left and right tie rod on rear axle carrier.

2 - 12 WHEEL ALIGNMENT ZH

SPECIFICATIONS
SPECIFICATIONS - WHEEL ALIGNMENT

DESCRIPTION SPECIFICATION

Vehicle level - front axle 1.4° (-2.1/+1.4)

Vehicle level - rear axle 0.4° (±0.8)

Ball point position 30,5±2 mm

Front axle toe-in 0° 20’±10’

Toe-out on turns with wheel on the inside of the curve

steered through 20°

Total rear axle toe 0 ° 33’±7’

ALIGNMENT SPECIFICATIONS

Front Axle Toe 2.5°

Rear Axle Toe 1.2°
Front Camber -1° 13’ (-1.22°)

Front Caster 5° 12’ (5.20°)

Rear Camber -1° 08’ (-1.13°)

Permissible difference in front axle camber between

right and left side of vehicle

-1° 25’±30’

20’

SPECIFICATIONS - TORQUE

TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Steering idler arm to bearing

bushing

Repair Nut 120 88.5 1060

Lock Nut 50 37 443

Cam bolt, rear axle tie rod 70 52 620

30 22 266

ZH FRONT SUSPENSION 2 - 13

FRONT SUSPENSION

TABLE OF CONTENTS

page page

FRONT SUSPENSION

STANDARD PROCEDURE - ADJUSTING

FRONT WHEEL BEARINGS ..............13

SPECIFICATIONS - TORQUE ..............14

SPECIAL TOOLS ........................15

KNUCKLE

DESCRIPTION .........................16

REMOVAL .............................16

INSTALLATION .........................20

HUB / BEARING

DESCRIPTION .........................22

REMOVAL .............................23

INSTALLATION .........................25

LOWER BALL JOINT

REMOVAL .............................27

INSTALLATION .........................30

LOWER CONTROL ARM

REMOVAL .............................32

INSTALLATION .........................34

UPPER CONTROL ARM

REMOVAL .............................36

INSTALLATION .........................37

SHOCK

REMOVAL .............................37

INSTALLATION .........................38

SPRING

REMOVAL .............................39

INSTALLATION .........................40

STABILIZER BAR

REMOVAL .............................42

INSTALLATION .........................43

FRONT SUSPENSION

STANDARD PROCEDURE - ADJUSTING FRONT WHEEL BEARINGS

1. Remove the wheel and tire assembly.

2. Install a wheel bolt (1) on the opposite side from the brake rotor retaining bolt (5).

3. Press the brake pads back in the brake caliper making sure they do not come in contact with the brake rotor.

4. Remove the dust cap (2).

2 - 14 FRONT SUSPENSION ZH

5. Loosen the hub nut bolt. Turn the hub nut (4) back until a slight end play is achieved.

6. Attach a dial indicator.

CAUTION: Do not turn the wheel hub while taking the measurement.

7. Adjust the wheel bearing end play by turning the hub nut (4) in stages while pushing and pulling the rotor firmly
back and forth. Adjust end play to 0.01–0.02 mm.

8. Tighten the hub nut bolt to 11 N·m (8 ft. lbs.) and recheck the wheel bearing end play.

9. Remove the dial indicator.

10. Install the wheel hub dust cap (2).

11. Remove the wheel bolt from the rotor.

12. Install the front wheel and tire assembly.

SPECIFICATIONS - TORQUE

TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Front Shock Absorber

Upper Nut

Front Shock Absorber

Lower Nut

Front Sway Bar To Lower

Control Arm Nut

Front Sway Bar Bushing

Nuts

M10 40 30 354

M8 20 15 177

Front Sway Bar To Frame

Nut

Upper Control Arm Joint

To Steering Knuckle

Clamping Nut 11 8 97

Lower Ball Joint To

Steering Knuckle

Lower Ball Joint To lower

Control Arm

Upper Control Arm To

Body Nut

Lower Control Arm To

Frame Nut

18 13 159

55 41 487

20 15 177

60 44 531

45 33 398

140 103 1240

105 77 929

65 50 575

120 88 1060

ZH FRONT SUSPENSION 2 - 15

SPECIAL TOOLS

9152 SPRING COMPRESSOR PLATES

C-3894–A Tie Rod Puller

9151 FRONT SPRING COMPRESSOR

9168 Ball Joint Puller

2 - 16 FRONT SUSPENSION ZH

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 calipers and hub bearing.

REMOVAL

CAUTION: When removing the steering knuckle
the shock absorber must remain installed.

1. Raise and support the vehicle.

2. Remove the front wheel and tire assembly.

3. Remove the front disc brake caliper (1). (Refer to 5

- BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - REMOVAL).

ZH FRONT SUSPENSION 2 - 17

4. Remove the front disc brake rotor (1). (Refer to 5 ­BRAKES/HYDRAULIC/MECHANICAL/ROTORS ­REMOVAL).

5. Remove the front wheel hub. (Refer to 2 - SUS­PENSION/FRONT/HUB / BEARING - REMOVAL).

6. Remove the disc brake dust shield by removing the
three hex bolts (1).

7. Remove the Wheel Speed Sensor by removing the
bolt and pulling the sensor straight out of the steer­ing knuckle.

2 - 18 FRONT SUSPENSION ZH

Note: Check the ball joint rubber boot for any wear
or damage. Repair as necessary.

Note: An allen wrench may be required to hold the
ball joint stud while removing the nut.

CAUTION: Do not use pneumatic tools to tighten
the bolt on the special tool.

8. Remove the tie rod end from the steering knuckle
by removing the nut from the tie rod joint stud.
Using Special Tool C-3894-A Two Jaw Puller,
slowly tighten the bolt until the tie rod end joint is
pushed out of the steering knuckle.

Note: An allen wrench may be required to hold the
ball joint stud while removing the nut.

9. Remove the lower control arm supporting ball joint
from the steering knuckle by removing the nut (1)
from the ball joint stud.

CAUTION: Do not use pneumatic tools to tighten
the bolt on the special tool.

10. Using Special Tool 9168 Ball Joint Puller (2)

slowly tighten the bolt until the ball joint (1) is
pushed out of the steering knuckle.

ZH FRONT SUSPENSION 2 - 19

Note: An allen wrench may be required to hold the
ball joint stud while removing the nut.

11. Remove the steering knuckle upper control arm

nut (1) from the upper ball joint stud.

CAUTION: Do not use pneumatic tools to tighten
the bolt on the special tool.

12. Using Special Tool 9168 Ball Joint Puller slowly

tighten the bolt until the upper ball joint is pushed
out of the steering knuckle.

13. Carefully remove the knuckle from the vehicle.

INSPECTION

1. Check the lower control arm supporting ball joint by
performing the following:

2. Remove the nuts (1) from the lower control arm
supporting ball joint.

3. Using Special Tool 9168 Ball Joint Puller (2) press
out the lower control arm supporting ball joint (1).

4. Check the lower control arm supporting ball joint. It
should be possible to move the ball pivot without
any play, binding, or creaking noises. Move the ball
pivot in all directions with a tube approximately 6
in. (150 mm) in length. Check the boot for any
cracks or damage. If the boot is leaking, replace
supporting or follower joint.

5. Measure the steering knuckle, if necessary.

2 - 20 FRONT SUSPENSION ZH

INSTALLATION

1. Install the steering knuckle and nut (1) to the upper
ball joint stud. Tighten to 45 N·m (33 ft. lbs.).

2. Install the steering knuckle and nut to the lower ball
joint stud (1). Tighten to 105 N·m (77 ft. lbs.).

3. Install the tie rod end and nut onto the steering
knuckle. Tighten to 50 N·m (37 ft. lbs.).

ZH FRONT SUSPENSION 2 - 21

4. Install the Wheel Speed Sensor (WSS) and bolt.
Tighten to 22 N·m (16 ft. lbs.).

5. Install the disc brake dust shield and three hex
bolts (1). Tighten to 22 N·m (16 ft. lbs.).

6. Install the front wheel hub. (Refer to 2 - SUSPEN­SION/FRONT/HUB / BEARING - INSTALLATION).

7. Install the front disc brake rotor (1). (Refer to 5 ­BRAKES/HYDRAULIC/MECHANICAL/ROTORS ­INSTALLATION).

2 - 22 FRONT SUSPENSION ZH

8. Install the front disc brake caliper (1). (Refer to 5 ­BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - INSTALLATION).

9. Install the front wheel and tire assembly. (Refer to
22 - TIRES/WHEELS - STANDARD PROCE­DURE).

10. Lower the vehicle and check vehicle alignment.

(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT

- SPECIFICATIONS).

HUB / BEARING

DESCRIPTION

The bearing (2) used in the front hub (1) of this vehicle is a roller bearing unit type. This assembly combines the
front wheel hub (1) and the front wheel bearing (2) into a two piece unit. The hub nut (3) holds the bearing (2) and
the front hub (1) to the steering knuckle’s spindle. The hub nut (3) has a locking bolt that locks the hub nut into
position on the spindle. The bearing is protected from outside elements by a metal dust cap (4). The bearings (2)
can only be replaced as a set. The bearings and the wheel hub can be replaced independently of one another.

ZH FRONT SUSPENSION 2 - 23

REMOVAL

1. Raise and support the vehicle.

2. Remove the front wheel and tire assembly.

3. Remove and inspect the front disc brake caliper
(1). (Refer to 5 - BRAKES/HYDRAULIC/MECHAN­ICAL/DISC BRAKE CALIPERS - REMOVAL).
Inspect for any damage or wear.

4. Remove and inspect the front disc brake rotor (1).
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
ROTORS - REMOVAL). Inspect for any damage or
wear.

2 - 24 FRONT SUSPENSION ZH

5. Remove the front wheel hub dust cap (4).

6. Loosen the hub nut bolt then remove the hub nut
(3) and then remove the tapered roller bearing (2).

7. Remove the front wheel hub (1) from the spindle.

INSPECTING HUB AND BEARINGS

1. Remove the bolts (1) and inspect the front disc
brake dust shield and replace if necessary.

ZH FRONT SUSPENSION 2 - 25

Note: Discoloration may be caused by generated
heat due to incorrect bearing end play settings.

CAUTION: Only replace the tapered roller bearing
and bearing races in pairs.

2. Inspect the spindle for any discoloration or wear on
the bearing seats or the contact surface of the
radial seal ring. Replace if necessary. (Refer to 2 ­SUSPENSION/FRONT/KNUCKLE - REMOVAL).

3. Inspect the front wheel hub (1). Inspect the
threaded bores and the rotor teeth for any wear or
damage.

4. Inspect the tapered roller bearing (2), bearing races
and the radial seal ring. The tapered roller bearings
and bearing races can be reused if:

• The tapered rollers and bearing races have a
smooth, grey running track.

• No discoloration (indicating, intense heat) is evi­dent.

• The roller cage and the face ends of the tapered rollers are not worn or damaged.

• The bearing races sit tight in the wheel hub.

INSTALLATION

1. Pack the front wheel hub (1) with grease, coat the
radial seal ring and also pack the space between
the sealing lip and the tapered roller bearing (2)
with grease. Install the front wheel hub (1) with the
inner tapered roller bearing (2) and the radial seal
ring onto spindle.

2. Install the hub nut (3) tight enough to hold the rotor
(5) in place.

2 - 26 FRONT SUSPENSION ZH

3. Install the front disc brake rotor (1). (Refer to 5 ­BRAKES/HYDRAULIC/MECHANICAL/ROTORS ­INSTALLATION).

4. Install the front disc brake caliper (6). (Refer to 5 ­BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - INSTALLATION).

5. Adjust the wheel bearing end play. (Refer to 2 ­SUSPENSION/FRONT/HUB / BEARING - DIAG­NOSIS AND TESTING).

6. Install the dust cap (4).

CAUTION: Before driving the vehicle, operate the
brake pedal several times until pressure in the
brake system is built up and maintained.

7. Install the wheel and tire assembly. (Refer to 22 ­TIRES/WHEELS - STANDARD PROCEDURE).

ZH FRONT SUSPENSION 2 - 27

LOWER BALL JOINT

REMOVAL

1. Raise and support the vehicle.

2. Remove the front wheel and tire assembly.

3. Remove the front disc brake caliper (1). (Refer to 5

- BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - REMOVAL).

4. Remove the front disc brake rotor (1). (Refer to 5 ­BRAKES/HYDRAULIC/MECHANICAL/ROTORS ­REMOVAL).

2 - 28 FRONT SUSPENSION ZH

5. Remove the front dust shield by removing the three
hex bolts (1).

6. Remove the front shock absorber bolt (1). (Refer to
2 - SUSPENSION/FRONT/SHOCK - REMOVAL).

7. Remove the front spring (1). (Refer to 2 - SUS­PENSION/FRONT/SPRING - REMOVAL).

ZH FRONT SUSPENSION 2 - 29

8. Remove the nuts (1 and 2) from the lower ball
joint.

CAUTION: Do not use pneumatic tools to tighten
the bolt on the special tool.

9. Using Special Tool 9168 Ball Joint Puller (1) press
out the outer ball joint stud from the steering
knuckle.

CAUTION: Do not use pneumatic tools to tighten
the bolt on the special tool.

10. Using Special Tool 9168 Ball Joint Puller (2) press

out and remove the upper ball joint stud from the
lower control arm.

2 - 30 FRONT SUSPENSION ZH

INSTALLATION

1. Clean the ball joint tapered bolt and the mounting
hole of the steering knuckle.

2. Install the lower ball joint onto the steering knuckle
and the lower control arm.

3. Install both nuts (1 and 2). Tighten to 105 N·m (77
ft. lbs.).

4. Install the front disc brake dust shield by installing
and tightening the three hex bolts (1).

ZH FRONT SUSPENSION 2 - 31

5. Install the front disc brake rotor (1). (Refer to 5 ­BRAKES/HYDRAULIC/MECHANICAL/ROTORS ­INSTALLATION).

6. Install the front disc brake caliper (1). (Refer to 5 ­BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - INSTALLATION).

7. Install the compressed front spring (1). (Refer to 2 ­SUSPENSION/FRONT/SPRING - INSTALLATION).

2 - 32 FRONT SUSPENSION ZH

8. Install the front shock absorber bolt and nut (1).
(Refer to 2 - SUSPENSION/FRONT/SHOCK ­INSTALLATION).

9. Install the front wheel and tire assembly. (Refer to
22 - TIRES/WHEELS - STANDARD PROCE­DURE).

LOWER CONTROL ARM

REMOVAL

1. Raise and support the vehicle.

2. Remove the front wheel and tire assembly.

3. Remove the front spring. (Refer to 2 - SUSPEN­SION/FRONT/SPRING - REMOVAL).

ZH FRONT SUSPENSION 2 - 33

4. Remove the shock absorber lower mounting nut
and bolt (1).

5. Pull the shock absorber out of the mounting
bracket.

6. Remove the sway bar from the lower control arm
by removing the two nuts (1) then removing the
clamp.

7. Remove the nut (2) attaching the lower control arm
to the lower ball joint.

2 - 34 FRONT SUSPENSION ZH

CAUTION: Do not use pneumatic tools to tighten
the bolt on the special tool.

8. Using Special Tool 9168 Ball Joint Puller (1) press
out the lower ball joint stud from the steering
knuckle.

CAUTION: Support the lower control arm before
removing mounting bolts.

9. Remove the two bolts (1) attaching the lower con­trol arm to the frame.

10. Remove the lower control arm from the vehicle.

INSTALLATION

1. Install the lower control arm to the vehicle.

2. Install the two bolts (1) attaching the lower control
arm to the frame. Tighten to 120 N·m (88 ft. lbs.).

ZH FRONT SUSPENSION 2 - 35

3. Install the nut (2) attaching the lower control arm to
the steering knuckle lower ball joint. Tighten to 45
N·m (33 ft. lbs.).

4. Install the sway bar clamp and bolts (1) to the
lower control arm. Tighten to 20 N·m (15 ft. lbs.).

5. Install the shock absorber bolt and nut (1) to the
lower control arm. Tighten to 55 N·m (41 ft. lbs.).

2 - 36 FRONT SUSPENSION ZH

6. Install the front spring (1). (Refer to 2 - SUSPEN­SION/FRONT/SPRING - INSTALLATION).

7. Lower the vehicle and check vehicle alignment.
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT ­STANDARD PROCEDURE).

8. Install the front wheel and tire assembly. (Refer to
22 - TIRES/WHEELS - STANDARD PROCE­DURE).

UPPER CONTROL ARM

REMOVAL

Note: If servicing the right upper control arm,
remove the air cleaner housing to access the bolt
and nut.

Note: To remove the upper control arm the shock
absorber must remain installed.

1. Raise and support the vehicle.

2. Remove the front wheel and tire assembly.

3. Wire tie the steering knuckle to the shock absorber
(arrow). This is to hold the steering knuckle from
falling away from the vehicle.

4. Remove the ball joint nut (3) from the upper control
arm (2).

CAUTION: Do not subject the brake hose or any
wheel speed sensor harness to any tension.

CAUTION: Do not use pneumatic tools to tighten the bolt on the tool.

5. Using Special Tool 9168 Ball Joint Puller, press the upper ball joint out of the steering knuckle.

6. Remove the upper control arm (2) from the body by removing the nut and bolt (1) from the inside of the engine
compartment on the shock tower.

ZH FRONT SUSPENSION 2 - 37

INSTALLATION

WARNING: TIGHTEN ALL NUTS AND BOLTS WITH
THE VEHICLE AT NORMAL RIDE HEIGHT.

1. Install the upper control arm (2) and the bolt and
nut (1) to the body. Tighten to 65 N·m (48 ft. lbs.)

Note: Clean the ball joint tapered bolt and mount­ing hole of the steering knuckle.

2. Install the upper ball joint (3) to the steering
knuckle. Tighten to 45 N·m (33 ft. lbs.)

3. Remove the wire tie attaching the steering knuckle
to the shock absorber.

4. Lower the vehicle and check vehicle alignment.
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT ­STANDARD PROCEDURE).

5. Install the wheel and tire assembly. (Refer to 22 ­TIRES/WHEELS - STANDARD PROCEDURE).

SHOCK

REMOVAL

Note: The vehicle must be standing on its wheels
when removing the upper shock absorber mount­ing nut.

1. Remove the shock absorber upper mounting nut
(1).

2. Remove the washer and rubber mounts.

3. Raise and support the vehicle.

2 - 38 FRONT SUSPENSION ZH

4. Remove the shock absorber nut and bolt (1) from
the lower control arm. Then remove the shock from
the vehicle by pulling it down and out of the vehi­cle.

5. Remove any mounting parts from the shock
absorber.

6. Inspect all mounting parts for any damage or
cracks.

INSTALLATION

1. Install the mounting hardware and bushings to the
lower mount and the shock absorber upper mount­ing stud.

2. Install the shock absorber to the vehicle by insert­ing the top first and then aligning the lower control
arm mounting bracket to the shock absorber.

3. Install the shock absorber lower bolt and nut (1) to
the lower control arm. Tighten to 55 N·m (41 ft.
lbs.).

4. Slowly lower the vehicle making sure to guide the
upper shock stud through the mounting hole.

5. Install the rubber mount and washer over the shock
absorber stud.

6. Install the shock absorber upper mounting nut (1).
Tighten to 18 N·m (13 ft. lbs.).

7. Lower the vehicle and check vehicle alignment.
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT ­STANDARD PROCEDURE).

ZH FRONT SUSPENSION 2 - 39

SPRING

REMOVAL

1. With the vehicle resting on its wheels remove the
upper shock absorber nut (1).

2. Remove the washer and rubber mount.

3. Raise and support the vehicle then remove the
lower shock absorber bolt and nut (1). Remove the
shock from the vehicle.

2 - 40 FRONT SUSPENSION ZH

4. Support the lower control arm with a suitable sup­porting device. Raise the lower control arm up until
it is almost level.

WARNING: ONLY USE APPROVED CLAMPING
DEVICES AND IF APPROPRIATE ALSO SCREEN
OFF THE DANGER AREA. INSPECT SPECIAL
TOOLS FOR DAMAGE AND FUNCTION. WEAR
SAFETY GLOVES AND EYE PROTECTION.

CAUTION: Risk of injury to hands and fingers from
being trapped or crushed when working on pre­loaded springs or spring bodies.

5. Using Special Tool 9151 Spring Compressor and
9152 Clamping Plates (1), carefully compress the
front spring.

6. Remove the nuts from the lower control arm
mounting bolts.

7. Carefully remove the lower control arm mounting
bolts from the body.

8. Lower the supporting device and swing the lower
control arm down while holding the front spring.
When enough clearance has been achieved from
the lower control arm and the upper spring perch,
remove the front spring from the vehicle.

INSTALLATION

1. Install the compressed front spring (1) with the rub­ber mount to the vehicle.

ZH FRONT SUSPENSION 2 - 41

2. Swing the lower control arm up to its mounting
position and install the bolts and nuts (1).

Note: To avoid suspension preload, the vehicle
must be at normal ride height before tightening
lower control arm bolts to final specifications.

3. Install the supporting device to the lower control
arm. Position the lower control arm so the distance
between the spring and the upper and lower
perches is snug making sure the spring is in its
correct mounting position.

4. Slowly release the front spring making sure it is in
its correct mounting position.

5. Lower and remove the supporting device so the
lower control arm is in its down position.

6. Install the shock absorber lower bolt and nut (1) to
the lower control arm. Tighten to 55 N·m (41 ft.
lbs.).

7. Lower the vehicle while guiding the shock into the
upper mounting surface.

8. Install the rubber mount and washer over the shock
absorber stud.

9. Install the shock absorber upper mounting nut (1).
Tighten to 18 N·m (13 ft. lbs.).

10. Tighten the lower control arm to 120 N·m (88 ft.

lbs.).

11. Lower the vehicle and check vehicle alignment.

(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT

- STANDARD PROCEDURE).

2 - 42 FRONT SUSPENSION ZH

STABILIZER BAR

REMOVAL

1. Remove the stabilizer bar brackets (1) from the right and left lower control arms.

2. Remove the stabilizer bar bracket (4) from the retainer bracket.

3. Remove retainer bracket (4) and bracket mounting plate (if necessary).

4. Remove the stabilizer bar (6) from the vehicle.

5. Remove all rubber bushings (3 and 5) off of the stabilizer bar (6).

ZH FRONT SUSPENSION 2 - 43

INSTALLATION

1. Install both right and left stabilizer bar bushings (3 and 5) onto the stabilizer bar (6).

Note: The lower control arms (2) may need to be raised to accept the stabilizer bar bushing (2) to its mating
surface.

2. Install the stabilizer bar (6) to the vehicle by loosely installing the bolts and nuts to all four brackets (1 and 4).

3. Align the stabilizer bar (6) so it is centered in the vehicle.

Note: Due to the preload of the bracket, install the hexagon socket bolt first.

4. Tighten both stabilizer bar bolts to frame.

5. Tighten both stabilizer bar hexagon socket bolts to the retainer (4).

6. Tighten both right and left stabilizer bar bracket nuts to the lower control arm (2). Torque to 20 N·m (15 ft. lbs.).

7. Install the stabilizer bar retainer and mounting plate (if removed).

8. Tighten the retainer bolt (4) to frame (if removed). Torque to 60 N·m (44 ft. lbs.).

9. Tighten the lower retainer nut to the fastening bracket (if removed). Torque to 20 N·m (15 ft. lbs.).

10. Tighten the upper retainer lever nut to the fastening bracket (if removed). Torque to 40 N·m (29 ft. lbs.).

11. Lower the vehicle and check vehicle alignment. (Refer to 2 - SUSPENSION/WHEELALIGNMENT - STANDARD

PROCEDURE).

2 - 44 REAR SUSPENSION ZH

REAR SUSPENSION

TABLE OF CONTENTS

page page

REAR SUSPENSION

SPECIFICATIONS - TORQUE ..............44

SPECIAL TOOLS ........................45

CAMBER STRUT

REMOVAL .............................46

INSTALLATION .........................46

TRAILING LINK

REMOVAL .............................47

INSTALLATION .........................47

LATERAL LINK

REMOVAL .............................48

INSTALLATION .........................48

TRACK BAR

REMOVAL .............................49

INSTALLATION .........................49

LOWER CONTROL ARM

REMOVAL .............................50

INSTALLATION .........................52

REAR SUSPENSION

SPECIFICATIONS - TORQUE

TORQUE SPECIFICATIONS

KNUCKLE

REMOVAL .............................54

INSTALLATION .........................59

HUB / BEARING

REMOVAL .............................63

INSTALLATION .........................66

STABILIZER BAR

REMOVAL .............................68

INSTALLATION .........................72

SHOCK

REMOVAL .............................75

INSTALLATION .........................76

SPRING

REMOVAL .............................78

INSTALLATION .........................80

REAR AXLE CARRIER

REMOVAL .............................81

INSTALLATION .........................87

Description N·m Ft. Lbs. In. Lbs.

Stabilizer Link to Stabilizer Bar 30 22 266

Stabilizer Bar to Stabilizer Link Nut 20 15 177

Bolt, Stabilizer Bar Clamp 20 15 177

Upper Shock Nut 18 13 159

Shock Absorber to Lower Control Arm 55 41 487

Rear Axle Carrier Nut 90 66 797

Rear Axle Carrier Rear Nut 90 66 797
Rear Axle Center Assembly At Front to Rear Axle Carrier 50 37 443
Rear Axle Center Assembly At Rear to Rear Axle Carrier 110 81 974

Lower Control Arm to Rear Axle Carrier 70 52 620

Lower Control Arm to Wheel Carrier 120 88 1060

Camber Strut to Rear Axle Carrier 70 52 620

Camber Strut to Wheel Carrier 70 52 620

Trailing Link to Rear Axle Carrier 70 52 620

Trailing Link to Wheel Carrier 70 52 620

Lateral Link to Rear Axle Carrier 70 52 620

Lateral Link to Wheel Carrier 30 22 266

Track Bar to Rear Axle Carrier 70 52 620

Track Bar to Wheel Carrier 70 52 620

ZH REAR SUSPENSION 2 - 45

SPECIAL TOOLS

9168 Ball Joint Puller

C-3894–A Tie Rod Puller

9150 Rear Spring Compressor

9152 Spring Compressor Plates

9199 BEARING TOOL

2 - 46 REAR SUSPENSION ZH

CAMBER STRUT

REMOVAL

1. Raise and support the vehicle.

2. Remove the wheel and tire assembly.

3. Remove the inner camber strut bolt (1) attaching
the camber strut to the rear axle carrier.

4. Remove the outer camber strut bolt (2) attaching
the camber strut to the wheel carrier.

Note: Lightly tap the camber strut with a plastic
headed hammer to loosen the rubber mounts from
the mounting flanges.

5. Remove the camber strut from the vehicle.

INSTALLATION

CAUTION: Vehicle must be at normal ride height
before tightening components to specified torque.

1. Install the camber strut onto the vehicle.

2. Install the outer camber strut bolt attaching the
camber strut to the wheel carrier.

3. Install the inner camber strut bolt attaching the
camber strut to the rear axle carrier.

4. Install the wheel and tire assembly.

5. Lower the vehicle so it is not being supported by
the lift.

6. Tighten the outer camber strut bolt attaching the
camber strut to the wheel carrier to 70 N·m (52 ft.
lbs.).

7. Tighten the inner camber strut bolt attaching the
camber strut to the rear axle carrier to 70 N·m (52
ft. lbs.).

8. Check vehicle alignment. (Refer to 2 - SUSPEN­SION/WHEEL ALIGNMENT - STANDARD PROCEDURE).

ZH REAR SUSPENSION 2 - 47

TRAILING LINK

REMOVAL

1. Raise and support the vehicle.

2. Remove the wheel and tire assembly.

3. Remove the inner trailing link bolt (1) attaching the
trailing link to the rear axle carrier.

4. Remove the outer trailing link bolt (2) attaching the
trailing link to the wheel carrier.

Note: Lightly tap the trailing link with a plastic
headed hammer to loosen the rubber mounts from
the mounting flanges.

5. Remove the trailing link from the vehicle.

INSTALLATION

1. Install the trailing link onto the vehicle.

CAUTION: Vehicle must be at normal ride height
before tightening components to specified torque.

2. Install the outer trailing link bolt (2) attaching the
trailing link to the wheel carrier.

3. Install the inner trailing link bolt (1) attaching the
trailing link to the rear axle carrier.

4. Install the wheel and tire assembly.

5. Lower the vehicle so it is not being supported by
the lift.

6. Tighten the outer trailing link bolt attaching the trail­ing link to the wheel carrier to 70 N·m (52 ft. lbs.).

7. Tighten the inner trailing link bolt attaching the trail­ing link to the rear axle carrier to 70 N·m (52 ft.
lbs.).

8. Check vehicle alignment. (Refer to 2 - SUSPEN­SION/WHEEL ALIGNMENT - STANDARD PROCE­DURE).

2 - 48 REAR SUSPENSION ZH

LATERAL LINK

REMOVAL

1. Raise and support the vehicle.

2. Remove the wheel and tire assembly.

3. Remove the inner lateral link bolt attaching the lat­eral link to the rear axle carrier.

4. Remove the lateral link ball joint nut (2).

CAUTION: Do not use pneumatic tools to tighten
the bolt on the tool.

5. Using Special Tool 9168 Ball Joint Puller, remove
the outer lateral link ball joint attaching the lateral
link to the wheel carrier.

Note: Lightly tap the lateral link with a plastic
headed hammer to loosen the rubber mounts from
the mounting flanges.

6. Remove the lateral link (1).

INSTALLATION

1. Install the lateral link onto the vehicle.

CAUTION: The rear axle shaft must be horizontal
when tightening the lateral link nuts.

2. Install the outer lateral link ball joint attaching the
lateral link to the wheel carrier.

CAUTION: The rear axle shaft must be horizontal
when tightening the lateral link nuts.

3. Install the inner lateral link bolt attaching the lateral
link to the rear axle carrier.

CAUTION: Vehicle must be at normal ride height before tightening components to specified torque.

4. Tighten the outer lateral link ball joint attaching the lateral link to the wheel carrier to 30 N·m (22 ft. lbs.).

5. Tighten the inner lateral link bolt attaching the lateral link to the rear axle carrier to 70 N·m (52 ft. lbs.).

ZH REAR SUSPENSION 2 - 49

TRACK BAR

REMOVAL

1. Raise and support the vehicle.

2. Remove the wheel and tire assembly.

3. Remove the inner track bar bolt attaching the track
bar to the rear axle carrier.

4. Remove the outer track bar bolt attaching the track
bar to the wheel carrier.

Note: Lightly tap the track bar with a plastic
headed hammer to loosen the rubber mounts from
the mounting flanges.

5. Remove the track bar from the vehicle.

INSTALLATION

1. Install the track bar onto the vehicle.

CAUTION: Vehicle must be at normal ride height
before tightening components to specified torque.

2. Install the outer track bar bolt attaching the track
bar to the wheel carrier.

3. Install the inner track bar bolt attaching the track
bar to the rear axle carrier.

4. Install the wheel and tire assembly.

5. Lower the vehicle so it is not being supported by
the lift.

6. Tighten the outer track bar bolt attaching the track
bar to the wheel carrier to 70 N·m (52 ft. lbs.).

7. Tighten the inner track bar bolt attaching the track
bar to the rear axle carrier to 70 N·m (52 ft. lbs.).

8. Check vehicle alignment. (Refer to 2 - SUSPEN­SION/WHEEL ALIGNMENT - STANDARD PROCE­DURE).

2 - 50 REAR SUSPENSION ZH

LOWER CONTROL ARM

REMOVAL

1. Raise and support the vehicle.

2. Remove the rear tire and wheel assembly.

3. Remove the rear lower control arm plastic shield by
removing the bolts (1) attaching the cover to the
lower control arm.

4. Remove the rear spring (1). (Refer to 2 - SUSPEN­SION/REAR/SPRING - REMOVAL).

ZH REAR SUSPENSION 2 - 51

5. Remove the rear shock absorber (1). (Refer to 2 ­SUSPENSION/REAR/SHOCK - REMOVAL).

6. Remove the rear stabilizer bar link (1) from the rear
lower control arm.

7. Remove the bolt attaching the rear lower control
arm to the rear wheel carrier.

8. Remove the rear lower control arm (4) from the
vehicle.

2 - 52 REAR SUSPENSION ZH

INSTALLATION

CAUTION: Vehicle must be at normal ride height
before tightening components to specified torque.

1. Install the bolt attaching the rear lower control arm
(4) to the rear wheel carrier. Tighten to 70 N·m (52
ft. lbs.)

2. Install the rear shock absorber (1). (Refer to 2 ­SUSPENSION/REAR/SHOCK - INSTALLATION).

3. Install the rear spring (1). (Refer to 2 - SUSPEN­SION/REAR/SPRING - INSTALLATION).

ZH REAR SUSPENSION 2 - 53

4. Install the rear lower control arm to the vehicle.
Tighten to 70 N·m (52 ft. lbs.).

5. Install the rear stabilizer bar link (1) to the rear
lower control arm. Tighten to 20 N·m (15 ft. lbs.).

6. Install the rear lower control arm plastic shield bolt
(1).

7. Install the wheel and tire assembly.

8. Check vehicle alignment. (Refer to 2 - SUSPEN­SION/WHEEL ALIGNMENT - STANDARD PROCE­DURE).

2 - 54 REAR SUSPENSION ZH

KNUCKLE

REMOVAL

1. Raise and support vehicle.

2. Remove the wheel and tire assembly.

3. Remove the rear disc brake caliper bolts (1).

4. Remove the rear disc brake caliper. (Refer to 5 ­BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - REMOVAL).

ZH REAR SUSPENSION 2 - 55

5. Remove the disc brake rotor (1). (Refer to 5 ­BRAKES/HYDRAULIC/MECHANICAL/ROTORS ­REMOVAL).

6. Remove the parking brake shoe assembly. (Refer
to 5 - BRAKES/PARKING BRAKE/SHOES ­REMOVAL).

7. Remove the parking brake cable (2). (Refer to 5 ­BRAKES/PARKING BRAKE/CABLES - REMOVAL).

2 - 56 REAR SUSPENSION ZH

8. Remove the rear Wheel Speed Sensor bolt (1).

9. Remove the rear Wheel Speed Sensor (2) from the
knuckle.

10. Remove the rear axle halfshaft nut (1) from the

rear hub assembly.

11. Remove the rear disc brake dust shield by remov-

ing the hex bolts (1) from the rear hub assembly.

ZH REAR SUSPENSION 2 - 57

12. Remove the camber strut, nuts and bolts (1-2).

(Refer to 2 - SUSPENSION/REAR/TOE LINK ­REMOVAL).

13. Remove the trailing link, nuts and bolts (1-2).

(Refer to 2 - SUSPENSION/REAR/TRAILING
LINK - REMOVAL).

14. Remove the lateral link, nuts and bolts (1-2).

(Refer to 2 - SUSPENSION/REAR/LATERAL LINK

- REMOVAL).

2 - 58 REAR SUSPENSION ZH

15. Remove the track bar. (Refer to 2 - SUSPEN-

SION/REAR/TRACK BAR - REMOVAL).

16. Remove the lower control arm. (Refer to 2 - SUS-

PENSION/REAR/LOWER CONTROL ARM ­REMOVAL).

17. Remove the knuckle (1) from the vehicle.

18. Inspect the bearing assembly (5) for any wear or

damage, replace if necessary. (Refer to 2 - SUS­PENSION/REAR/HUB / BEARING - REMOVAL).

ZH REAR SUSPENSION 2 - 59

INSTALLATION

CAUTION: The rear axle halfshaft must be horizon­tal when tightening all nuts and bolts.

1. Install the knuckle to the vehicle.

2. Install the trailing link, nuts and bolts (1-2). (Refer
to 2 - SUSPENSION/REAR/TOE LINK - INSTALLA­TION).

2 - 60 REAR SUSPENSION ZH

3. Install the trailing link nuts and bolts (1-2). (Refer to
2 - SUSPENSION/REAR/TRAILING LINK ­INSTALLATION).

4. Install the lateral link nuts and bolts (1-2). (Refer to
2 - SUSPENSION/REAR/LATERAL LINK - INSTAL­LATION).

5. Install the track bar nuts and bolts (1-2). (Refer to 2

- SUSPENSION/REAR/TRACK BAR - INSTALLA­TION).

6. Install the lower control arm. (Refer to 2 - SUS­PENSION/REAR/LOWER CONTROL ARM ­INSTALLATION).

ZH REAR SUSPENSION 2 - 61

7. Install the rear disc brake dust shield by installing
the bolts (1) to the rear hub assembly. Tighten the
bolts to 10 N·m (89 in. lbs.).

8. Install the rear axle halfshaft to the rear hub
assembly.

Note: A new halfshaft outer retaining nut must be
used.

9. Install the rear axle halfshaft outer retaining nut (1).
Tighten the halfshaft nut to 220 N·m (164 ft. lbs.).

10. Install the rear Wheel Speed Sensor (2). (Refer to

5 - BRAKES/ELECTRICAL/REAR WHEEL
SPEED SENSOR - INSTALLATION).

2 - 62 REAR SUSPENSION ZH

11. Install the parking brake cable (2). (Refer to 5 -

BRAKES/PARKING BRAKE/CABLES - INSTALLA­TION).

12. Install the parking brake shoe assembly (1-5).

(Refer to 5 - BRAKES/PARKING BRAKE/SHOES

- INSTALLATION).

13. Install the disc brake rotor (1). (Refer to 5 -

BRAKES/HYDRAULIC/MECHANICAL/ROTORS ­INSTALLATION).

ZH REAR SUSPENSION 2 - 63

14. Install the rear disc brake caliper and bolts (1).

(Refer to 5 - BRAKES/HYDRAULIC/MECHANI­CAL/DISC BRAKE CALIPERS - INSTALLATION).

15. Install the wheel and tire assembly. (Refer to 22 -

TIRES/WHEELS - STANDARD PROCEDURE).

16. Check vehicle alignment. (Refer to 2 - SUSPEN-

SION/WHEEL ALIGNMENT - STANDARD PRO­CEDURE).

HUB / BEARING

REMOVAL

1. Raise and support the vehicle.

2. Remove the disc brake calipers and bolts (1).

2 - 64 REAR SUSPENSION ZH

3. Remove the rear disc brake rotor (1). (Refer to 5 ­BRAKES/HYDRAULIC/MECHANICAL/ROTORS ­REMOVAL).

4. Remove the parking brake shoes (1-5). (Refer to 5

- BRAKES/PARKING BRAKE/SHOES ­REMOVAL).

5. Remove the rear axle halfshaft nut (1).

6. Remove the rear axle halfshaft (Refer to 3 - DIF­FERENTIAL & DRIVELINE/HALF SHAFT ­REMOVAL).

ZH REAR SUSPENSION 2 - 65

7. Remove the snap ring (4) from the rear hub
assembly housing.

8. Using the Special Tool 9181 Bearing Tool, remove
the bearing (4) on the hub (1).

CAUTION: Be sure not to mar or damage the rear
axle halfshaft flange while in vise.

9. Remove the inner bearing race from the rear axle
halfshaft flange by screwing the clamping pliers
onto the puller then tighten.

10. Clamp the rear axle halfshaft flange in vise.

11. Fit the thrust piece with the large diameter on the

rear axle halfshaft flange.

12. Place the complete puller over the inner bearing

race.

13. Clamp it firmly at the upper grooves of the clamp-

ing pliers over the tapered sleeve of the puller.

14. Pull the inner bearing race off the rear axle half-

shaft flange using the puller.

15. Check the lateral and radial runout of the rear axle halfshaft flange. Replace rear axle halfshaft flange if test

values are exceeded.

• Permissible lateral runout 0.0011 in. (0.03 mm).

• Permissible radial runout 0.0011 in. (0.03 mm).

2 - 66 REAR SUSPENSION ZH

INSTALLATION

1. Using the Special Tool 9199 Bearing Tool (1) install
the bearing (2) by pulling it into the wheel carrier
(3) until it touches the shoulder of the wheel carrier.

Note: Insure that the snap ring is correctly fitted in
the rear wheel carrier.

2. Install the snap ring (4) into the rear wheel carrier.

Note: Verify the pressure plate lies flush against
the bearings inner race during insertion.

3. Install the rear axle halfshaft flange (1).

4. Install the parking brake shoes (1-5). (Refer to 5 ­BRAKES/PARKING BRAKE/SHOES - INSTALLA­TION).

ZH REAR SUSPENSION 2 - 67

5. Install the disc brake rotor (1). (Refer to 5 ­BRAKES/HYDRAULIC/MECHANICAL/ROTORS ­INSTALLATION).

6. Install the rear disc brake caliper bolts (1). (Refer
to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - INSTALLATION).

7. Install the rear axle halfshaft. (Refer to 3 - DIFFER­ENTIAL & DRIVELINE/HALF SHAFT - INSTALLA­TION).

8. Install wheel and tire assembly. (Refer to 22 ­TIRES/WHEELS - STANDARD PROCEDURE).

2 - 68 REAR SUSPENSION ZH

STABILIZER BAR

REMOVAL

1. Raise and support the vehicle.

2. Remove both wheel and tire assemblies.

3. Remove the right and left wheel speed sensors (2).
(Refer to 5 - BRAKES/ELECTRICAL/REAR
WHEEL SPEED SENSOR - REMOVAL).

4. Remove the rear brake hoses (1) from the rear
brake calipers. (Refer to 5 - BRAKES/HYDRAULIC/
MECHANICAL/BRAKE LINES - REMOVAL).

ZH REAR SUSPENSION 2 - 69

5. Remove the rear springs (1). (Refer to 2 - SUS­PENSION/REAR/SPRING - REMOVAL).

6. Remove the rear shocks (1). (Refer to 2 - SUS­PENSION/REAR/SHOCK - REMOVAL).

7. Remove the rear parking brake cables (2) from the
parking brake equalizer (1). (Refer to 5 - BRAKES/
PARKING BRAKE/CABLES - REMOVAL).

2 - 70 REAR SUSPENSION ZH

8. Remove the propeller shaft nuts (1) from the rear
axle differential carrier.

9. Remove the propeller shaft (Refer to 3 - DIFFER­ENTIAL & DRIVELINE/PROPELLER SHAFT ­REMOVAL).

10. Remove the rear stabilizer bar links (2) from the

stabilizer bar (1).

11. Block and support the rear axle carrier (1) with a

suitable lifting device (2).

ZH REAR SUSPENSION 2 - 71

12. Remove the two bolts (1) attaching the rear axle

carrier to the front portion of the frame.

13. Remove the two bolts (2) attaching the rear axle

carrier to the rear portion of the frame.

14. Lower the rear differential housing down approxi-

mately4-5inches allowing enough room for the
stabilizer bar to be removed from the vehicle.

15. Remove the rear stabilizer bar clamps (3) by

removing the nuts (1) from the studs and then
removing the stabilizer bar (2).

16. Remove the rear stabilizer bar from the vehicle by

maneuvering it over the axle carrier and away
from the vehicle.

2 - 72 REAR SUSPENSION ZH

INSTALLATION

1. Install the rear stabilizer bar into the vehicle.

2. Raise the rear differential housing and install the
four bolts (1) attaching it to the vehicle. Tighten to
90 N·m (66 ft. lbs.).

3. Install the rear spring (1). (Refer to 2 - SUSPEN­SION/REAR/SPRING - INSTALLATION).

4. Install the rear shock (1). (Refer to 2 - SUSPEN­SION/REAR/SHOCK - INSTALLATION).

ZH REAR SUSPENSION 2 - 73

5. Loosely install the rear stabilizer clamps (1-3).

6. Install the rear stabilizer bar links (2) to the rear
control arm. Tighten to 30 N·m (22 ft. lbs.).

7. Tighten the rear stabilizer clamp nuts (1). Tighten
to 20 N·m (15 ft. lbs.).

2 - 74 REAR SUSPENSION ZH

8. Install the propeller shaft to the rear differential car­rier. (Refer to 3 - DIFFERENTIAL & DRIVELINE/
PROPELLER SHAFT - INSTALLATION).

9. Install the rear parking brake cables (2) to the park­ing brake equalizer (1). (Refer to 5 - BRAKES/
PARKING BRAKE/CABLES - INSTALLATION).

10. Install the rear brake hoses (1) to the rear brake

calipers. (Refer to 5 - BRAKES/HYDRAULIC/ME­CHANICAL/BRAKE LINES - INSTALLATION) .

ZH REAR SUSPENSION 2 - 75

11. Install the rear wheel speed sensors (2). (Refer to

5 - BRAKES/ELECTRICAL/REAR WHEEL SPEED
SENSOR - INSTALLATION).

12. Install the wheel and tire assembly. (Refer to 22 -

TIRES/WHEELS - STANDARD PROCEDURE).

SHOCK

REMOVAL

Note: The vehicle must be resting on its wheels
before removing the top shock absorber mounting
hardware.

1. Remove the shock absorber upper mounting hard­ware (1).

2. Raise and support the vehicle.

2 - 76 REAR SUSPENSION ZH

3. Remove the lower control arm plastic cover by
removing the bolts (1) attaching the cover to the
lower control arm.

4. Remove the shock absorber (1) from the lower
control arm.

5. Inspect the shock absorber.

INSTALLATION

1. Install the shock absorber (1) onto the lower control
arm then install the bolt and nut (2). Tighten to 55
N·m (41 ft. lbs.).