Chrysler GS 2000 Workshop Manual

NS LUBRICATION AND MAINTENANCE 0 - 1

LUBRICATION AND MAINTENANCE

TABLE OF CONTENTS

page page

LUBRICANTS ............................. 1

MAINTENANCE SCHEDULES ................. 3

LUBRICANTS

TABLE OF CONTENTS

page page

SERVICE PROCEDURES

PARTS AND LUBRICANT

RECOMMENDATIONS ....................1

CLASSIFICATION OF LUBRICANTS............1

INTERNATIONAL SYMBOLS .................2

SERVICE PROCEDURES

PARTS AND LUBRICANT RECOMMENDATIONS

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

ENGINE COOLANT

The green and the orange engine coolant MUST
NOT BE MIXED. When replacing coolant the com­plete system flush must be performed before using
the replacement coolant.

CLASSIFICATION OF LUBRICANTS

Only lubricants that bear designations defined by
the following organization should be used to service a
DaimlerChrysler vehicle.

• Society of Automotive Engineers (SAE)

• American Petroleum Institute (API) (Fig. 1)

• National Lubricating Grease Institute (NLGI)

(Fig. 2)

JUMP STARTING, TOWING, AND HOISTING.... 12

FLUID CHECK/FILL POINTS AND

LUBRICATION LOCATIONS.................2

SPECIFICATIONS

FLUID CAPACITIES ........................2

viscosities. These are specified with a dual SAE vis­cosity grade which indicates the cold-to-hot tempera­ture viscosity range.

• SAE 30 = single grade engine oil.

• SAE 10W-30 = multiple grade engine oil.

DaimlerChrysler only recommends multiple grade

engine oils.

API QUALITY CLASSIFICATION

This symbol (Fig. 1) on the front of an oil container
means that the oil has been certified by the Ameri­can Petroleum Institute (API) to meet all the lubri­cation requirements specified by DaimlerChrysler.

Refer to Group 9, Engine for gasoline engine oil
specification.

ENGINE OIL

SAE VISCOSITY RATING INDICATES ENGINE OIL VISCOSITY

An SAE viscosity grade is used to specify the vis-

cosity of engine oil. Engine oils also have multiple

Fig. 1 API Symbol

FLEXIBLE FUEL ENGINE OIL – 3.3L ENGINE

Engine Oil Selection for Operating on E-85
Fuel If vehicle operates on E-85 fuel either full or

0 - 2 LUBRICATION AND MAINTENANCE NS

SERVICE PROCEDURES (Continued)

part-time, use only Mopart Flexible Fuel SAE 5W-30
engine oil or an equivalent that meets Daimler­Chrysler Standard MS-9214. Equivalent commercial
Flexible Fuel engine oils may be labeled as Multi­Fuel, Variable Fuel, Flexible Fuel, etc. These engine
oil is preferred for use in Flexible Fuel engines.

CAUTION: If Flexible Fuel engine oil is not used
when using E-85 fuel, engine wear or damage may
result.

GEAR LUBRICANTS

SAE ratings also apply to multiple grade gear
lubricants. In addition, API classification defines the
lubricants usage.

LUBRICANTS AND GREASES

Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 2) 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 following symbols indi­cate the highest quality.

FLUID CHECK/FILL POINTS AND LUBRICATION
LOCATIONS

The fluid check/fill points and lubrication locations

are located in each applicable Sections.

SPECIFICATIONS

FLUID CAPACITIES

Fig. 3 International Symbols

Fig. 2 NLGI Symbol

1 – WHEEL BEARINGS
2 – CHASSIS LUBRICATION
3 – CHASSIS AND WHEEL BEARINGS

INTERNATIONAL SYMBOLS

DaimlerChrysler Corporation uses international
symbols to identify engine compartment lubricant
and fluid check and fill locations (Fig. 3).

Fuel Tank ..................... 76L(20gal.)

Engine Oil, With Filter – 2.4 Liter Engine . . . 4.7 L

(5.0 qts.)

Engine Oil, With Filter – 3.0 Liter Engine . . . 4.0 L

(4.5 qts.)

Engine Oil, With Filter – 3.3 Liter Engine . . . 4.0 L

(4.5 qts.)

Engine Oil, With Filter – 3.8 Liter Engine . . . 4.0 L

(4.5 qts.)

Cooling System 2.4 Liter Engine * ........ 10.6 L

(11.23 qts.)

Cooling System 3. O Liter Engine * ....... 12.3 L

(13 qts.)

Cooling System 3.3 or 3.8 Liter Engine * . . . 12.5 L

(13.23 qts.)

With rear heater add additional coolant ..... 2.7L

(2.9 qts.)
Automatic Transaxle Service Fill . . . 3.8 L (4.0 qts.)

Automatic Transaxle 31TH/O-haul Fill ...... 8.0L

(8.5 qts.)

Automatic Transaxle 41TE/O-haul Fill ...... 8.6L

(9.1 qts.)

Power Transfer Unit ............1.15 L (1.2 qts.)

Power Steering ................ 0.81 L (1.7 pts.)

NOTE:

• * Includes heater and coolant recovery bottle

filled to MAX level.

NS LUBRICATION AND MAINTENANCE 0 - 3

MAINTENANCE SCHEDULES

TABLE OF CONTENTS

page page

DESCRIPTION AND OPERATION

MAINTENANCE SCHEDULES ................3

UNSCHEDULED INSPECTION................3

SPECIFICATIONS

SCHEDULE – A – CHRYSLER TOWN AND

COUNTRY VEHICLES.....................3

DESCRIPTION AND OPERATION

MAINTENANCE SCHEDULES

DESCRIPTION

There are two maintenance schedules that show

proper service for your vehicle.

First is Schedule – A. It lists all the scheduled
maintenance to be performed under “normal” operat­ing conditions.

Second is Schedule – B. It is a schedule for vehi­cles that are operated under the following conditions:

UNSCHEDULED INSPECTION

At Each Stop For Fuel

• Check engine oil level and add as required.

• Check windshield washer solvent and add as

required.

Once A Month

• Check tire pressure and look for unusual wear

or damage.

• Check fluid levels of coolant reservoir, brake
master cylinder, power steering and transmission.
Add fluid as required.

• Check all lights and all other electrical items for
correct operation.

SCHEDULE–B–CHRYSLER TOWN AND

COUNTRY VEHICLES.....................4

SCHEDULE – A – PLYMOUTH/DODGE

VEHICLES .............................7

SCHEDULE–B–PLYMOUTH/DODGE

VEHICLES .............................8

If mileage is less than 7,500 miles (12 000 km)

yearly, replace the engine oil filter at each oil change.

EMISSION CONTROL SYSTEM MAINTENANCE

The scheduled emission maintenance listed in bold

type on the Maintenance Schedules, must be done at

the mileage specified to assure the continued proper
functioning of the emission control system. These,
and all other maintenance services included in this
manual, should be done to provide the best vehicle
performance and reliability. More frequent mainte­nance may be needed for vehicles in severe operating
conditions such as dusty areas and very short trip
driving.

SPECIFICATIONS

SCHEDULE–A–CHRYSLER TOWN AND
COUNTRY VEHICLES

7,500 Miles (12 000 km) or at 6 months

• Change the engine oil.

• Replace the engine oil filter.

15,000 Miles (24 000 km) or at 12 months

• Change the engine oil.

• Replace the engine oil filter.

At Each Oil Change

• Inspect the exhaust system.

• Inspect brake hoses.

• Inspect the CV joints and front suspension com-

ponent boots and seals.

• Rotate the tires at each oil change interval
shown on Schedule – A (7,500 miles - 12 000 km) or
every other interval on Schedule – B (6,000 miles ­10 000 km).

• Check the engine coolant level, hoses, and
clamps.

22,500 Miles (36 000 km) or at 18 months

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the brake linings.

30,000 Miles (48 000 km) or at 24 months

• Change the engine oil.

• Replace the engine oil filter.

• Replace the engine air cleaner element

(filter).

• Inspect the tie rod ends and boot seals.

0 - 4 LUBRICATION AND MAINTENANCE NS

SPECIFICATIONS (Continued)

37,500 Miles (60 000 km) or at 30 months

• Change the engine oil.

• Replace the engine oil filter.

45,000 Miles (72 000 km) or at 36 months

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the brake linings.

52,500 Miles (84 000 km) or at 42 months

• Change the engine oil.

• Replace the engine oil filter.

60,000 Miles (96 000 km) or at 48 months

• Change the engine oil.

• Replace the engine oil filter.

• Replace the engine air cleaner element

(filter).

• Check the PCV valve and replace, if neces­sary.*

• Inspect the serpentine drive belt, replace if nec­essary.

• Inspect the tie rod ends and boot seals.

67,500 Miles (108 000 km) or at 54 months

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the brake linings.

75,000 Miles (120 000 km) or at 60 months

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the serpentine drive belt and replace if

necessary. This maintenance is not required if the
belt was previously replaced.

• Flush and replace engine coolant at 60 months.

100,000 Miles (160,000 km)

• Replace the spark plugs.

• Replace the ignition cables.

• Flush and replace engine coolant if not done at

60 months.

105,000 Miles (168 000 km) or at 84 months

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the serpentine drive belt and replace if

necessary. This maintenance is not required if the
belt was previously replaced.

112,500 Miles (180 000 km) or at 90 months

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the brake linings.

120,000 Miles (192 000 km) or at 96 months

• Change the engine oil.

• Replace the engine oil filter.

• Replace the engine air cleaner element

(filter).

• Check and replace the PCV valve, if neces-

sary.*

• Inspect the serpentine drive belt Not required if

replaced at 75,000, 90,000 or 105,000 miles.

• Inspect the tie rod ends and boot seals.

*This maintenance is recommended by Daimler­Chrysler Corporation to the owner but is not
required to maintain the emissions warranty.

NOTE: Inspection and service should also be per­formed anytime a malfunction is observed or sus­pected. Retain all receipts.

82,500 Miles (132 000 km) or at 66 months

• Change the engine oil.

• Replace the engine oil filter.

90,000 Miles (144 000 km) or at 72 months

• Change the engine oil.

• Replace the engine oil filter.

• Replace the engine air cleaner element

(filter).

• Check the PCV valve and replace, if neces-

sary. Not required if previously changed.*

• Inspect the serpentine drive belt, replace if nec­essary. This maintenance is not required if the belt
was previously replaced.

• Inspect the tie rod ends and boot seals.

• Inspect the brake linings.

97,500 Miles (156 000 km) or at 78 months

• Change the engine oil.

• Replace the engine oil filter.

SCHEDULE–B–CHRYSLER TOWN AND
COUNTRY VEHICLES

Follow this schedule if the vehicle is usually oper-

ates under one or more of the following conditions.

• Frequent short trip driving less than 5 miles (8

km)

• Frequent driving in dusty conditions

• Frequent trailer towing

• Day and night temperatures are below freezing

• Frequent long periods of engine idling

• Frequent stop and go driving

• More than 50% of your driving is at sustained

high speeds during hot weather, above 90°F (32°C)

• Use of E-85 (ethanol) fuel in 3.3 liter engines

• Taxi, police or delivery service

3,000 Miles (5 000 km)

• Change the engine oil.

• Replace the engine oil filter.

NS LUBRICATION AND MAINTENANCE 0 - 5

SPECIFICATIONS (Continued)

6,000 Miles (10 000 km)

• Change the engine oil.

• Replace the engine oil filter.

9,000 Miles (14 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the brake linings.

12,000 Miles (19 000 km)

• Change the engine oil.

• Replace the engine oil filter.

15,000 Miles (24 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the engine air cleaner element (fil-

ter). Replace as necessary.*

• Change the All Wheel Drive (AWD) power trans­fer unit fluid. (See the note at the end of Schedule –
B.)

18,000 Miles (29 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the brake linings.

21,000 Miles (34 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Change the All Wheel Drive (AWD) overrunning

clutch and rear carrier fluid. (See the note at the end
of Schedule – B.)

24,000 Miles (38 000 km)

• Change the engine oil.

• Replace the engine oil filter.

27,000 Miles (43 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the brake linings.

30,000 Miles (48 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Replace the engine air cleaner element

(filter).

• Inspect the PCV valve, replace as neces­sary.*

• Change the All Wheel Drive (AWD) power trans­fer unit fluid. (See the note at the end of Schedule –
B.)

• Inspect the tie rod ends and boot seals.

33,000 Miles (53 000 km)

• Change the engine oil.

• Replace the engine oil filter.

36,000 Miles (58 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the brake linings.

39,000 Miles (62 000 km)

• Change the engine oil.

• Replace the engine oil filter.

42,000 Miles (67 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Change the All Wheel Drive (AWD) overrunning

clutch and rear carrier fluid. (See the note at the end
of Schedule – B.)

45,000 Miles (72 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the engine air cleaner element (fil-

ter). Replace as necessary.*

• Change the All Wheel Drive (AWD) power trans­fer unit fluid. (See the note at the end of Schedule –
B.)

• Inspect the brake linings.

48,000 Miles (77 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Flush and replace the engine coolant.

51,000 Miles (82 000 km)

• Change the engine oil.

• Flush and replace the engine coolant.

54,000 Miles (86 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the brake linings.

57,000 Miles (91 000 km)

• Change the engine oil.

• Replace the engine oil filter.

60,000 Miles (96 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Replace the engine air cleaner element

(filter).

• Inspect the PCV valve and replace if nec­essary.*

• Inspect the serpentine drive belt and replace if
necessary.

0 - 6 LUBRICATION AND MAINTENANCE NS

SPECIFICATIONS (Continued)

• Change the All Wheel Drive (AWD) power trans­fer unit fluid. (See the note at the end of Schedule –
B.)

• Inspect the tie rod ends and boot seals.

63,000 Miles (101 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the brake linings.

• Change the All Wheel Drive (AWD) overrunning

clutch and rear carrier fluid. (See the note at the end
of Schedule – B.)

66,000 Miles (106 000 km)

• Change the engine oil.

• Replace the engine oil filter.

69,000 Miles (110 000 km)

• Change the engine oil.

• Replace the engine oil filter.

72,000 Miles (115 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the brake linings.

75,000 Miles (120 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the engine air cleaner element (fil-

ter) and replace as necessary.*

• Replace the spark plugs.

• Replace the ignition cables.

• Inspect the serpentine drive belt and replace if

necessary. This maintenance is not required if belt
was previously replaced.

• Change the All Wheel Drive (AWD) power trans­fer unit fluid. (See the note at the end of Schedule –
B.)

• Flush and replace the engine coolant.

87,000 Miles (139 000 km)

• Change the engine oil.

• Replace the engine oil filter.

90,000 Miles (144 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Replace the engine air cleaner element

(filter).

• Check the PCV valve and replace if neces-

sary. Not required if previously changed.*

• Inspect the serpentine drive belt and replace if
necessary. This maintenance is not required if belt
was previously replaced.

• Change the All Wheel Drive (AWD) power trans­fer unit fluid. (See the note at the end of Schedule –
B.)

• Inspect the tie rod ends and boot seals.

• Inspect the brake linings.

93,000 Miles (149 000 km)

• Change the engine oil.

• Replace the engine oil filter.

96,000 Miles (154 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Drain and refill the automatic transmission fluid

and replace the filter. (See the note at the end of
Schedule – B.)

99,000 Miles (158 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the brake linings.

102,000 Miles (163 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Flush and replace the engine coolant.

78,000 Miles (125 000 km)

• Change the engine oil.

• Replace the engine oil filter.

81,000 Miles (130 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the brake linings.

84,000 Miles (134 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Change the All Wheel Drive (AWD) overrunning

clutch and rear carrier fluid. (See the note at the end
of Schedule – B.)

105,000 Miles (168 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the engine air cleaner element (fil-

ter) and replace as necessary.*

• Inspect the serpentine drive belt and replace if
necessary. This maintenance is not required if belt
was previously replaced.

• Change the All Wheel Drive (AWD) power trans­fer unit fluid. (See the note at the end of Schedule –
B.)

• Change the All Wheel Drive (AWD) overrunning
clutch and rear carrier fluid. (See the note at the end
of Schedule – B.)

NS LUBRICATION AND MAINTENANCE 0 - 7

SPECIFICATIONS (Continued)

108,000 Miles (173 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the brake linings.

111,000 Miles (178 000 km)

• Change the engine oil.

• Replace the engine oil filter.

114,000 Miles (182 000 km)

• Change the engine oil.

• Replace the engine oil filter.

117,000 Miles (187 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the brake linings.

120,000 Miles (192 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Replace the engine air cleaner element

(filter).

• Inspect the PCV valve and replace as nec-

essary.*

• Inspect the serpentine drive belt. Not required if

replaced at 75,000, 90,000 or 105,000 miles.

• Change the All Wheel Drive (AWD) power trans­fer unit fluid. (See the note at the end of Schedule –
B.)

• Inspect the tie rod ends and boot seals.

*This maintenance is recommended by Daimler­Chrysler Corporation to the owner but is not
required to maintain the emissions warranty.

NOTE: Operating the vehicle more than 50% in
heavy traffic during hot weather, above 90°F (32°C),
using the vehicle for police, taxi, limousine type
operation or trailer towing require the more fre­quent transaxle service noted in Schedule – B. Per­form these services if vehicle usually operates
under these conditions.

NOTE: Inspection and service should also be per­formed anytime a malfunction is observed or sus­pected.

SCHEDULE–A–PLYMOUTH/DODGE
VEHICLES

7,500 Miles (12 000 km) or at 6 months

• Change the engine oil.

• Replace the engine oil filter.

15,000 Miles (24 000 km) or at 12 months

• Change the engine oil.

• Replace the engine oil filter.

• Inspect and adjust the generator belt tension on

2.4 liter engines.

22,500 Miles (36 000 km) or at 18 months

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the brake linings.

30,000 Miles (48 000 km) or at 24 months

• Change the engine oil.

• Replace the engine oil filter.

• Replace the engine air cleaner element (fil-

ter).

• Replace the spark plugs on 2.4 liter and 3.0

liter engines.

• Inspect and adjust the generator belt and power

steering pump belt tension on 2.4 liter engines.

• Inspect the tie rod ends and boot seals.

• Adjust bands on 3–speed transmissions.

37,500 Miles (60 000 km) or at 30 months

• Change the engine oil.

• Replace the engine oil filter.

45,000 Miles (72 000 km) or at 36 months

• Change the engine oil.

• Replace the engine oil filter.

• Inspect and adjust the generator belt tension on

2.4 liter engines.

• Inspect the brake linings.

52,500 Miles (84 000 km) or at 42 months

• Change the engine oil.

• Replace the engine oil filter.

60,000 Miles (96 000 km) or at 48 months

• Change the engine oil.

• Replace the engine oil filter.

• Replace the engine air cleaner element (fil-

ter).

• Replace the ignition cables (2.4 liter and 3.0

liter engines.

• Check the PCV valve and replace, if necessary.*

• Replace the spark plugs on 2.4 liter and 3.0

liter engines.

• Check and replace, if necessary, the engine tim-

ing belt on 3.0 liter engines.

• Inspect the generator belt and power steering
pump belt tension, and replace the belt, if necessary,
on 2.4 liter engines.

• Inspect the serpentine drive belt (3.3 liter and

3.8 liter engines), replace if necessary.

• Inspect the tie rod ends and boot seals.

• Adjust bands on 3–speed transmissions.

0 - 8 LUBRICATION AND MAINTENANCE NS

SPECIFICATIONS (Continued)

67,500 Miles (108 000 km) or at 54 months

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the brake linings.

75,000 Miles (120 000 km) or at 60 months

• Change the engine oil.

• Replace the engine oil filter.

• Inspect and adjust the generator belt tension on

2.4 liter engines.

• Inspect the serpentine drive belt on 3.3 liter and

3.8 liter engines, and replace if necessary. This main­tenance is not required if belt was previously
replaced.

• Flush and replace the engine coolant at 60

months.

82,500 Miles (132 000 km) or at 66 months

• Change the engine oil.

• Replace the engine oil filter.

90,000 Miles (144 000 km) or at 72 months

• Change the engine oil.

• Replace the engine oil filter.

• Replace the engine air cleaner element (fil-

ter).

• Check the PCV valve and replace, if necessary.

Not required if previously changed.*

• Replace the spark plugs on 2.4 liter and 3.0

liter engines.

• Inspect and adjust the generator belt and power

steering pump belt tension on 2.4 liter engines.

• Inspect the serpentine drive belt on 3.3 liter and

3.8 liter engines, and replace if necessary. This main­tenance is not required if belt was previously
replaced.

• Check and replace, if necessary, the engine tim­ing belt on 3.0 liter engines. This maintenance is not
required if belt was previously replaced.

• Inspect the tie rod ends and boot seals.

• Inspect the brake linings.

• Adjust bands on 3–speed transmissions.

97,500 Miles (156 000 km) or at 78 months

• Change the engine oil.

• Replace the engine oil filter.

100,000 Miles (160,000 km)

• Replace the spark plugs 3.3 liter and 3.8 liter
engines.

• Replace the ignition cables 3.3 liter and 3.8
liter engines.

• Flush and replace the engine coolant if not done
at 60 months.

105,000 Miles (168 000 km) or at 84 months

• Change the engine oil.

• Replace the engine oil filter.

• Inspect and adjust the generator belt tension on

2.4 liter engines.

• Inspect the serpentine drive belt on 3.3 liter and

3.8 liter engines, and replace if necessary. This main­tenance is not required if belt was previously
replaced.

112,500 Miles (180 000 km) or at 90 months

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the brake linings.

120,000 Miles (192 000 km) or at 96 months

• Change the engine oil.

• Replace the engine oil filter.

• Replace the engine air cleaner element (fil-

ter).

• Replace the ignition cables 2.4 liter and 3.0

liter engines.

• Check and replace the PCV valve, if necessary.*

• Replace the spark plugs 2.4 liter and 3.0 liter

engines.

• Inspect the generator belt and power steering
pump belt tension, replace belt if necessary on 2.4
liter engines.

• Inspect the serpentine drive belt on 3.3 liter and

3.8 liter engines. Not required if replaced at 75,000,
90,000 or 105,000 miles.

• Replace the engine timing belt on 2.4 liter
engine only.

• Check and replace, if necessary, the engine tim-
ing belt on 3.0 liter engines. This maintenance is

not required if belt was replaced at 90,000 miles (144
000 km).

• Inspect the tie rod ends and boot seals.

• Adjust bands on 3–speed transmissions.

* This maintenance is recommended by Daimler­Chrysler Corporation to the owner but is not
required to maintain the emissions warranty.

Inspection and service should also be performed
anytime a malfunction is observed or suspected.
Retain all receipts.

SCHEDULE–B–PLYMOUTH/DODGE
VEHICLES

Follow this schedule if the vehicle is usually oper­ates under one or more of the following conditions.

• Frequent short trips of less than 5 miles

• Frequent driving in dusty conditions

• Frequent trailer towing

• Day and night temperatures are below freezing

• Frequent stop and go driving

• Extensive periods of idling

NS LUBRICATION AND MAINTENANCE 0 - 9

SPECIFICATIONS (Continued)

• Frequent operation at sustained high speeds

during hot weather, above 90°F (32°C)

• Use of E-85 (ethanol) fuel in 3.3 liter engines.

3,000 Miles (5 000 km)

• Change the engine oil.

• Replace the engine oil filter.

6,000 Miles (10 000 km)

• Change the engine oil.

• Replace the engine oil filter.

9,000 Miles (14 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the brake linings.

12,000 Miles (19 000 km)

• Change the engine oil.

• Replace the engine oil filter.

15,000 Miles (24 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the engine air cleaner element (fil-

ter). Replace as necessary.*

• Adjust bands on 3–speed transmission. (See the

note at the end of Schedule – B.)

• Change the All Wheel Drive (AWD) power trans­fer unit fluid. (See the note at the end of Schedule –
B.)

• Inspect and adjust the generator belt tension on

2.4 liter engines.

18,000 Miles (29 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the brake linings.

21,000 Miles (34 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Change the All Wheel Drive (AWD) overrunning

clutch and rear carrier fluid. (See the note at the end
of Schedule – B.)

24,000 Miles (38 000 km)

• Change the engine oil.

• Replace the engine oil filter.

27,000 Miles (43 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the brake linings.

30,000 Miles (48 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Replace the engine air cleaner element (fil-

ter).

• Inspect the PCV valve and replace as neces-

sary.*

• Replace the spark plugs 2.4 liter and 3.0 liter

engines.

• Inspect and adjust the generator belt and power

steering pump belt tension on 2.4 liter engines.

• Adjust bands transmission fluid and replace the

filter. (See the note at the end of Schedule – B.)

• Change the All Wheel Drive (AWD) power trans­fer unit fluid. (See the note at the end of Schedule –
B.)

• Inspect the tie rod ends and boot seals.

33,000 Miles (53 000 km)

• Change the engine oil.

• Replace the engine oil filter.

36,000 Miles (58 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the brake linings.

39,000 Miles (62 000 km)

• Change the engine oil.

• Replace the engine oil filter.

42,000 Miles (67 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Change the All Wheel Drive (AWD) overrunning

clutch and rear carrier fluid. (See the note at the end
of Schedule – B.)

45,000 Miles (72 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the engine air cleaner element (fil-

ter). Replace as necessary.*

• Inspect and adjust the generator belt tension on

2.4 liter engines.

• Adjust bands on 3–speed transmission. (See the
note at the end of Schedule – B.)

• Change the All Wheel Drive power transfer unit
fluid. (See the note at the end of Schedule – B.)

• Inspect the brake linings.

48,000 Miles (77 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Drain and replace the automatic transmission

fluid and filter.

0 - 10 LUBRICATION AND MAINTENANCE NS

SPECIFICATIONS (Continued)

51,000 Miles (82 000 km)

• Change the engine oil.

• Replace the engine oil filter.

54,000 Miles (86 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the brake linings.

57,000 Miles (91 000 km)

• Change the engine oil.

• Replace the engine oil filter.

60,000 Miles (96 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Replace the engine air cleaner element (fil-

ter).

• Replace the ignition cables (2.4 liter and 3.0

liter engines).

• Inspect the PCV valve and replace if neces-

sary.*

• Replace the spark plugs on 2.4 liter and 3.0

liter engines).

• Check and replace, if necessary, the engine tim-

ing belt on 3.0 liter engines.

• Inspect the generator belt and power steering
pump belt tension, replace belt if necessary on 2.4
liter engines.

• Inspect the serpentine drive belt on 3.3 liter and

3.8 liter engines and replace if necessary.

• Adjust bands on 3–speed transmissions. (See the
note at the end of Schedule – B.)

• Change the All Wheel Drive (AWD) power trans­fer unit fluid. (See the note at the end of Schedule –
B.)

• Inspect the tie rod ends and boot seals.

• Inspect the brake linings.

75,000 Miles (120 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the engine air cleaner element (fil-

ter) and replace as necessary.*

• Replace the spark plugs (3.3 liter and 3.8 liter

engines).

• Replace the ignition cables (3.3 liter and 3.8

liter engines).

• Inspect and adjust the generator belt tension on

2.4 liter engines.

• Inspect the serpentine drive belt on 3.3 liter and

3.8 liter engines, and replace if necessary. This main­tenance is not required if belt was previously
replaced.

• Adjust bands on 3–speed transaxle. (See the

note at the end of Schedule – B.)

• Change the All Wheel Drive power transfer unit

fluid. (See the note at the end of Schedule – B.)

78,000 Miles (125 000 km)

• Change the engine oil.

• Replace the engine oil filter.

81,000 Miles (130 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the brake linings.

84,000 Miles (134 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Change the All Wheel Drive (AWD) overrunning

clutch and rear carrier fluid. (See the note at the end
of Schedule – B.)

63,000 Miles (101 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Change the All Wheel Drive (AWD) overrunning

clutch and rear carrier fluid. (See the note at the end
of Schedule – B.)

• Inspect the brake linings.

66,000 Miles (106 000 km)

• Change the engine oil.

• Replace the engine oil filter.

69,000 Miles (110 000 km)

• Change the engine oil.

• Replace the engine oil filter.

72,000 Miles (115 000 km)

• Change the engine oil.

• Replace the engine oil filter.

87,000 Miles (139 000 km)

• Change the engine oil.

• Replace the engine oil filter.

90,000 Miles (144 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Replace the engine air cleaner element (fil-

ter).

• Check the PCV valve and replace if necessary.

Not required if previously changed.*

• Replace the spark plugs on 2.4 liter and 3.0

liter engines.

• Check and replace, if necessary, the engine tim-

ing belt on 3.0 liter engines. This maintenance is

not required if belt was previously replaced.

• Inspect and adjust the generator belt and power

steering pump belt tension on 2.4 liter engines.

NS LUBRICATION AND MAINTENANCE 0 - 11

SPECIFICATIONS (Continued)

• Inspect the serpentine drive belt (3.3 liter and

3.8 liter engines) and replace if necessary. This main­tenance is not required if belt was previously
replaced.

• Adjust bands on 3–speed transmission. (See the
note at the end of Schedule – B.)

• Change the All Wheel Drive (AWD) power trans­fer unit fluid. (See the note at the end of Schedule –
B.)

• Inspect the tie rod ends and boot seals.

• Inspect the brake linings.

93,000 Miles (149 000 km)

• Change the engine oil.

• Replace the engine oil filter.

96,000 Miles (154 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Drain and replace the automatic transmission

fluid and filter.

99,000 Miles (158 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the brake linings.

102,000 Miles (163 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Flush and replace the engine coolant.

105,000 Miles (168 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the engine air cleaner element (fil-

ter) and replace as necessary.*

• Inspect and adjust the generator belt tension on

2.4 liter engines.

• Inspect the serpentine drive belt on 3.3 liter and

3.8 liter engines and replace if necessary. This main­tenance is not required if the belt was previously
replaced.

• Adjust bands on 3–speed transmission. (See the
note at the end of Schedule – B.)

• Change the All Wheel Drive (AWD) power trans­fer unit fluid. (See the note at the end of Schedule –
B.)

• Change the All Wheel Drive (AWD) overrunning
clutch and rear carrier fluid. (See the note at the end
of Schedule – B.)

108,000 Miles (173 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the brake linings.

111,000 Miles (178 000 km)

• Change the engine oil.

• Replace the engine oil filter.

114,000 Miles (182 000 km)

• Change the engine oil.

• Replace the engine oil filter.

117,000 Miles (187 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Inspect the brake linings.

120,000 Miles (192 000 km)

• Change the engine oil.

• Replace the engine oil filter.

• Replace the engine air cleaner element (fil-

ter).

• Replace the ignition cables on 2.4 liter and 3.0

liter engines.

• Inspect the PCV valve and replace as neces-

sary.*

• Replace the spark plugs on 2.4 liter and 3.0

liter engines.

• Check and replace, if necessary, the engine tim-

ing belt on 3.0 liter engines. This maintenance is

not required if belt was replaced at 90,000 miles (144
000 km).

• Inspect the generator belt and power steering

pump belt tension, replace the belt if necessary on

2.4 liter engines.

• Inspect the serpentine drive belt on 3.3 liter and

3.8 liter engines. Not required if replaced at 75,000,
90,000 or 105,000 miles.

• Replace the engine timing belt on 2.4 liter

engines.

• Adjust bands on 3–speed transmission. (See the

note at the end of Schedule – B.)

• Change the All Wheel Drive (AWD) power trans­fer unit fluid. (See the note at the end of Schedule –
B.)

• Inspect the tie rod ends and boot seals.

* This maintenance is recommended by Daimler­Chrysler Corporation to the owner but is not
required to maintain the emissions warranty.

NOTE: Operating the vehicle more than 50% in
heavy traffic during hot weather, above 90°F (32°C),
using vehicle for police, taxi, limousine type opera­tion or trailer towing require the more frequent tran­saxle service noted in Schedule – B. Perform these
services if vehicle usually operate under these con­ditions.

Inspection and service should also be performed
anytime a malfunction is observed or suspected.

0 - 12 LUBRICATION AND MAINTENANCE NS

JUMP STARTING, TOWING, AND HOISTING

TABLE OF CONTENTS

page page

SERVICE PROCEDURES

JUMP STARTING PROCEDURE..............12

SERVICE PROCEDURES

JUMP STARTING PROCEDURE

WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN BATTERY/STARTING/CHARG­ING SECTIONS. DO NOT JUMP START A FROZEN
BATTERY, PERSONAL INJURY CAN RESULT. DO
NOT JUMP START WHEN MAINTENANCE FREE
BATTERY INDICATOR DOT IS YELLOW OR BRIGHT
COLOR. DO NOT JUMP START A VEHICLE WHEN
THE BATTERY FLUID IS BELOW THE TOP OF LEAD
PLATES. DO NOT ALLOW JUMPER CABLE
CLAMPS TO TOUCH EACH OTHER WHEN CON­NECTED TO A BOOSTER SOURCE. DO NOT USE
OPEN FLAME NEAR BATTERY. REMOVE METALLIC
JEWELRY WORN ON HANDS OR WRISTS TO AVOID
INJURY BY ACCIDENTAL ARCING OF BATTERY
CURRENT. WHEN USING A HIGH OUTPUT BOOST­ING DEVICE, DO NOT ALLOW BATTERY VOLTAGE
TO EXCEED 16 VOLTS. REFER TO INSTRUCTIONS
PROVIDED WITH DEVICE BEING USED.

TOWING RECOMMENDATIONS..............13

HOISTING RECOMMENDATIONS ............14

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 jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to neg­ative terminal (-). DO NOT allow clamps at opposite
end of cables to touch, electrical arc will result.
Review all warnings in this procedure.

(5) On disabled vehicle, connect RED jumper cable
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the
ground cable attaching point as possible (Fig. 1).

(6) Start the engine in the vehicle which has the
booster battery, let the engine idle a few minutes,
then start the engine in the vehicle with the dis­charged battery.

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:

(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.

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

(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

Fig. 1 Jumper Cable Clamp Connections

1 – BATTERY POSITIVE CABLE
2 – POSITIVE JUMPER CABLE
3 – TEST INDICATOR
4 – BATTERY NEGATIVE CABLE
5 – BATTERY
6 – NEGATIVE JUMPER CABLE
7 – ENGINE GROUND

NS LUBRICATION AND MAINTENANCE 0 - 13

SERVICE PROCEDURES (Continued)

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

(7) Allow battery in disabled vehicle to charge to
at least 12.4 volts (75% charge) before attempting to
start engine. If engine does not start within 15 sec­onds, stop cranking engine and allow starter to cool
(15 minutes), before cranking again.

DISCONNECT CABLE CLAMPS AS FOLLOWS:

• Disconnect BLACK cable clamp from engine

ground on disabled vehicle.

• When using a Booster vehicle, disconnect
BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive
terminal.

• Disconnect RED cable clamp from battery posi­tive terminal on disabled vehicle.

TOWING RECOMMENDATIONS

WARNINGS AND CAUTIONS

WARNING: DO NOT ALLOW TOWING ATTACHMENT
DEVICES TO CONTACT THE FUEL TANK OR LINES,
FUEL LEAK CAN RESULT.

DO NOT LIFT OR TOW VEHICLE BY FRONT OR

REAR BUMPER.

DO NOT GO 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.

Do not secure vehicle to towing device by the use

of front or rear suspension or steering components.

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, air dams, or spoilers.

RECOMMENDED TOWING EQUIPMENT

To avoid damage to bumper fascia and air dams

use:

• FWD vehicles, use a flat bed towing device or
wheel lift is recommended (Fig. 2).

• AWD vehicles, a flat bed towing device or wheel

lift and towing dolly is recommended (Fig. 2).

When using a wheel lift towing device, be sure the
disabled vehicle has at least 100 mm (4 in.) ground
clearance. If minimum ground clearance cannot be
reached, use a towing dolly. If a flat bed device is
used, the approach angle should not exceed 15
degrees.

Fig. 2 Recommended Towing Devices

1 – WHEEL LIFT
2 – FLAT BED

GROUND CLEARANCE

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

LOCKED VEHICLE TOWING

When a locked vehicle must be towed with the
front wheels on the ground, use a towing dolly or flat
bed hauler.

FLAT TOWING WITH TOW BAR

• Three speed automatic transaxle vehicles can be
flat towed at speeds not to exceed 40 km/h (25 mph)
for not more than 25 km (15 miles). The steering col­umn must be unlocked and gear selector in neutral.

• Four speed electronic automatic transaxle vehi­cles can be flat towed at speeds not to exceed 72
km/h (44 mph) for not more than 160 km (100 miles).
The steering column must be unlocked and gear
selector in neutral.

0 - 14 LUBRICATION AND MAINTENANCE NS

SERVICE PROCEDURES (Continued)

FLAT BED TOWING TIE DOWNS

CAUTION: Do not tie vehicle down by attaching
chains or cables to suspension components or
engine mounts, damage to vehicle can result.

The vehicle can be tied to a flat bed device using
the two pair of front slots on the bottom surface of
the rails, behind the front wheels. The two pair of
rear slots on the bottom of the rail between the
bumper extension bolts and on the bottom of the rail
just rearward of the jounce bumper. Vehicles
equipped with a rearsway bar have brackets at this
location.

TOWING – FRONT WHEEL LIFT

If the vehicle is being towed from the front, when­ever possible ensure at lest 10 inches road clearness
to the tires.

TOWING – REAR WHEEL LIFT

If a vehicle cannot be towed with the front wheels
lift, the rear wheels can be lifted provided the follow­ing guide lines are observed.

CLE. WHEN THE ENGINE 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 or front crossmember, dam­age to vehicle can result.

TO HOIST OR JACK VEHICLE SEE (Fig. 3).

Vehicles have factory rear hoisting pads. These
pads are stamped, “Hoist Point”. The front hoisting
points are at the bottom of the front rail below the S.
A. E. hoisting symbol (inverted triangle). Verify clear­ance of hoist arm to sill flange to avoid damage.

CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.

• On AWD vehicles, all four wheels must be free to

rotate. Use towing dollies at unlifted end of vehicle.

• Unlock steering column and secure steering
wheel in straight ahead position with a clamp device
designed for towing.

• Three speed automatic transaxle vehicles can be
flat towed at speeds not to exceed 40 km/h (25 mph)
for not more than 25 km (15 miles). The steering col­umn must be unlocked and gear selector in neutral.

• Four speed electronic automatic transaxle vehi­cles can be flat towed at speeds not to exceed 72
km/h (44 mph) for not more than 160 km (100 miles).
The steering column must be unlocked and gear
selector in neutral.

HOISTING RECOMMENDATIONS

Refer to Owner’s Manual provided with vehicle for

proper emergency jacking procedures.

WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-

Fig. 3 Hoisting and Jacking Points

ITEM DESCRIPTION

1 Frame Contract Lift (Single Post)

Chassis Lift (Dual Post)

Outboard Lift (Dual Post)

Floor Jack

2 Drive On Lift

NS/GS LUBRICATION AND MAINTENANCE 0 - 1

LUBRICATION AND MAINTENANCE

TABLE OF CONTENTS

page page

GENERAL INFORMATION .................... 1

MAINTENANCE SCHEDULES ................. 2

GENERAL INFORMATION

TABLE OF CONTENTS

page page

GENERAL INFORMATION

ENGINE OIL — GASOLINE ENGINES ..........1

ENGINE OIL—DIESEL ENGINES ..............1

GENERAL INFORMATION

ENGINE OIL — GASOLINE ENGINES

Use only oils conforming to API (American Petro­leum Institute) Quality SJ and Energy Conserving II,
or SH and Energy Conserving II, or ACEA A1–96.

SAE VISCOSITY GRADE

To assure of properly formulated engine oils, it is
recommended that SAE Grade 5W-30 engine oils that
meet Chrysler material standard MS-6395, be used.
SAE Grade 10W-30 oils are also acceptable when the
temperatures do not fall below 0°C. In areas where
these grades are not generally available, higher SAE
grades may be used.

Lubricants which have both an SAE grade number
and the proper API service classification shown on
the container should be used.

ENGINE OIL—DIESEL ENGINES

Use only Diesel Engine Oil meeting standard MIL­2104C or API Classification CD or higher or CCML
D4, D5.

SAE VISCOSITY GRADE

CAUTION: Low viscosity oils must have the proper
API quality or the CCMC G5 designation.

JUMP STARTING, HOISTING AND TOWING ..... 5

MANUAL TRANSMISSION FLUID (A-558 and

A-598 Models)...........................1

FLUID CAPACITIES ........................1

To assure of properly formulated engine oils, it is
recommended that SAE Grade 15W-40 engine oils
that meet Chrysler material standard MS-6395, be
used. European Grade 10W-40 oils are also accept­able.

Oils of the SAE 5W-40 or 8W-80 grade number are
preferred when minimum temperatures consistently
fall below -12°C.

MANUAL TRANSMISSION FLUID (A-558 and
A-598 Models)

Use only SAE 10W-40 engine oils carrying the
European CCMC-G5 classification to fill the A-598
5–speed manual transmission.

FLUID CAPACITIES

Fuel Tank ............................ 76L

2.0L Gasoline Engine Oil with Filter ........ 4.3L

2.5L VM Diesel Engine Oil With Filter ...... 6.5L

2.0L Gasoline Engine Cooling System* ...... 6.0L

2.5L VM Diesel Engine Cooling System* . . . 10.0 L

Transmission—5-Speed Manual ........... 2.2L

* Includes heater and coolant recovery tank filled
to Max level. Add 2.76L if equipped with Rear
Heater.

0 - 2 LUBRICATION AND MAINTENANCE NS/GS

MAINTENANCE SCHEDULES

TABLE OF CONTENTS

page page

GENERAL INFORMATION

MAINTENANCE SCHEDULE .................2

MAINTENANCE SCHEDULE—DIESEL ENGINE . . . 2

GENERAL INFORMATION

MAINTENANCE SCHEDULE

Refer to the NS/GS Service Manual for Gasoline
Engine and non-engine related Maintenance Sched­ules.

MAINTENANCE SCHEDULE—DIESEL ENGINE

The following are engine related Maintenance
items which are unique to Diesel engine-equipped
vehicles. Refer to the NS/GS Service Manual for Gas­oline Engine and non-engine related Maintenance
Schedules.

The service intervals are based on odometer read­ings in kilometers. There are two maintenance sched­ules that show proper service intervals. Use the
schedule that best describes the conditions the vehi­cle is operated under. Schedule-A lists all the sched­uled maintenance to be performed under normal
operating conditions. Schedule-B is the schedule for
vehicles that are operated under one or more of the
following conditions:

• Day and night temperatures are below freezing.

• Stop and go driving.

• Long periods of engine idling.

• Driving in dusty conditions.

• Short trips of less than 5 miles.

• Operation at sustained high speeds during hot

weather above 32°C (90°F).

• Taxi, police or delivery service.

• Trailer towing.

UNSCHEDULED INSPECTION

At Each Stop for Fuel

• Check engine oil level, add as required.

• Check windshield washer solvent and add if

required.

Once a Month

• Check tire pressure and look for unusual wear

or damage.

• Inspect battery and clean and tighten terminals

as required.

UNSCHEDULED INSPECTION................2

SCHEDULE—A (DIESEL)....................2

SCHEDULE—B (DIESEL)....................3

• Check fluid levels of coolant reservoir, brake
master cylinder, power steering and transaxle and
add as needed.

• Check all lights and all other electrical items for
correct operation.

• Check rubber seals on each side of the radiator
for proper fit.

At Each Oil Change

• Inspect exhaust system.

• Inspect brake hoses

• Inspect the CV joints and front suspension com-

ponents

• Rotate the tires at each oil change interval
shown on Schedule—A (7,500 miles) or every other
interval shown on Schedule— B (6,000 miles).

• Check the coolant level, hoses, and clamps.

• If your mileage is less than 7,500 miles (12 000

km) yearly, replace the engine oil filter at each oil
change.

• Replace engine oil filter.

SCHEDULE—A (DIESEL)

1 000 KM

• Change engine oil.

• Change engine oil filter.

• Check all fluid levels.

• Check correct torque, intake manifold mounting

nuts.

• Check correct torque, exhaust manifold mount­ing nuts.

Check correct torque, turbocharger mounting nuts.

•

• Check correct torque, water manifold bolts.

10 000 KM

• Change engine oil.

• Change engine oil filter.

20 000 KM

• Change engine oil.

• Change engine oil filter.

• Replace air filter element.

• Drive belt visual inspection.

• Check glow plug operation.

NS/GS LUBRICATION AND MAINTENANCE 0 - 3

GENERAL INFORMATION (Continued)

30 000 KM

• Change engine oil.

• Change engine oil filter.

40 000 KM

• Change engine oil.

• Change engine oil filter.

• Replace air filter element.

• Drive belt visual inspection.

• Replace fuel filter/water separator element.**

50 000 KM

• Change engine oil.

• Change engine oil filter.

60 000 KM

• Change engine oil.

• Change engine oil filter.

• Replace air filter element.

• Replace drive belt.

• Check engine smoke.

• Replace engine coolant.

70 000 KM

• Change engine oil.

• Change engine oil filter.

EVERY 10 000 KM AFTER 100 000 KM

• Change engine oil.

• Change engine oil filter.

EVERY 20 000 KM AFTER 100 000 KM

• Change engine oil.

• Change engine oil filter.

• Replace air filter element.

• Drive belt visual inspection.

• Check glow plug operation.

SCHEDULE—B (DIESEL)

500 KM

• Check correct torque, intake manifold mounting
nuts.

• Check correct torque, exhaust manifold mount­ing nuts.

• Check correct torque, turbocharger mounting
nuts.

• Check correct torque, water manifold bolts.

1 000 KM

• Change engine oil.

• Change engine oil filter.

• Check all fluid levels.

80 000 KM

• Change engine oil.

• Change engine oil filter.

• Replace air filter element.

• Drive belt visual inspection.

• Replace fuel filter/water separator element.**

90 000 KM

• Change engine oil.

• Change engine oil filter.

100 000 KM

• Change engine oil.

• Change engine oil filter.

• Replace air filter element.

• Drive belt visual inspection.

• Check glow plug operation.

160 000 KM

• Flush and replace engine coolant.

EVERY 40 000 KM AFTER 80 000 KM

• Replace fuel filter/water separator element.**

**The fuel filter/water separator element should be
replaced once a year if the vehicle is driven less than
40 000 km annually or if power loss from fuel star­vation is detected.

5 000 KM

• Change engine oil.

• Change engine oil filter.

10 000 KM

• Change engine oil.

• Change engine oil filter.

• Replace air filter element.

• Drive belt visual inspection.

15 000 KM

• Change engine oil.

• Change engine oil filter.

20 000 KM

• Change engine oil.

• Change engine oil filter.

• Replace air filter element.

• Drive belt visual inspection.

25 000 KM

• Change engine oil.

• Change engine oil filter.

30 000 KM

• Change engine oil.

• Change engine oil filter.

• Replace air filter element.

• Replace drive belt.

• Check engine smoke.

0 - 4 LUBRICATION AND MAINTENANCE NS/GS

GENERAL INFORMATION (Continued)

35 000 KM

• Change engine oil.

• Change engine oil filter.

• Change MTX Fluid

40 000 KM

• Change engine oil.

• Change engine oil filter.

• Replace air filter element.

• Drive belt visual inspection.

• Diesel engines only—Replace fuel filter/water

separator element.

45 000 KM

• Change engine oil.

• Change engine oil filter.

50 000 KM

• Change engine oil.

• Change engine oil filter.

• Replace air filter element.

• Drive belt visual inspection.

55 000 KM

• Change engine oil.

• Change engine oil filter.

60 000 KM

• Change engine oil.

• Change engine oil filter.

• Replace air filter element.

• Drive belt visual inspection.

• Diesel engines only—Replace fuel filter/water

separator element.

65 000 KM

• Change engine oil.

• Change engine oil filter.

70 000 KM

• Change engine oil.

• Change engine oil filter.

• Replace air filter element.

• Drive belt visual inspection.

• Change MTX fluid

75 000 KM

• Change engine oil.

• Change engine oil filter.

• Replace air filter element.

• Replace drive belt.

• Check engine smoke.

• Replace engine coolant.

85 000 KM

• Change engine oil.

• Change engine oil filter.

90 000 KM

• Change engine oil.

• Change engine oil filter.

• Replace air filter element.

• Drive belt visual inspection.

95 000 KM

• Change engine oil.

• Change engine oil filter.

100 000 KM

• Change engine oil.

• Change engine oil filter.

• Replace air filter element.

• Drive belt visual inspection.

• Check glow plug operation.

• Diesel engines only—Replace fuel filter/water

separator element.

• Change MTX fluid

160 000 KM

• Flush and replace engine coolant.

EVERY 5 000 KM AFTER 100 000 KM

• Change engine oil.

• Change engine oil filter.

EVERY 10 000 KM AFTER 100 000 KM

• Change engine oil.

• Change engine oil filter.

• Replace air filter element.

• Drive belt visual inspection.

• Check glow plug operation.

EVERY 20 000 KM AFTER 100 000 KM

• Diesel engines only—Replace fuel filter/water

separator element.

EVERY 35 000 KM AFTER 100 000 KM

• Change MTX fluid

80 000 KM

• Change engine oil.

• Change engine oil filter.

NS/GS LUBRICATION AND MAINTENANCE 0 - 5

JUMP STARTING, HOISTING AND TOWING

TABLE OF CONTENTS

page

SERVICE PROCEDURES

TOWING RECOMMENDATIONS...............5

SERVICE PROCEDURES

TOWING RECOMMENDATIONS

WARNINGS AND CAUTIONS

WARNING: DO NOT ALLOW TOWING ATTACHMENT
DEVICES TO CONTACT THE FUEL TANK OR LINES,
FUEL LEAK CAN RESULT.

DO NOT LIFT OR TOW VEHICLE BY FRONT OR
REAR BUMPER, OR BUMPER ENERGY ABSORBER
UNITS.

DO NOT GO 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.

Do not attach towing device to front or rear sus­pension components.

Do not secure vehicle to towing device by the use
of front or rear suspension or steering components.

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, air dams, or spoilers.

RECOMMENDED TOWING EQUIPMENT

To avoid damage to bumper fascia and air dams
use of a flat bed towing device or wheel lift (Fig. 1) is
recommended. When using a wheel lift towing device,
be sure the disabled vehicle has at least 100 mm (4
in.) ground clearance. If minimum ground clearance
cannot be reached, use a towing dolly. If a flat bed

device is used, the approach angle should not exceed
15 degrees.

Fig. 1 Recommended Towing Devices

1 – WHEEL LIFT
2 – FLAT BED

GROUND CLEARANCE

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

LOCKED VEHICLE TOWING

When a locked vehicle must be towed with the
front wheels on the ground, use a towing dolly or flat
bed hauler.

FLAT TOWING WITH TOW BAR

• 4-speed electronic automatic transaxle vehicles
can be flat towed at speeds not to exceed 72 km/h (44
mph) for not more than 160 km (100 miles). The
steering column must be unlocked and gear selector
in neutral.

0 - 6 LUBRICATION AND MAINTENANCE NS/GS

SERVICE PROCEDURES (Continued)

FLAT BED TOWING TIE DOWNS

CAUTION: Do not tie vehicle down by attaching
chains or cables to suspension components or
engine mounts, damage to vehicle can result.

NS vehicles can be tied to a flat bed device using
the reinforced loops located under the front and rear
bumpers on the drivers side of the vehicle. There are
also four reinforced elongated holes for T or R-hooks
located on the bottom of the front frame rail torque
boxes behind the front wheels and forward of the
rear wheels inboard of the rocker panel weld seam.

TOWING—FRONT WHEEL LIFT

Chrysler International recommends that a vehicle
be towed with the front end lifted, whenever possible.
A 90 cm (36 in.) length of 4x4 wood beam can be
placed between the wheel lift device and the bottom
of the fascia to prevent damage to vehicle during the
lifting operation. The beam can removed after lifting
the front of the vehicle.

TOWING—REAR WHEEL LIFT

If a vehicle cannot be towed with the front wheels
lifted, the rear wheels can be lifted provided the fol­lowing guide lines are observed.

CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.

• On AWD vehicles, all four wheels must be free to

rotate. Use towing dollies at unlifted end of vehicle.

• Unlock steering column and secure steering
wheel in straight ahead position with a clamp device
designed for towing.

• 4-speed electronic automatic transaxle vehicles
can be flat towed at speeds not to exceed 72 km/h (44
mph) for not more than 160 km (100 miles). The
steering column must be unlocked and gear selector
in neutral.

TOWING—TOW HOOKS

Fig. 2

1–NOSPACE
2 – TOW HOOK

WARNING: Do not use the tow hook to lift the vehi­cle off the ground.

A tow-hook bolt, located in the rear interior trim
storage compartment (with jack), is provided with
your vehicle. The tow hook is used for towing the
vehicle with all four wheels on the ground only. It
can be attached to the vehicle through an opening in
the lower front fascia. The tow hook must be fully
seated to the attach bracket through the lower front
fascia as shown. If the tow hook is not fully seated to
the attach bracket the vehicle should not be towed.

NOTE: The tow hook bolt protective plug must be
removed from the tow hook bracket prior to bolt
attachment. The tow hook is used ONLY for towing
the vehicle with all four wheels on the ground.

NS SUSPENSION 2 - 1

SUSPENSION

TABLE OF CONTENTS

page page

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

FRONT SUSPENSION ...................... 10

WHEEL ALIGNMENT

TABLE OF CONTENTS

page page

DESCRIPTION AND OPERATION

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

DIAGNOSIS AND TESTING

SUSPENSION AND STEERING DIAGNOSIS .....3

SERVICE PROCEDURES

PRE-WHEEL ALIGNMENT INSPECTION ........5

DESCRIPTION AND OPERATION

WHEEL ALIGNMENT

DESCRIPTION

Vehicle wheel alignment is the proper adjustment
of all interrelated front and rear suspension angles.
These angles are what affects the handling and
steering of the vehicle when it is in motion.

The method of checking a vehicle’s front and rear
wheel alignment will vary depending on the type and
manufacturer of the equipment being used. Instruc­tions furnished by the manufacturer of the equip­ment being used should always be followed to ensure
accuracy of the alignment, except when alignment
specifications recommended by DaimlerChrysler Cor­poration differ.

Typical wheel alignment angles and measurements
are camber, caster, toe, and thrust angle.

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

CURB HEIGHT MEASUREMENT ..............5

WHEEL ALIGNMENT .......................5

SPECIFICATIONS

WHEEL ALIGNMENT SPECIFICATIONS.........9

• Camber is the number of degrees the top of the
tire and wheel assembly is tilted either inward or
outward (Fig. 1). Camber is a tire wearing angle.
Excessive negative camber will cause tread wear at
the inside of the tire, while excessive positive camber
will cause outside tire wear.

• Cross Camber is the difference between left and
right camber. To achieve the cross camber reading,
subtract the right side camber reading from the left.
For example, if the left camber is +0.3° and the right
camber is 0.0°, the cross camber would be +0.3°.

• Caster is the number of degrees of forward or
rearward tilt of the steering knuckle (Fig. 2). For­ward tilt provides a negative caster angle, while rear­ward tilt provides a positive caster angle. Although
caster does not affect tire wear, a caster imbalance
(side-to-side) on the vehicle may cause the vehicle to
lead to the side with the least positive caster. Caster
is not adjustable on this vehicle.

2 - 2 SUSPENSION NS

DESCRIPTION AND OPERATION (Continued)

• Cross Caster is the difference between left and

right caster.

• Toe is measured in degrees or inches and is the
difference in width between the centered leading and
trailing edges of the tires on the same axle (Fig. 3).
Toe-in means that the front width is more narrow
than the rear. Toe-out means that the front width is
wider than the rear.

• Thrust Angle is defined as the average of the toe
settings on each rear wheel. If this measurement is
out of specification, readjust the rear wheel toe so
that each wheel has 1/2 of the total toe measure­ment. When readjusting, do not exceed the total toe
specification.

Wheel alignment on this vehicle is to be checked
and all alignment adjustments are to be made with
the vehicle standing at its curb height specification.
Curb height is the riding height of the vehicle mea­sured from a certain point on the vehicle to the
ground while the vehicle is setting on a flat, level
surface.

1 – POSITIVE
2 – NEGATIVE

Fig. 2 Caster

1 – NEGATIVE
2 – POSITIVE

Fig. 1 Camber

Fig. 3 Toe

1 – TOE-IN
2 – TOE-OUT

NS SUSPENSION 2 - 3

DIAGNOSIS AND TESTING

SUSPENSION AND STEERING DIAGNOSIS

CONDITION POSSIBLE CAUSES CORRECTION

Front End Whine On Turns 1. Defective wheel bearing 1. Replace wheel bearing

2. Incorrect wheel alignment 2. Check and reset wheel alignment

3. Worn tires 3. Replace tires

Front End Growl Or
Grinding On Turns

Front End Clunk Or Snap
On Turns

1. Defective wheel bearing 1. Replace wheel bearing

2. Engine mount grounding 2. Check for motor mount hitting frame
rail and reposition engine as required

3. Worn or broken C/V joint 3. Replace C/V joint

4. Loose wheel lug nuts 4. Verify wheel lug nut torque

5. Incorrect wheel alignment 5. Check and reset wheel alignment

6. Worn tires 6. Replace tires

7. Front strut pin in upper strut mount 7. Replace the front strut upper mount
and bearing

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

2. Worn or broken C/V joint 2. Replace C/V joint

3. Worn or loose tie rod 3. Tighten or replace tie rod end

4. Worn or loose ball joint 4. Tighten or replace ball joint

5. Worn/loose control arm bushing 5. Replace control arm bushing

6. Loose stabilizer bar. 6. Tighten stabilizer bar to specified
torque

7. Loose strut mount to body

attachment

8. Loose crossmember bolts 8. Tighten crossmember bolts to

7. Tighten strut attachment to specified
torque

specified torque

Front End Whine With
Vehicle Going Straight At A
Constant Speed

Front End Growl Or
Grinding With Vehicle
Going Straight At A
Constant Speed

Front End Whine When
Accelerating Or
Decelerating

1. Defective wheel bearing 1. Replace wheel bearing

2. Incorrect wheel alignment 2. Check and reset wheel alignment

3. Worn tires 3. Replace tires

4. Worn or defective transaxle gears or

bearings

1. Engine mount grounding 1. Reposition engine as required

2. Worn or broken C/V joint 2. Replace C/V joint

1. Worn or defective transaxle gears or

bearings

4. Replace transaxle gears or bearings

1. Replace transaxle gears or bearings

2 - 4 SUSPENSION NS

DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

Front End Clunk When
Accelerating Or Decelerating

Road Wander 1. Incorrect tire pressure 1. Inflate tires to recommended pressure

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

2. Worn or defective transaxle gears or

bearings

3. Loose lug nuts 3. Verify wheel lug nut torque

4. Worn or broken C/V joint 4. Replace C/V joint

5. Worn or loose ball joint 5. Tighten or replace ball joint

6. Worn or loose control arm bushing 6. Replace control arm bushing

7. Loose crossmember bolts 7. Tighten crossmember bolts to

8. Worn tie rod end 8. Replace tie rod end

2. Incorrect front or rear wheel toe 2. Check and reset wheel toe

3. Worn wheel bearings 3. Replace wheel bearing

4. Worn control arm bushings 4. Replace control arm bushing

5. Excessive friction in steering gear 5. Replace steering gear

6. Excessive friction in steering shaft

coupling

7. Excessive friction in strut upper

bearing

2. Replace transaxle gears or bearings

specified torque

6. Replace steering coupler

7. Replace strut bearing

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

pressure

2. Radial tire lead 2. Perform lead correction procedure

3. Incorrect front wheel camber 3. Check and reset front wheel camber

4. Power steering gear imbalance 4. Replace power steering gear

5. Wheel braking 5. Correct braking condition causing
lateral pull

Excessive Steering Free
Play

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

1. Incorrect Steering Gear Adjustment 1. Adjust Or Replace Steering Gear

2. Worn or loose tie rod ends 2. Replace or tighten tie rod ends

3. Loose steering gear mounting bolts 3. Tighten steering gear bolts to specified
torque

4. Loose or worn steering shaft coupler 4. Replace steering shaft coupler

pressure

2. Lack of lubricant in steering gear 2. Replace steering gear

3. Low power steering fluid level 3. Fill power steering fluid reservoir to
correct level

4. Loose power steering pump drive

belt

5. Lack of lubricant in ball joints 5. Lubricate or replace ball joints

6. Steering gear malfunction 6. Replace steering gear

7. Lack of lubricant in steering coupler 7. Replace steering coupler

4. Correctly adjust power steering pump
drive belt

NS SUSPENSION 2 - 5

SERVICE PROCEDURES

PRE-WHEEL ALIGNMENT INSPECTION

Before any attempt is made to change or correct
the wheel alignment, the following inspection and
necessary corrections must be made to the vehicle to
ensure proper alignment.

(1) Be sure the fuel tank is full of fuel. If the fuel
tank is not full, the reduction in weight will affect
the curb height of the vehicle and the alignment
specifications.

(2) The passenger and luggage compartments of
the vehicle should be free of any load that is not fac­tory equipment.

(3) Check the tires on the vehicle. The tires are to
be inflated to the recommended air pressure. All tires
must be the same size and in good condition with
approximately the same tread wear.

(4) Check the front tire and wheel assemblies for
excessive radial runout.

(5) Inspect all suspension component fasteners for
looseness and torque.

(6) Inspect the lower front ball joints and all steer­ing linkage for looseness and any sign of wear or
damage.

(7) Inspect the rubber bushings on all the suspen­sion components for signs of wear or deterioration. If
any bushings show signs of wear or deterioration,
they should be replaced prior to aligning the vehicle.

(8) Check vehicle curb height to verify it is within
specifications. Refer to CURB HEIGHT MEASURE-

MENT in this section. If curb height is out of speci­fications, check for broken or sagged springs.

CURB HEIGHT MEASUREMENT

The wheel alignment is to be checked and all align­ment adjustments made with the vehicle at its
required curb height specification.

Vehicle height is to be checked with the vehicle on
a flat, level surface, preferably a vehicle alignment
rack. The tires are to be inflated to the recommended
pressure. All tires are to be the same size as stan­dard equipment. Vehicle height is checked with the
fuel tank full of fuel, and no passenger or luggage
compartment load.

Vehicle height is not adjustable. If the measure­ment is not within specifications, inspect the vehicle
for bent or weak suspension components. Compare
the parts tag on the suspect coil spring(s) to the
parts book and the vehicle sales code, checking for a
match. Once removed from the vehicle, compare the
coil spring height to a correct new or known good coil
spring. The heights should vary if the suspect spring
is weak.

(1) Measure from the inboard edge of the wheel
opening fender lip directly above the wheel center
(spindle), to the floor or alignment rack surface.

(2) When measuring, the maximum left-to-right
differential is not to exceed 12.5 mm (0.5 in.).

(3) Compare the measurements to the specifica­tions listed in the following CURB HEIGHT SPECI­FICATIONS chart.

CURB HEIGHT SPECIFICATIONS

VEHICLE FRONT REAR

ALL GAS ENGINED VEHICLES

WITH TIRE SIZES P205/75R 14

AND P215/65R 15

ALL GAS ENGINED VEHICLES

WITH TIRE SIZES P215/70R 15,

P215/65R 16 AND P215/60R 17

CNG AND ELECTRIC VEHICLES

747.5 mm 6 10 mm 766.0 mm 6 10 mm

29.43 in. 6 0.39 in. 30.15 in. 6 0.39 in.

753.5 mm 6 10 mm 772.0 mm 6 10 mm

29.66 in. 6 0.39 in. 30.39 in. 6 0.39 in.

783.5 mm 6 10 mm 802.5 mm 6 10 mm

30.85 in. 6 0.39 in. 31.59 in. 6 0.39 in.

WHEEL ALIGNMENT

(1) Position the vehicle on an alignment rack.

(2) Perform the PRE-WHEEL ALIGNMENT
INSPECTION. It can be found elsewhere in this sec­tion.

(3) Install all required alignment equipment on
the vehicle per the alignment equipment manufactur­er’s instructions. On this vehicle, a four-wheel align­ment is recommended.

NOTE: Prior to reading the vehicle’s alignment
readouts, the front and rear of vehicle should be
jounced. Induce jounce (rear first, then front) by
grasping the center of the bumper and jouncing
each end of vehicle an equal number of times. The
bumper should always be released when vehicle is
at the bottom of the jounce cycle.

(4) Read the vehicle’s current front and rear align-

ment settings. Compare the vehicle’s current align-

2 - 6 SUSPENSION NS

SERVICE PROCEDURES (Continued)

ment settings to the vehicle specifications for camber,
caster and toe-in. Refer to WHEEL ALIGNMENT
SPECIFICATIONS in this section of this service
manual group.

(5) If front camber and caster are not within spec­ifications, proceed to CAMBER AND CASTER below.
If caster and camber are within specifications, pro­ceed to TOE which can be found following CAMBER
AND CASTER. Rear camber, caster and toe are not
adjustable. If found not to be within specifications,
reinspect for damaged suspension or body compo­nents and replace as necessary.

CAMBER AND CASTER

Camber and caster settings on this vehicle are
determined at the time the vehicle is designed, by
the location of the vehicle’s suspension components.
This is referred to as NET BUILD. The result is no
required adjustment of camber and caster after the
vehicle is built or when servicing the suspension
components. Thus, when performing a wheel align­ment, caster and camber are not normally considered
adjustable angles. Camber and caster should be
checked to ensure they meet vehicle specifications.

If front camber is found not to meet alignment
specifications, it can be adjusted using an available
camber adjustment bolt package. Before installing a
camber adjustment bolt package on a vehicle found
to be outside the specifications, inspect the suspen­sion components for any signs of damage or bending.

brake flex hose when removed from the strut
assembly. If necessary use a wire hanger to sup­port the steering knuckle assembly or if required
remove the brake flex hose from the caliper assem­bly.

CAUTION: The knuckle to strut assembly attaching
bolt shanks are serrated and must not be turned
during removal. Remove the nuts while holding the
bolts stationary.

(3) Remove the top and bottom, strut clevis
bracket to steering knuckle attaching bolts (Fig. 4)
and discard. Separate the steering knuckle from the
strut clevis bracket and position steering knuckle so
it is out of the way of the strut.

CAUTION: Do not attempt to adjust the vehicles
wheel; alignment by heating, bending or by per­forming any other modification to the vehicle’s front
suspension components or body.

If camber readings are not within specifications,
use the following procedure to install the front cam­ber adjustment bolt package and then adjust front
camber.

CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION

The camber adjustment bolt package contains 2
flange bolts, 2 cam bolts, 2 dog bone washers, and 4
nuts. This package services both sides of the vehicle.
Use the package to attach the strut clevis bracket to
the steering knuckle after the strut clevis bracket
has been modified. To install and adjust the camber
adjustment bolt package, follow the procedure below.

(1) Raise the vehicle until its tires are not support­ing the weight of the vehicle.

(2) Remove the front tire and wheel assemblies.

CAUTION: When removing the steering knuckle
from the strut clevis bracket, do not put a strain on
the brake flex hose. Also, do not let the weight of
the steering knuckle assembly be supported by the

Fig. 4 Clevis Bracket To Steering Knuckle Attaching

Bolts

1 – STRUT CLEVIS BRACKET
2 – ATTACHING BOLTS
3 – TIE ROD END
4 – ROTOR
5 – STEERING KNUCKLE

CAUTION: When slotting the bottom mounting hole
on the strut clevis bracket, do not enlarge the hole
beyond the indentations on the sides of the strut
clevis bracket (Fig. 5).

(4) Using an appropriate grinder and grinding
wheel, slot the bottom hole in both sides of the strut
clevis bracket (Fig. 5).

CAUTION: After slotting the strut clevis bracket
hole, do not install the original attaching bolts when
assembling the steering knuckle to the strut assem­bly. Only the flange bolts, cam bolts, and dog bone
washers from the service package must be used to
attach the steering knuckle to the strut after the
mounting hole is slotted.

NS SUSPENSION 2 - 7

SERVICE PROCEDURES (Continued)

(6) Install a dog bone washer on the steering
knuckle to strut clevis bracket attaching bolts, then
install the nuts onto the bolts from the service pack­age (Fig. 7). Tighten the bolts just enough to hold the
steering knuckle in position when adjusting camber,
while still allowing the steering knuckle to move in
clevis bracket.

Fig. 5 Strut Clevis Bracket Bolt Hole Grinding Area

1 – UPPER STRUT TO STEERING KNUCKLE ATTACHING HOLE
2 – CAMBER ADJUSTMENT SLOT INDENTATION AREA ON

CLEVIS BRACKET
3 – LOWER STRUT TO STEERING KNUCKLE ATTACHING HOLE
4 – STRUT CLEVIS BRACKET

(5) Position the knuckle back into the strut clevis
bracket. Install a flanged bolt from the service pack­age into the upper mounting hole. Install a cam bolt
into the bottom mounting hole. Both bolts should
point forward once installed (Fig. 6).

Fig. 6 Package Bolts Correctly Installed (Left

Shown)

1 – STEERING KNUCKLE
2 – FLANGED BOLT IN TOP HOLE
3 – CAM BOLT IN BOTTOM HOLE
4 – STRUT CLEVIS BRACKET

Fig. 7 Dog Bone Washer And Nuts Installed On

Attaching Bolts

1 – STEERING KNUCKLE
2 – DOG BONE WASHER
3 – STRUT CLEVIS BRACKET
4 – ATTACHING NUTS

(7) Repeat the procedure to the other side strut

clevis bracket.

(8) Reinstall both front tire and wheel assemblies

and tighten to specifications.

(9) Lower the vehicle. Jounce the front and rear of

vehicle an equal amount of times.

(10) Adjust the front camber to the preferred set­ting by rotating the lower eccentric cam bolt against
the cam stop areas on the strut clevis bracket (Fig.

8). When camber is set, tighten the upper strut clevis
bracket bolt and lower cam bolt. Again jounce front
and rear of vehicle an equal amount of times and
verify front camber setting. Torque both front strut to
steering knuckle attaching bolts to 90 N·m (65 ft.
lbs.) plus an additional 1/4 turn after the required
torque is met.

(11) If toe readings obtained are not within the
required specification range, adjust toe to meet the
preferred specification setting. Toe is adjustable
using the following procedure.

2 - 8 SUSPENSION NS

SERVICE PROCEDURES (Continued)

Fig. 8 Camber Adjustment Cam Bolt

1 – STEERING KNUCKLE
2 – CLEVIS BRACKET CAM STOP AREAS
3 – LOWER ECCENTRIC CAMBER ADJUSTMENT BOLT

TOE

(1) Center the steering wheel and lock in place

using a steering wheel clamp.

CAUTION: Do not twist front inner tie rod to steer­ing gear rubber boots during front wheel Toe
adjustment.

(2) Loosen front inner to outer tie rod end jam
nuts (Fig. 9). Grasp inner tie rods at serrations and
rotate inner tie rods of steering gear (Fig. 9) to set
front toe to the preferred toe specification. Refer to
WHEEL ALIGNMENT SPECIFICATIONS in this
group of the service manual for preferred specifica­tion.

Fig. 9 Front Wheel Toe Adjustment

1 – INNER TIE ROD SERRATION
2 – OUTER TIE ROD JAM NUT
3 – OUTER TIE ROD END
4 – INNER TIE ROD
5 – STEERING KNUCKLE

(3) Tighten tie rod jam nuts (Fig. 9) to 75 N·m (55

ft. lbs.) torque.

(4) Adjust steering gear to tie rod boots at the

inner tie rod.

(5) Remove steering wheel clamp.
(6) Remove the alignment equipment.

(7) Road test the vehicle to verify the steering
wheel is straight and the vehicle does not wander or
pull.

NS SUSPENSION 2 - 9

SPECIFICATIONS

WHEEL ALIGNMENT SPECIFICATIONS

NOTE: All specifications are given in degrees.

FRONT WHEEL ALIGNMENT PREFERRED SETTING ACCEPTABLE RANGE

CAMBER
All vehicles except those with tire sizes P205/75R 15,

P215/65R 16 and P215/60R 17
Vehicles with tire sizes P205/75R 15, P215/65R 16 and

P215/60R 17
Cross Camber (Maximum side-to-side difference) 0.0° 0.50°

CASTER* +1.40° +0.40° to +2.40°
Cross Caster (Maximum side-to-side difference) 0.0° 1.00°

TOTAL TOE** +0.10° −0.10° to +0.30°
Maximum side-to-side difference 0.0° 0.06°

REAR WHEEL ALIGNMENT PREFERRED SETTING ACCEPTABLE RANGE

CAMBER* 0.0° -0.25° to +0.25°
ALTERNATIVE FUEL VEHICLES ONLY* -0.10° -0.35° to +0.15°

TOTAL TOE* ** 0.0° −0.40° to +0.40°
THRUST ANGLE* 0.0° -0.30° to +0.30°
Notes:

* For reference only. These are non-adjustable angles.
** TOTAL TOE is the sum of both left and right wheel toe settings. TOTAL TOE must be equally split between

each front wheel to ensure the steering wheel is centered after setting toe. Positive toe is toe-in and negative toe
is toe-out

NOTE: All wheel alignments are to be set at curb
height. Refer to CURB HEIGHT MEASUREMENT in
SERVICE PROCEDURES.

+0.15° -0.25° to +0.55°

+0.05° -0.35° to +0.45°

2 - 10 SUSPENSION NS

FRONT SUSPENSION

TABLE OF CONTENTS

page page

DESCRIPTION AND OPERATION

FRONT SUSPENSION SYSTEM..............10

STRUT ASSEMBLY (FRONT) ................12

STEERING KNUCKLE .....................12

HUB AND BEARING (FRONT) ...............12

LOWER CONTROL ARM ...................13

BALL JOINT .............................13

STABILIZER BAR (FRONT) .................13

DIAGNOSIS AND TESTING

STRUT ASSEMBLY (FRONT) ................14

STEERING KNUCKLE .....................14

HUB AND BEARING (FRONT) ...............14

LOWER CONTROL ARM ...................15

BALL JOINT .............................15

STABILIZER BAR (FRONT) .................15

SERVICE PROCEDURES

LUBRICATION ...........................15

REMOVAL AND INSTALLATION

STRUT ASSEMBLY (FRONT) ................15

DESCRIPTION AND OPERATION

FRONT SUSPENSION SYSTEM

DESCRIPTION

This vehicle has a MacPherson strut type front

suspension design (Fig. 1).

OPERATION

The front suspension allows each wheel on a vehi­cle to adapt to different road surfaces and conditions
without greatly affecting the opposite wheel and the
ability to control the vehicle. Each side of the front
suspension is allowed to pivot so the vehicle can be
steered in the direction preferred.

STEERING KNUCKLE .....................17

HUB AND BEARING (FRONT) ...............22

LOWER CONTROL ARM ...................25

STABILIZER BAR (FRONT) .................29

WHEEL MOUNTING STUDS (FRONT) .........31

DISASSEMBLY AND ASSEMBLY

STRUT ASSEMBLY (FRONT) ................32

LOWER CONTROL ARM (BALL JOINT SEAL

BOOT) ...............................36

LOWER CONTROL ARM (BALL JOINT) ........37

LOWER CONTROL ARM (FRONT BUSHING) ....39

LOWER CONTROL ARM (REAR BUSHING) .....41

STABILIZER BAR BUSHING (FRONT) .........42

SPECIFICATIONS

FRONT SUSPENSION FASTENER TORQUES . . . 42

SPECIAL TOOLS

FRONT SUSPENSION .....................42

A strut assembly is used in place of the front sus­pension upper control arm and upper ball joint.
When a vehicle strikes a bump, the force is trans­ferred through the hub, bearing, and knuckle, into
the strut assembly to absorb the force and dampen it.
The top of the strut is mounted directly to the strut
tower of the vehicle. During steering maneuvers, the
strut assembly (through a pivot bearing in the upper
strut mount) and steering knuckle (through the lower
ball joint) turn as an assembly.

NS SUSPENSION 2 - 11

DESCRIPTION AND OPERATION (Continued)

1 – TOWER
2 – STRUT ASSEMBLY
3 – STABILIZER BAR LINK
4 – STABILIZER BAR
5 – ISOLATOR BUSHING
6 – FRAME RAIL
7 – CRADLE/CROSSMEMBER
8 – LOWER CONTROL ARM
9 – BALL JOINT
10 – WHEEL STOP
11 – HUB AND BEARING

Fig. 1 Front Suspension System

12 – STEERING KNUCKLE
13 – STRUT
14 – LOWER SPRING ISOLATOR
15 – COIL SPRING
16 – JOUNCE BUMPER
17 – DUST SHIELD
18 – SPRING SEAT
19 – PIVOT BEARING
20 – UPPER MOUNT
21 – NUT

2 - 12 SUSPENSION NS

DESCRIPTION AND OPERATION (Continued)

STRUT ASSEMBLY (FRONT)

DESCRIPTION

A Macpherson type strut assembly is used in place
of a front suspension upper control arm and upper
ball joint (Fig. 1). The bottom of the strut mounts
directly to the steering knuckle using 2 attaching
bolts and nuts going through the strut clevis bracket
and steering knuckle. The top of the strut mounts
directly to the strut tower of the vehicle using the
threaded studs on the strut assemblies upper mount.

The strut assembly includes the following compo­nents:

• Upper mount

• Pivot bearing

• Upper spring seat (and isolator)

• Dust shield

• Jounce bumper

• Coil spring

• Lower spring isolator

• Strut

Each component is serviced by removing the strut
assembly from the vehicle and disassembling it.

Coil springs are rated separately for each corner or
side of the vehicle depending on optional equipment
and type of vehicle service. If the coil springs require
replacement, be sure that the springs needing
replacement are replaced with springs meeting the
correct load rating and spring rate for the vehicle
and its specific options.

OPERATION

The strut assembly cushions the ride of the vehicle,
controlling vibration, along with jounce and rebound
of the suspension.

The coil spring controls ride quality and maintains
proper ride height.

The spring isolators isolate the coil spring at the
top and bottom from coming into metal-to-metal con­tact with the upper seat and strut.

The jounce bumper limits suspension travel and
metal-to-metal contact under full jounce condition.

The strut dampens jounce and rebound motions of
the coil spring and suspension.

During steering maneuvers, the strut assembly
(through a pivot bearing in the upper strut mount)
and steering knuckle (through the lower ball joint)
turn as an assembly.

STEERING KNUCKLE

DESCRIPTION

The steering knuckle is a single casting with legs
machined for attachment of the strut assembly, steer­ing linkage, disc brake caliper, and lower control arm
ball joint (Fig. 2). The hub and bearing assembly is

mounted in the center of the steering knuckle using
4 bolts. The driveshaft’s constant velocity (C/V) stub
shaft is splined through the center of the hub and
bearing and is held in place using a nut, nut lock and
cotter pin.

Fig. 2 Steering Knuckle

1 – FRONT STRUT ASSEMBLY
2 – FRONT STEERING KNUCKLE
3 – TIE ROD END
4 – STUB AXLE
5 – HUB/BEARING ASSEMBLY
6 – DISC BRAKE CALIPER MOUNTING BOSSES
7 – DISC BRAKE CALIPER ABUTMENT

OPERATION

The steering knuckle pivots with the strut assem­bly between the lower ball joint and the pivot bearing
in the strut assembly. The steering gear outer tie rod
end connects to the trailing end of each knuckle,
allowing the vehicle to be steered.

The center of the knuckle supports the hub and
bearing and axle shaft.

HUB AND BEARING (FRONT)

DESCRIPTION

The front wheel bearing and front wheel hub of
this vehicle are a hub and bearing unit type assem­bly. This unit combines the front wheel mounting
hub (flange) and the front wheel bearing into a
sealed one-piece unit. The hub and bearing is
mounted to the center of the steering knuckle (Fig.

1). It is retained by four mounting bolts accessible
from the rear of the steering knuckle. The hub flange
has five wheel mounting studs.

Vehicles equipped with 14 inch wheels have a 4
inch wheel mounting stud pattern. Vehicles equipped
with larger wheels have a 4 1/2 inch wheel mounting
stud pattern. If a hub and bearing assembly needs to
be replaced, be sure that the replacement assembly

NS SUSPENSION 2 - 13

DESCRIPTION AND OPERATION (Continued)

has the same size wheel mounting stud pattern as
the original part.

The wheel mounting studs used to mount the tire
and wheel to the vehicle are the only replaceable
components of the hub and bearing assembly. Other­wise, the hub and bearing is serviced only as a com­plete assembly.

OPERATION

The hub and bearing has internal bearings that
allow the hub to rotate with the driveshaft, along
with the tire and wheel. The five wheel mounting
studs mount the tire and wheel, and brake rotor to
the vehicle.

LOWER CONTROL ARM

Fig. 3 Ball Joint

DESCRIPTION

The lower control arm is an iron casting with 2
rubber bushings and a ball joint (Fig. 1). The front
lower control arm bushing is the spool type and is
pressed into the lower control arm. The rear lower
control arm bushing is a push-on bushing that is
pushed over a stem on the rear of the lower control
arm. The lower control arm ball joint is pressed into
the outer end of the arm.

The lower control arm is mounted to the front sus­pension crossmember using a pivot bolt through the
center of the front pivot bushing, and a retainer
which traps the rear bushing in the crossmember.

The ball joint has a non-tapered stud with a notch
for clamp bolt clearance. The stud is clamped and
locked into the steering knuckle leg with a clamp
bolt.

OPERATION

The lower control arm supports the lower end of
the steering knuckle and allows for the up and down
movement of the suspension during the jounce and
rebound travel. The lower control arm ball joint con­nects the arm to the steering knuckle.

BALL JOINT

DESCRIPTION

The ball joint is an integral part of the lower con­trol arm (Fig. 1). The ball joint has a non-tapered
stud that is clamped and locked into the steering
knuckle leg using a pinch bolt. The ball joint stud
has a notch formed in the side of it for pinch bolt
installation.

The ball joint has a non-vented seal boot. The seal
boot has an integrated heat shield (Fig. 3).

The ball joint used in the lower control arm of this
vehicle is a sealed-for-life ball joint and requires no
maintenance lubrication. The ball joint has been

1 – BALL JOINT SEAL BOOT
2 – BALL JOINT STUD
3 – LOWER CONTROL ARM
4 – SHIELD

lubricated-for-life during the manufacturing process.
Once lubricated-for-life, the grease fitting head is
snapped off by the manufacturer. This is done to
eliminate the possibility of lubrication latter during
the ball joints life, thus damaging the non-vented
seal boot.

NOTE: The ball joint does not require any type of
additional lubrication for the life of the vehicle. No
attempt should be made to ever add any lubrication
to the lower ball joint.

The ball joint used on this vehicle is replaceable
and if found defective can be serviced as a separate
component of the lower control arm assembly. Refer
to Diagnosis And Testing in this section for proper
testing of the ball joint.

OPERATION

The ball joint is a pivotal joint on the lower control
arm that allows the knuckle to move up and down,
and turn with ease.

STABILIZER BAR (FRONT)

DESCRIPTION

The stabilizer bar interconnects both front struts of
the vehicle and is attached to the front crossmember
(Fig. 1).

Attachment of the stabilizer bar to the front cross­member is through 2 rubber-isolator cushion bush­ings and retainers. A double ball jointed stabilizer
bar link is used to attach each end of the stabilizer
bar to the front strut assemblies. All parts of the sta­bilizer bar are replaceable as individual components.

2 - 14 SUSPENSION NS

DESCRIPTION AND OPERATION (Continued)

The stabilizer bar to front crossmember cushion
bushings are split for easy removal and installation.
The split in the bushings should be positioned toward
the rear of the vehicle, with the square corner facing
down, when the stabilizer bar is installed.

OPERATION

Jounce and rebound movements affecting one
wheel are partially transmitted to the opposite wheel
of the vehicle through the stabilizer bar. This helps
to minimize the body roll of the vehicle during sus­pension movement.

Connecting the stabilizer bar links to the strut
assemblies helps reduce the fore-and-aft rate of the
stabilizer bar from the rest of the front suspension.

DIAGNOSIS AND TESTING

STRUT ASSEMBLY (FRONT)

(1) Inspect for damaged or broken coil springs
(Fig. 4).

(2) Inspect for torn or damaged strut assembly
dust boots (Fig. 4).

(3) Inspect the coil spring isolator on the lower
spring seat, (Fig. 4) for any signs of damage or dete­rioration.

strut rod and strut shaft seal is not unusual and does
not affect performance of the strut assembly (Fig. 5).
Also inspect jounce bumpers for signs of damage or
deterioration.

Fig. 5 Strut Assembly Leakage Inspection

1 – DUST BOOT
2 – STRUT SHAFT
3 – STRUT FLUID RESERVOIR
4 – INSPECT THIS AREA FOR EVIDENCE OF EXCESSIVE FLUID

LEAKAGE

Fig. 4 Strut Assembly Inspection

1 – DUST BOOT
2 – COIL SPRING ISOLATOR
3 – STRUT ASSEMBLY
4 – COIL SPRING

(4) Lift dust boot (Fig. 5) and inspect strut assem­bly for evidence of fluid running from the upper end
of fluid reservoir. (Actual leakage will be a stream of
fluid running down the side and dripping off lower
end of unit). A slight amount of seepage between the

STEERING KNUCKLE

The front suspension knuckle is not a repairable
component of the vehicles front suspension IT MUST
BE REPLACED.. If bent, broken or damaged in any
way, do not attempt to straighten or repair the steer­ing knuckle.

Service replacement of the front hub/bearing
assembly can be done with the front steering knuckle
remaining on the vehicle.

HUB AND BEARING (FRONT)

The condition of the front hub and bearing assem­bly is diagnosed using the inspection and testing pro­cedure detailed below.

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

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

NS SUSPENSION 2 - 15

DIAGNOSIS AND TESTING (Continued)

LOWER CONTROL ARM

Inspect lower control arm for signs of damage from
contact with the ground or road debris. If lower con­trol arm shows any sign of damage, inspect lower
control arm for distortion. Do not attempt to repair
or straighten a broken or bent lower control arm. If
damaged, the lower control arm casting is serviced
only as a complete component.

The serviceable components of the lower control
arm are: the ball joint, the ball joint grease seal and
the lower control arm isolator bushings.

Inspect both lower control arm isolator bushings
for severe deterioration, and replace as required.
Inspect the ball joint per the inspection procedure in
this section of the service manual and replace as
required. Refer to BALL JOINT in this section of this
service manual group.

BALL JOINT

With the weight of the vehicle resting on the road
wheels, grasp the grease fitting (which from the
manufacturer should have the head missing) on the
bottom of the ball joint and with no mechanical assis­tance or added force attempt to rotate the grease fit­ting.

If the ball joint is worn, the grease fitting will
rotate easily. If movement is noted, replacement of
the ball joint is recommended.

REMOVAL AND INSTALLATION

STRUT ASSEMBLY (FRONT)

REMOVAL

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

(1) Raise the vehicle. See Hoisting in the Lubrica­tion and Maintenance section of this service manual
for the required lifting procedure to be used for this
vehicle.

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

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

(4) Remove the hydraulic brake hose routing
bracket and the speed sensor cable routing bracket
from the strut damper brackets (Fig. 6).

STABILIZER BAR (FRONT)

Inspect for broken or distorted sway bar bushings,
bushing retainers, and worn or damaged sway bar to
strut attaching links. If sway bar to front suspension
cradle bushing replacement is required, bushing can
be removed from sway bar by opening slit and peel­ing bushing off sway bar.

SERVICE PROCEDURES

LUBRICATION

There are no serviceable lubrication points on the
front suspension. The front lower ball joints have
grease fittings which have had the head snapped off
by the manufacturer after they have been filled. This
has been done to eliminate the possibility of damag­ing the non-vented seals. Grease will not leak from
the broken grease fittings. The ball joints are sealed
for life and require no maintenance.

CAUTION: No attempt should be made to replace
the ball joint grease fitting with a new fitting, then
filling the ball joint with grease. Damage to the
grease seal can result.

Fig. 6 Brake Hose And Speed Sensor Cable Routing

1 – STRUT DAMPER
2 – WHEEL SPEED SENSOR CABLE
3 – ROUTING BRACKET
4 – HYDRAULIC BRAKE HOSE
5 – ATTACHING BOLT
6 – ROUTING BRACKET

CAUTION: When removing the nut from the stud of
the stabilizer bar link, do not allow the stud to
rotate in it’s socket. Hold the stud from rotating by
placing an open-end wrench on the flat machined
into the stud (Fig. 7).

(5) Remove the stabilizer bar link from the bracket
on the strut assembly (Fig. 7). To do so, place an
open-end wrench on the flat machined into the link’s

2 - 16 SUSPENSION NS

REMOVAL AND INSTALLATION (Continued)

mounting stud, then remove the nut while holding
the wrench in place. Push the stud out of the
bracket.

Fig. 7 Stabilizer Bar Link To Strut Attachment

1 – NUT
2 – STRUT
3 – STABILIZER BAR LINK

(7) Remove the 3 nuts attaching the strut assem­bly upper mount to the strut tower (Fig. 9) and
remove the strut assembly from the vehicle.

Fig. 9 Strut Assembly To Strut Tower Attaching

Nuts

1 – WINDSHIELD WIPER MODULE
2 – STRUT TOWER
3 – STRUT MOUNT ATTACHING BOLTS
4 – UPPER STRUT MOUNT

CAUTION: The steering knuckle to strut assembly
attaching bolts are serrated and must not be turned
during removal. Remove nuts while holding bolts
stationary in the steering knuckles.

(6) Remove the 2 strut assembly clevis bracket to

steering knuckle attaching bolts (Fig. 8).

Fig. 8 Strut Damper Attachment To Steering

Knuckle

1 – STRUT CLEVIS BRACKET
2 – ATTACHING BOLTS
3 – TIE ROD END
4 – ROTOR
5 – STEERING KNUCKLE

(8) To disassemble and reassemble the strut
assembly, refer to Disassembly And Assembly in this
section.

INSTALLATION

(1) Install strut assembly into strut tower, aligning
and installing the 3 studs on the upper strut mount
into the holes in shock tower. Install the 3 upper
strut mount attaching nut/washer assemblies (Fig.

9). Then using a crow foot. tighten the 3 attaching
nuts to a torque of 28 N·m (250 in. lbs.).

CAUTION: The steering knuckle to strut assembly
attaching bolts are serrated and must not be turned
during installation. Install nuts while holding bolts
stationary in the steering knuckles.

(2) Align strut assembly with steering knuckle.
Position arm of steering knuckle into strut assembly
clevis bracket. Align the strut assembly clevis
bracket mounting holes with the steering knuckle
mounting holes. Install the 2 strut assembly to steer­ing knuckle attaching bolts (Fig. 8). If strut assem-

bly is attached to steering knuckle using a cam
bolt, the cam bolt must be installed in the lower
slotted hole on strut clevis bracket. Also,
attaching bolts should be installed with the
nuts facing the front of the vehicle (Fig. 8).
Tighten the strut assembly to steering knuckle
attaching bolts to a torque of 88 N·m (65 ft. lbs.)

NS SUSPENSION 2 - 17

REMOVAL AND INSTALLATION (Continued)

plus an additional 1/4 turn after specified
torque is met.

(3) Install the stabilizer bar link mounting stud

through the bracket on the strut assembly (Fig. 7).

CAUTION: When installing the nut on the mounting
stud of the stabilizer bar link, do not allow the stud
to rotate in it’s socket. Hold the stud from rotating
by placing an open-end wrench on the flat
machined into the stud (Fig. 7).

(4) Hand thread the nut on the end of the stabi­lizer bar link stud. Hold the stud from turning by
placing an open-end wrench on the flat machined
into the link’s mounting stud, then tighten the nut
while holding the wrench in place (Fig. 7). Tighten
the nut to a torque of 88 N·m (65 ft. lbs.).

(5) Install the hydraulic brake hose and speed sen­sor cable routing brackets on the strut assembly
brackets (Fig. 6). Tighten the routing bracket attach­ing bolts to a torque of 13 N·m (10 ft. lbs.).

(6) Install the wheel/tire assembly on the vehicle.

(7) Install and tighten the wheel mounting stud
nuts in proper sequence until all nuts are torqued to
half specification. Then repeat the tightening
sequence to the full specified torque of 135 N·m (100
ft. lbs.).

Fig. 10 Hub And Bearing To Stub Axle Retaining Nut

1 – HUB/BEARING
2 – NUT LOCK
3 – COTTER PIN
4 – STUB AXLE

STEERING KNUCKLE

REMOVAL

(1) Raise vehicle on jack stands or centered on a
frame contact type hoist. Refer to Hoisting in the
Lubrication And Maintenance section of this manual
for the required lifting procedure to be used for this
vehicle.

(2) Remove the cotter pin and nut lock (Fig. 10)
from the end of the stub axle.

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

(4) Remove the wave washer (Fig. 11) from the end
of the stub axle

CAUTION: Wheel bearing damage will result if after
loosening hub nut, vehicle is rolled on the ground
or the weight of the vehicle is allowed to be sup­ported by the tires.

Fig. 11 Wave Washer

1 – HUB/BEARING ASSEMBLY
2 – WAVE WASHER
3 – STUB AXLE

(5) With the vehicle’s brakes applied to keep hub
from turning, loosen and remove the stub axle to
hub nut.

2 - 18 SUSPENSION NS

REMOVAL AND INSTALLATION (Continued)

(6) Remove the 2 front disc brake caliper to steer-

ing knuckle attaching bolts (Fig. 12).

Fig. 14 Correctly Supported Disc Brake Caliper

1 – STEERING KNUCKLE

Fig. 12 Front Disc Brake Caliper Attaching Bolts

1 – DISC BRAKE CALIPER ASSEMBLY
2 – STEERING KNUCKLE
3 – DISC BRAKE CALIPER MOUNTING BOLTS
4 – DRIVESHAFT

(7) Remove the disc brake caliper from the steer­ing knuckle. Caliper is removed by first rotating top
of caliper away from steering knuckle and then
removing bottom of caliper out from under machined
abutment on steering knuckle (Fig. 13).

2 – BRAKE FLEX HOSE
3 – CALIPER ASSEMBLY
4 – WIRE HANGER
5 – STRUT ASSEMBLY

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

ing assembly (Fig. 15).

Fig. 13 Brake Caliper Mounting To Steering Knuckle

1 – CALIPER ASSEMBLY
2 – ROTOR
3 – STEERING KNUCKLE
4 – MACHINED ABUTMENT

(8) Support disc brake caliper assembly by using a
wire hook and suspending it from the strut assembly
(Fig. 14). Do not allow the brake caliper assem-

bly to hang by the brake flex hose.

Fig. 15 Remove/Install Brake Rotor

1 – HUB
2 – STEERING KNUCKLE
3 – BRAKING DISC (ROTOR)
4 – WHEEL MOUNTING STUD

NS SUSPENSION 2 - 19

REMOVAL AND INSTALLATION (Continued)

(10) Remove nut attaching outer tie rod end to
steering knuckle (Fig. 16). Nut is to be removed

from tie rod end using the following procedure,
hold tie rod end stud with a 11/32 socket while
loosening and removing nut with a wrench.

Fig. 16 Removing Tie Rod End Attaching Nut

1 – TIE ROD END
2 – STEERING KNUCKLE
3 – WRENCH
4 – 11/32 SOCKET
5 – TIE ROD END STUD

(11) Remove tie rod end from steering knuckle
using Remover, Special Tool MB-991113 (Fig. 17).

(12) Remove the front wheel speed sensor (Fig. 18)

from the steering knuckle.

Fig. 18 Front Wheel Speed Sensor

1 – MOUNTING BOLT
2 – WHEEL SPEED SENSOR
3 – STEERING KNUCKLE

(13) If equipped, remove the wheel stop (Fig. 19)

from the steering knuckle. When installing the

pinch bolt when assembling the steering
knuckle to the ball joint, the pinch bolt must be
installed from the rear facing the front on the
vehicle.

Fig. 17 Tie Rod End Removal From Steering

Knuckle Arm

1 – TIE ROD END
2 – SPECIAL TOOL MB-991113
3 – STUD
4 – STEERING KNUCKLE ARM

Fig. 19 Wheel Stop Location On Steering Knuckle

1 – STEERING KNUCKLE
2 – WHEEL STOP
3 – LOWER CONTROL ARM
4 – ROTOR

2 - 20 SUSPENSION NS

REMOVAL AND INSTALLATION (Continued)

(14) Remove the steering knuckle to ball joint
stud, clamping nut and bolt (Fig. 20) from the steer­ing knuckle.

Fig. 20 Control Arm To Steering Knuckle

Attachment

1 – CLAMPING NUT/BOLT
2 – LOWER CONTROL ARM
3 – BALL JOINT
4 – STEERING KNUCKLE
5 – ROTOR

(15) Using a pry bar, separate steering knuckle
from ball joint stud (Fig. 21). Note: Use caution

when separating ball joint stud from steering
knuckle, so ball joint seal does not get cut.

NOTE: Care must be taken not to separate the
inner C/V joint during this operation. Do not allow
driveshaft to hang by inner C/V joint after removing
outer C/V Joint from the hub/bearing assembly in
steering knuckle, end of driveshaft must be sup­ported.

(16) Pull steering knuckle assembly out and away
from the outer C/V joint of the driveshaft assembly
(Fig. 22).

Fig. 22 Steering Knuckle Separation From

Driveshaft

1 – DRIVESHAFT STUB AXLE
2 – HUB/BEARING ASSEMBLY
3 – LOWER CONTROL ARM
4 – BALL JOINT
5 – STEERING KNUCKLE

Fig. 21 Separating Ball Joint Stud From Steering

Knuckle

1 – STEERING KNUCKLE
2 – BALL JOINT STUD
3 – BALL JOINT SEAL
4 – LOWER CONTROL ARM
5–PRYBAR

CAUTION: The steering knuckle to strut assembly
attaching bolts are serrated and must not be turned
during removal. Remove nuts while holding bolts
stationary in the steering knuckles.

(17) Remove the 2 steering knuckle to strut
damper clevis bracket attaching bolts (Fig. 23).

(18) Remove the steering knuckle from the strut.

(19) If the hub and bearing needs to be trans­ferred, remove the 4 bolts attaching the hub and
bearing to the knuckle and remove the hub and bear­ing from the steering knuckle.

INSTALLATION

(1) If the hub and bearing needs to be installed in
the knuckle, place the hub and bearing squarely into
the center hole of the steering knuckle aligning the
threaded mounting holes of the hub and bearing with
the mounting holes in the steering knuckle. Install
the 4 mounting bolts and tighten them to a torque of
65 N·m (45 ft. lbs.).

NS SUSPENSION 2 - 21

REMOVAL AND INSTALLATION (Continued)

(2) Install steering knuckle back in clevis bracket
of strut damper assembly (Fig. 23). Install the strut
damper to steering knuckle attaching bolts. Tighten
both attaching bolts to a torque of 90 N·m (65 ft. lbs.)
plus an additional 1/4 turn.

(3) Slide drive shaft back into front hub and bear­ing assembly. Then install steering knuckle onto the
stud of the ball joint assembly (Fig. 22).

(4) Install a new steering knuckle to ball joint
stud, clamping bolt and nut (Fig. 20). Tighten the
clamping bolt and nut to a torque of 145 N·m (105 ft.
lbs.).

(5) Install tie rod end into steering knuckle. Start
attaching nut onto stud of tie rod end. While holding
stud of tie rod end stationary using a 11/32 socket,
(Fig. 16) tighten tie rod end to steering knuckle

Fig. 23 Strut To Steering Knuckle Attaching Bolts

1 – STRUT CLEVIS BRACKET
2 – ATTACHING NUTS/BOLTS
3 – STEERING KNUCKLE

attaching nut. Then using a crowfoot and 11/32
socket (Fig. 25), tighten the tie rod end attaching nut
to a torque of 54 N·m (40 ft. lbs.).

CAUTION: The steering knuckle to strut assembly
attaching bolts are serrated and must not be turned
during installation. Install nuts while holding bolts
stationary in the steering knuckles.

CAUTION: If the vehicle being serviced is equipped
with eccentric strut assembly attaching bolts, the
eccentric bolt must be installed in the bottom (slot­ted) hole on the strut clevis bracket (Fig. 24).

Fig. 24 Correctly Installed Eccentric Attaching Bolt

1 – STEERING KNUCKLE
2 – FLANGED BOLT IN TOP HOLE
3 – CAM BOLT IN BOTTOM HOLE
4 – STRUT CLEVIS BRACKET

Fig. 25 Torquing Tie Rod End Attaching Nut

1 – STEERING KNUCKLE
2 – TIE ROD END
3 – CROWFOOT
4 – 11/32 SOCKET
5 – TORQUE WRENCH

(6) Install braking disc on hub and bearing assem­bly (Fig. 15).

(7) Install disc brake caliper assembly on steering
knuckle. Caliper is installed by first sliding bottom of
caliper under abutment on steering knuckle, and
then rotating top of caliper against top abutment
(Fig. 13).

(8) Install disc brake caliper assembly to steering
knuckle attaching bolts (Fig. 12). Tighten the disc
brake caliper assembly attaching bolts to a torque of
22 N·m (195 in. lbs.).

2 - 22 SUSPENSION NS

REMOVAL AND INSTALLATION (Continued)

(9) Clean all foreign matter from the threads of
the outer C/V joint stub axle. Install the washer and
stub axle to hub/bearing assembly nut on stub axle
and securely tighten nut.

(10) Install wheel speed sensor and mounting bolt
(Fig. 18) on steering knuckle. Tighten the speed sen­sor attaching bolt to a torque of 7 N·m (60 in. lbs.).

(11) Install front wheel and tire assembly. Install
and tighten the wheel mounting stud nuts in proper
sequence until all nuts are torqued to half the
required specification. Then repeat the tightening
sequence to the full specified torque of 135 N·m (100
ft. lbs.).

(12) Lower vehicle.

(13) With the vehicle’s brakes applied to keep hub
from turning, tighten the hub nut to a torque of 244
N·m (180 ft. lbs.) (Fig. 26).

cle to allow the hub/bearing assembly to be
pressed out of the steering knuckle. Refer to Front
Steering Knuckle in this section of the service man­ual for the required removal and installation proce­dure.

(1) Remove the cotter pin, and nut lock from the

stub axle (Fig. 27).

Fig. 27 Cotter Pin And Nut Lock

1 – HUB/BEARING
2 – NUT LOCK
3 – COTTER PIN
4 – STUB AXLE

Fig. 26 Torquing Front Stub Axle To Hub Nut

1 – TORQUE WRENCH

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

(15) Install the hub nut lock, and a new cotter pin
(Fig. 10). Wrap cotter pin prongs tightly around the
hub nut lock as shown in (Fig. 10).

(16) Set front Toe on vehicle to required specifica­tion. Use procedure listed under Wheel Alignment, in
the Suspension section of this service manual.

HUB AND BEARING (FRONT)

REMOVAL

NOTE: Replacement of the Unit III front hub/bearing
assembly can be normally done without having to
remove the steering knuckle from the vehicle. In the
event that the hub/bearing is frozen in the steering
knuckle and cannot be removed by hand it will have
to be pressed out of the steering knuckle. The
steering knuckle will require removal from the vehi-

(2) Remove the spring wave washer (Fig. 28) from

the end of the stub axle.

Fig. 28 Nut Lock Wave Washer

1 – HUB/BEARING ASSEMBLY
2 – WAVE WASHER
3 – STUB AXLE

NS SUSPENSION 2 - 23

REMOVAL AND INSTALLATION (Continued)

CAUTION: Wheel bearing damage will result if after
loosening hub nut, vehicle is rolled on the ground
or the weight of the vehicle is allowed to be sup­ported by the tires.

(3) With the aid of a helper applying the brakes to
keep the front hub from turning, loosen but do not

remove the hub nut. The hub and driveshaft are
splined together through the knuckle (bearing)
and retained by the hub nut.

(4) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri­cation and Maintenance section of this manual, for
the required lifting procedure to be used for this
vehicle.

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

(6) Remove front disc brake caliper to steering
knuckle attaching bolts. (Fig. 29).

Fig. 30 Brake Caliper Assembly Removal/Installation

1 – CALIPER ASSEMBLY
2 – ROTOR
3 – STEERING KNUCKLE
4 – MACHINED ABUTMENT

Fig. 29 Front Disc Brake Caliper Mounting Bolts

1 – DISC BRAKE CALIPER ASSEMBLY
2 – STEERING KNUCKLE
3 – DISC BRAKE CALIPER MOUNTING BOLTS
4 – DRIVESHAFT

(7) Remove disc brake caliper assembly from steer­ing knuckle. Caliper is removed by first rotating top
of caliper away from steering knuckle, and then
removing bottom of caliper out from under machined
abutment. (Fig. 30)

(8) Support disc brake caliper assembly using a
wire hook, (Fig. 31) do not hang caliper assembly

by hydraulic hose.

Fig. 31 Supporting Brake Caliper

1 – STEERING KNUCKLE
2 – BRAKE FLEX HOSE
3 – CALIPER ASSEMBLY
4 – WIRE HANGER
5 – STRUT ASSEMBLY

2 - 24 SUSPENSION NS

REMOVAL AND INSTALLATION (Continued)

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

(10) Remove the retaining nut and the washer
(Fig. 32) from the end of the stub axle.

Fig. 32 Hub/Bearing To Stub Axle Retaining Nut And

Washer

1 – RETAINING NUT
2 – TIE ROD END
3 – STUB AXLE
4 – WASHER
5 – HUB/BEARING ASSEMBLY
6 – STEERING KNUCKLE

(11) Remove the four hub and bearing assembly
mounting bolts from the rear of steering knuckle
(Fig. 33).

(12) Remove the hub and bearing assembly from

the steering knuckle (Fig. 34).

Fig. 34 Hub and Bearing Assembly Removal From

Steering Knuckle

1 – STUB AXLE
2 – HUB/BEARING ASSEMBLY
3 – STEERING KNUCKLE
4 – BEARING SEAL

INSTALLATION

CAUTION: Hub and bearing assembly mounting
surfaces on the steering knuckle and halfshaft (Fig.

35) must be smooth and completely free of foreign
material or nicks prior to installing hub and bearing
assembly.

Fig. 33 Hub/Bearing Assembly Mounting Bolts

1 – FRONT HUB
2 – STEERING KNUCKLE
3 – HUB/BEARING MOUNTING BOLTS (4)
4 – DRIVESHAFT

Fig. 35 Hub And Bearing Assembly Mounting

Surfaces

1 – BEARING SEAL
2 – STUB AXLE
3 – THESE SURFACES MUST BE CLEAN AND FREE OF NICKS

BEFORE INSTALLING BEARING ASSEMBLY

4 – STEERING KNUCKLE

NS SUSPENSION 2 - 25

REMOVAL AND INSTALLATION (Continued)

CAUTION: When installing hub and bearing assem­bly into steering knuckle, be careful not to damage
the bearing seal (Fig. 35) on the outer C/V joint.

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

(2) Install the 4 hub/bearing assembly to steering
knuckle attaching bolts (Fig. 33). Equally tighten all
4 mounting bolts in a criss-cross pattern until hub/
bearing assembly is squarely seated against front of
steering knuckle. Then tighten the 4 hub and bearing
assembly mounting bolts to a torque of 65 N·m (45
ft.lbs.)

(3) Install the hub/bearing assembly to stub shaft
washer and retaining nut (Fig. 36). Tighten, but do

not torque the hub nut at this time.

(6) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting stud nuts in proper
sequence until all nuts are torqued to half specifica­tion. Then repeat the tightening sequence to the full
specified torque of 129 N·m (95 ft. lbs.).

(7) Lower vehicle to the ground.

CAUTION: When tightening hub/bearing assembly
to stub shaft retaining nut, do not exceed the max­imum torque of 244 N·m (180 ft. lbs.).

(8) With vehicle brakes applied to keep vehicle
from moving, torque stub shaft to hub/bearing assem­bly retaining nut to 244 N·m (180 ft. lbs.).

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

LOWER CONTROL ARM

REMOVE

(1) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri­cation and Maintenance section of this manual, for
the required lifting procedure to be used for this
vehicle.

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

(3) Remove the wheel stop (Fig. 37) from the steer­ing knuckle. When installing the pinch bolt when

assembling the steering knuckle to the ball
joint, the pinch bolt must be installed from the
rear facing the front on the vehicle (Fig. 37).

Fig. 36 Hub/Bearing To Stub Axle Washer And

Retaining Nut

1 – RETAINING NUT
2 – TIE ROD END
3 – STUB AXLE
4 – WASHER
5 – HUB/BEARING ASSEMBLY
6 – STEERING KNUCKLE

(4) Install the braking disk on the hub and bearing

assembly.

(5) Install front brake caliper back over braking
disc and align with caliper mounting holes on steer­ing knuckle (Fig. 30). Caliper is installed by first
installing bottom of caliper under machined abut­ment on bottom of steering knuckle and then rotat­ing top of caliper toward steering knuckle. Install the
disc brake caliper to steering knuckle attaching bolts
(Fig. 29) and tighten to a torque of 19 N·m (168 in.
lbs.).

Fig. 37 Wheel Stop Location On Steering Knuckle

1 – STEERING KNUCKLE
2 – WHEEL STOP
3 – LOWER CONTROL ARM
4 – ROTOR

2 - 26 SUSPENSION NS

REMOVAL AND INSTALLATION (Continued)

(4) Remove the nut and bolt clamping the steering
knuckle to the ball joint stud. (Fig. 38)

Fig. 39 Front Suspension Cradle Plate And

Mounting Bolts

Fig. 38 Control Arm To Steering Knuckle

Attachment

1 – CLAMPING NUT/BOLT
2 – LOWER CONTROL ARM
3 – BALL JOINT
4 – STEERING KNUCKLE
5 – ROTOR

1 – FRONT SUSPENSION CRADLE
2 – CRADLE PLATEATTACHING BOLT M12 (1)
3 – CRADLE PLATE TO CRADLE ATTACHING BOLTS M14 (9)

NOTE: The attaching bolts for the cradle plate are
of two different thread sizes. Nine of the bolts are a
M-14 thread and one of the bolts is a M-12 thread.
Refer to (Fig. 39) for the cradle plate attaching bolt
locations.

(5) Remove the 10 bolts (Fig. 39) attaching the cra­dle plate to the front suspension cradle. Then remove
the cradle plate from the cradle.

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

(6) Using a pry bar, separate steering knuckle
from ball joint stud (Fig. 40). Use caution when

separating ball joint stud from steering
knuckle, so ball joint seal does not get cut.

(7) Loosen but do not remove the pivot bolt (Fig.

41) attaching the front bushing of the lower control
arm to the front suspension cradle.

(8) Remove retainer (Fig. 42) attaching rear bush­ing of lower control arm to front suspension cradle.

Fig. 40 Separating Ball Joint Stud From Steering

Knuckle

1 – STEERING KNUCKLE
2 – BALL JOINT STUD
3 – BALL JOINT SEAL
4 – LOWER CONTROL ARM
5–PRYBAR

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

NS SUSPENSION 2 - 27

REMOVAL AND INSTALLATION (Continued)

Fig. 41 Lower Control Arm Bushing To Cradle Pivot

Bolt

1 – FRONT SUSPENSION CRADLE
2 – CONTROL ARM PIVOT BUSHING BOLT
3 – CONTROL ARM REAR BUSHING RETAINER
4 – LOWER CONTROL ARM

Fig. 42 Control Arm Bushing To Suspension Cradle

Retainer

1 – SUSPENSION CRADLE
2 – BUSHING RETAINER
3 – LOWER CONTROL ARM

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

43).

Fig. 43 Suspension Cradle To Frame Rail Mounting

Bolts

1 – FRAME RAIL
2 – FRONT SUSPENSION CRADLE
3 – MOUNTING BOLT
4 – MOUNTING BOLT

(10) Lower the left front corner of the suspension

cradle until pivot bolt will clear end of transaxle (Fig.

44). Remove the pivot bolt and the lower control arm
from the cradle.

Fig. 44 Lowering Front Suspension Cradle

1–PRYBAR
2 – TRANSAXLE
3 – LOWER CONTROL ARM PIVOT BOLT
4 – FRONT SUSPENSION CRADLE

NOTE: When removing the left lower control arm
from the vehicle, the front suspension cradle needs
to be lowered for the pivot bolt to clear the tran­saxle.

INSTALL

NOTE: If the left lower control arm is being
installed on the vehicle the front suspension cradle
needs to be lowered for the pivot bolt to clear the
transaxle.

2 - 28 SUSPENSION NS

REMOVAL AND INSTALLATION (Continued)

(1) Position lower control arm assembly into front
suspension cradle. If installing the left lower con-

trol arm, pry down on the left front corner of
the suspension cradle until the pivot bolt clears
the end of the transaxle (Fig. 44). Install pivot

bolt attaching front bushing of lower control arm to
front suspension cradle (Fig. 45). Do not tighten or
torque pivot bolt at this time.

Fig. 46 Installing Lower Control Arm Rear Bushing

Retainer

1 – LOWER CONTROL ARM
2 – BUSHING RETAINER
3 – GROOVE
4 – FRONT SUSPENSION CRADLE
5 – RAISED RIB
6 – REAR BUSHING

Fig. 45 Lower Control Arm Bushing Pivot Bolt

Correctly Installed

1 – LOWER CONTROL ARM BUSHING PIVOT BOLT
2 – LOWER CONTROL ARM
3 – FRONT SUSPENSION CRADLE

(2) Install retainer (Fig. 46) attaching rear bush­ing of lower control arm to front suspension cradle.

When installing retainer, be sure raised rib on
rear bushing (Fig. 46) is positioned in the
groove on the retainer. Do not torque attaching
bolts at this time.

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

(3) Raise the front suspension cradle against the
front frame rails. Align the cradle with the reference
marks on the frame rails.

(4) Tighten the 4 mounting bolts for the front sus­pension cradle to a torque of 163 N·m (120 ft. lbs.).

(5) Install lower control arm ball joint stud into
steering knuckle. Then install the bolt and nut,
clamping the steering knuckle to the ball joint stud
(Fig. 38). Tighten the clamping bolt to a torque of
145 N·m (105 ft. lbs.).

(6) Install the cradle plate on front suspension cra­dle and then install the 10 cradle plate to cradle
attaching bolts (Fig. 39). Tighten the 9 M-14 attach­ing bolts (Fig. 39) to a torque of 165 N·m (123 ft.
lbs.). Tighten the 1 M-12 attaching bolt (Fig. 39) to a
torque of 108 N·m (80 ft. lbs.).

CAUTION: When locating jack stands under lower
control arm, do not place the jack stands under the
ball joints (Fig. 47).

(7) Position jack stands under the lower control
arms as close to the ball joints as possible (Fig. 47).
Lower the vehicle onto the jack stands, until the jack
stands are supporting the total weight of the vehicle
(Fig. 47).

Fig. 47 Jack Stands Supporting Vehicle Weight

1 – LOWER CONTROL ARMS
2 – BALL JOINT
3 – JACK STANDS
4 – BALL JOINT

NS SUSPENSION 2 - 29

REMOVAL AND INSTALLATION (Continued)

(8) Tighten front lower control arm pivot bolt (Fig.

45) to a torque of 183 N·m (135 ft. lbs.) first, then
tighten rear lower control arm bushing retainer
attaching bolts (Fig. 42) to a torque of 68 N·m (50 ft.
lbs.).

(9) Install the wheel/tire assembly on the vehicle.

(10) Install and tighten the wheel mounting stud
nuts in proper sequence until all nuts are torqued to
half specification. Then repeat the tightening
sequence to the full specified torque of 135 N·m (100
ft. lbs.).

(11) Remove jack stands and lower vehicle to the
ground.

STABILIZER BAR (FRONT)

REMOVAL

(1) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri­cation and Maintenance section of this manual, for
the required lifting procedure to be used for this
vehicle.

NOTE: The attaching bolts for the cradle plate are
of two different thread sizes. Nine of the bolts are a
M-14 thread and one of the bolts is a M-12 thread.
Refer to (Fig. 48) for the cradle plate attaching bolt
locations.

CAUTION: When removing the nut from the stud of
the stabilizer bar link, do not allow the stud to
rotate in it’s socket. Hold the stud from rotating by
placing an open-end wrench on the flat machined
into the stud (Fig. 49).

(3) Remove the stabilizer bar links from each end
of the stabilizer bar (Fig. 49). To do so, place an open­end wrench on the flat machined into the link’s
mounting stud, then remove the nut while holding
the wrench in place. Push each stud out of the hole
in the stabilizer bar.

(2) Remove the 10 bolts (Fig. 48) attaching the cra­dle plate to the front suspension cradle. Then remove
the cradle plate from the cradle.

Fig. 48 Cradle Plate And Mounting Bolts

1 – FRONT SUSPENSION CRADLE
2 – CRADLE PLATEATTACHING BOLT M12 (1)
3 – CRADLE PLATE TO CRADLE ATTACHING BOLTS M14 (9)

Fig. 49 Stabilizer Bar Link To Stabilizer Bar

Attachment

1 – RATCHET
2 – WRENCH
3 – STRUT
4 – STABILIZER BAR LINK
5 – NUT
6 – STABILIZER BAR

(4) Remove the stabilizer bar bushing retainers

from the front suspension cradle (Fig. 50).

(5) Remove the stabilizer bar and bushings as an

assembly from the front suspension cradle.

2 - 30 SUSPENSION NS

REMOVAL AND INSTALLATION (Continued)

Fig. 50 Front Stabilizer Bar Bushing Retainers

1 – STEERING GEAR
2–SWAYBAR
3 – RAISED BEAD
4 – FRONT SUSPENSION CRADLE
5 – SWAY BAR BUSHING RETAINERS

INSTALLATION

(1) If the stabilizer bar to front suspension cradle
bushings require replacement at time of inspection,
install new bushings before installing stabilizer bar.
Bushings are replaced by opening slit on bushings
and peeling them off stabilizer bar. Install new bush­ings on stabilizer bar by spreading bushing at slit
and forcing them on the stabilizer bar. Bushings

must be installed on stabilizer bar so slit in
bushing will be facing toward the rear of vehi­cle with the square corner toward the ground,
when the stabilizer bar is installed on the vehi­cle (Fig. 51).

(2) Position stabilizer bar into front suspension
cradle so stabilizer bar bushings are aligned with
depressions in cradle. Install stabilizer bar bushing
retainers onto crossmember aligning raised bead on
retainer with cutouts in bushings (Fig. 52). Do not

tighten Stabilizer bar bushing retainers at this
time.

(3) Check position of the stabilizer bar in the front
suspension cradle. The center of the curved section of
the stabilizer bar must be aligned with the raised
line in the center of the front suspension cradle (Fig.

53).

(4) Install the stabilizer bar link mounting stud
through the hole in each end of the stabilizer bar
(Fig. 49).

CAUTION: When installing the nut on the mounting
stud of the stabilizer bar link, do not allow the stud
to rotate in it’s socket. Hold the stud from rotating

Fig. 51 Correctly Installed Stabilizer Bar To Cradle

Bushing

1 – SWAY BAR ISOLATOR BUSHING
2 – SLIT IN SWAY BAR BUSHING
3–SWAYBAR

Fig. 52 Stabilizer Bar Bushing Retainer Installation

1–SWAYBAR
2 – SWAY BAR BUSHING
3 – BUSHING SPLIT
4 – FRONT SUSPENSION CRADLE
5 – BUSHING CUT-OUT
6 – BUSHING RETAINER
7 – RAISED BEAD

by placing an open-end wrench on the flat
machined into the stud (Fig. 49).

(5) Hand-thread the nut on the end of each stabi­lizer bar link stud. Hold the studs from turning by
placing an open-end wrench on the flat machined
into the link’s mounting stud, then tighten each nut
while holding the wrench in place (Fig. 49). Tighten
each nut to a torque of 88 N·m (65 ft. lbs.).

NS SUSPENSION 2 - 31

REMOVAL AND INSTALLATION (Continued)

Fig. 53 Stabilizer Bar Correctly Positioned In Cradle

1 – RAISED BEAD
2–SWAYBAR
3 – WHEN INSTALLING SWAY BAR THE RAISED BEAD ON THE

SUSPENSION CRADLE MUST BE IN THE CENTER OF
RADIUS IN SWAY BAR

4 – FRONT SUSPENSION CRADLE

(6) Tighten the stabilizer bar bushing retainer to
cradle attaching bolts (Fig. 50) to 68 N·m (50 ft. lbs.)
torque.

(7) Install the cradle plate on front suspension cra­dle and then install the 10 cradle plate to cradle
attaching bolts (Fig. 48). Tighten the 9 M-14 attach­ing bolts (Fig. 48) to a torque of 165 N·m (123 ft.
lbs.). Tighten the 1 M-12 attaching bolt (Fig. 48) to a
torque of 108 N·m (80 ft. lbs.).

(8) Lower the vehicle.

WHEEL MOUNTING STUDS (FRONT)

REMOVAL

CAUTION: If a wheel mounting stud needs to be
replaced in the hub and bearing assembly, the
studs CANNOT be hammered out of the hub flange.
If a stud is removed by hammering it out of the
bearing flange, damage to the hub and bearing
assembly will occur leading to premature bearing
failure.

(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in the Lubri­cation and Maintenance section of this manual for
the required lifting procedure to be used for this
vehicle.

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

Remove the disc brake caliper assembly from the

(3)
steering knuckle (Fig. 54). Refer to the Brake section of
this service manual for the removal procedure.

Fig. 54 Disc Brake Caliper Mounting

1 – DISC BRAKE CALIPER ASSEMBLY
2 – STEERING KNUCKLE
3 – DISC BRAKE CALIPER MOUNTING BOLTS
4 – DRIVESHAFT

(4) Remove brake rotor from hub, by pulling it

straight off wheel mounting studs. (Fig. 55)

Fig. 55 Removing Brake Rotor

1 – HUB
2 – STEERING KNUCKLE
3 – BRAKING DISC (ROTOR)
4 – WHEEL MOUNTING STUD

2 - 32 SUSPENSION NS

REMOVAL AND INSTALLATION (Continued)

(5) Install a lug nut on the wheel stud to be
removed from the hub and bearing assembly, so the
threads on the stud are even with end of lug nut.
Install Remover, Special Tool C-4150A on hub and
bearing assembly flange and wheel stud (Fig. 56).

Fig. 57 Installing Wheel Stud Into Hub And Bearing

1 – WASHERS
2 – HUB / BEARING ASSEMBLY
3 – WHEEL LUG NUT
4 – STEERING KNUCKLE

Fig. 56 Wheel Stud Removal

1 – LUG NUT
2 – HUB / BEARING ASSEMBLY
3 – SPECIAL TOOL C-4150A
4 – STEERING KNUCKLE
5 – WHEEL STUD

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

INSTALLATION

(1) Install replacement wheel stud into flange of
hub and bearing assembly. Install washers on wheel
stud, then install a wheel lug nut on stud with flat
side of lug nut against washers (Fig. 57).

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

(3) Install the brake rotor back on the hub and
bearing assembly. (Fig. 55)

(4) Install front brake caliper back over brake
rotor and align with caliper mounting holes on steer­ing knuckle (Fig. 54). Refer to the Brake section of
this service manual for the disc brake caliper instal­lation procedure.

(5) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting lug nuts in proper
sequence until all nuts are torqued to half specifica-

tion, then repeat the tightening sequence to the full
specified torque of 135 N·m (100 ft. lbs.).

(6) Lower vehicle to the ground.

DISASSEMBLY AND ASSEMBLY

STRUT ASSEMBLY (FRONT)

The Strut assembly must be removed from the
vehicle for it to be disassembled and assembled.
Refer to REMOVAL AND INSTALLATION in this
section for the required procedure.

For the disassembly and assembly of the strut
assembly, use strut spring compressor, Pentastar Ser­vice Equipment (PSE) tool W-7200, or the equivalent,
to compress the coil spring. Follow the manufactur­er’s instructions closely.

DISASSEMBLY

(1) If both struts are being serviced at the same
time, mark the coil spring and strut assembly accord­ing to which side of the vehicle the strut was
removed from, and which strut the coil spring was
removed from.

(2) Position the strut assembly in the strut coil
spring compressor following the manufacturers
instructions (Fig. 58). The strut clevis bracket should
be positioned outward. Position the upper hooks on
top of the coil spring upper seat (Fig. 59). Place a
clamp on the lower end of the coil spring, so the strut
is held in place once the strut shaft nut is removed
(Fig. 58).

NS SUSPENSION 2 - 33

DISASSEMBLY AND ASSEMBLY (Continued)

WARNING: DO NOT REMOVE THE STRUT SHAFT
NUT BEFORE THE COIL SPRING IS COMPRESSED.
THE COIL SPRING IS HELD UNDER PRESSURE
AND MUST BE COMPRESSED, REMOVING SPRING
TENSION FROM THE UPPER MOUNT AND PIVOT
BEARING, BEFORE THE SHAFT NUT IS REMOVED.

(3) Compress the coil spring until all coil spring
tension is removed from the upper mount.

(4) Install Strut Nut Socket, Special Tool 6864, on
the strut shaft retaining nut (Fig. 60). Next, install a
10 mm socket on the hex on the end of the strut
shaft. While holding the strut shaft from turning,
remove the nut from the strut shaft.

Fig. 58 Strut Assembly In Compressor

1 – STRUT SPRING COMPRESSOR
2 – CLAMP
3 – CLEVIS BRACKET
4 – STRUT ASSEMBLY

Fig. 59 Upper Hooks Positioned

1 – UPPER HOOKS
2 – UPPER SEAT
3 – UPPER MOUNT

Fig. 60 Retaining Nut Removal/Installation

1 – UPPER MOUNT
2 – SPECIAL TOOL 6864

(5) Remove the upper mount from the strut shaft.

(6) If the upper pivot bearing needs to be serviced,
remove it from the top of the coil spring upper seat
by pulling it straight up.

(7) Remove the clamp from the bottom of the coil
spring and remove the strut out through the bottom
of the coil spring.

NOTE: If the coil spring or upper mount need to be
serviced, proceed with the next step, otherwise,
proceed with step 10.

(8) Release the tension from the coil spring by
backing off the compressor drive fully. Push back the
compressor upper hooks and remove the upper spring
seat.

(9) Remove the coil spring from the spring com­pressor.

2 - 34 SUSPENSION NS

2000 NS Service Manual

DISASSEMBLY AND ASSEMBLY (Continued)

(10) Remove the dust shield and jounce bumper
(Fig. 61) as an assembly from the strut shaft by pull­ing both straight up and off the strut shaft. The dust
shield cannot be separated from the jounce bumper
until after it is removed from strut shaft.

• Inspect the strut for any condition of shaft bind-

ing over the full stroke of the shaft.

• Check the upper mount for cracks and distortion

and its retaining studs for any sign of damage.

• Check the upper seat for severe deterioration of

Publication No. 81-370-0005
TSB 26-03-00 March, 2000

the rubber isolator

• Check for binding of the strut assembly pivot

bearing.

• Inspect the dust shield for rips and deteriora-

tion.

• Inspect the jounce bumper for cracks and signs

of deterioration.

ASSEMBLY

NOTE: If the coil spring has been removed from the
spring compressor, proceed with the next step, oth­erwise, proceed with step 5.

(1) Place the coil spring in the compressor follow-

ing the manufacturers instructions (Fig. 63). Proper

Fig. 61 Dust Shield/Jounce Bumper

1 – JOUNCE BUMPER
2 – STRUT SHAFT
3 – DUST SHIELD

(11) Remove the jounce bumper from the dust
shield. The jounce bumper is removed from the dust
shield by collapsing the dust shield until the jounce
bumper can be pulled free from the dust boot.

(12) Remove the spring isolator from the lower
spring seat on the strut (Fig. 62).

orientation of the spring to the strut (once installed)
is necessary. Consider the following when placing the
coil spring in the compressor: From above, the com­pressor back is at the 12 o’clock position and you,
standing in the front of the machine, are at the 6
o’clock position. For left side springs, place the lower
coil spring end at the 7 o’clock position. For right
side springs, place the lower coil spring end at the 5
o’clock position.

Fig. 62 Strut Lower Spring Seat Isolator

1 – STRUT ASSEMBLY SPRING SEAT
2 – STRUT ASSEMBLY
3 – COIL SPRING ISOLATOR
4 – RETAINING TABS (2)

(13) Inspect the strut assembly components for the
following and replace as necessary:

Fig. 63 Coil Spring Positioned

1 – SPRING COMPRESSOR LOWER HOOKS
2 – END OF SPRING COIL

(2) Install the upper seat on top of the coil spring.
Position the notch in the perimeter of the upper seat
toward the front of the compressor (Fig. 64).

NS SUSPENSION 2 - 35

DISASSEMBLY AND ASSEMBLY (Continued)

isolator are installed in the 2 holes in the spring
seat. When installed, the oversize holes in the spring
seat should line up with the holes in the spring iso­lator.

(7) Install the jounce bumper (Fig. 66) on the strut
shaft. The jounce bumper is to be installed with the
small end pointing downward (Fig. 66).

Fig. 64 Upper Seat Notch Position

1 – PIVOT BEARING
2 – NOTCH
3 – FRONT OF COMPRESSOR
4 – UPPER SEAT

(3) Position the upper hooks on top of the coil
spring upper seat so the upper hooks span the outer
shoulder of the upper seat.

(4) Compress the coil spring.

(5) If the pivot bearing has been removed form the
upper seat, install the pivot bearing on the top of the
upper spring seat (Fig. 65). The bearing must be
installed on upper seat with the smaller diameter
side of the pivot bearing toward the spring seat. Be
sure the pivot bearing is sitting flat on the spring
seat once mounted.

Fig. 66 Jounce Bumper On Strut Shaft

1 – STRUT SHAFT
2 – JOUNCE BUMPER
3 – STRUT
4 – SPRING SEAT

(8) Install the dust shield (Fig. 67) on the strut.
Collapse and stretch the dust shield down over the
top of the jounce bumper until the dust shield snaps
into the slot on the jounce bumper. Return the dust
shield to its fully extended length.

Fig. 65 Pivot Bearing Installation

1 – PIVOT BEARING
2 – UPPER SEAT

(6) Install the spring isolator on the lower spring
seat of the strut (Fig. 62). When installing the spring
isolator, be sure the 2 retaining tabs on the spring

Fig. 67 Installing Dust Shield

1 – DUST BOOT
2 – STRUT SHAFT
3 – JOUNCE BUMPER
4 – STRUT

2 - 36 SUSPENSION NS

DISASSEMBLY AND ASSEMBLY (Continued)

(9) Install the strut through the bottom of the coil
spring until the lower spring seat contacts the lower
end of the coil spring. The clevis bracket on the strut
should point straight outward away from the com­pressor (to the 6 o’clock position). Install the clamp
on the lower end of the coil spring and strut, so the
strut is held in place (Fig. 58). Proper orientation of
the coil spring to the strut is necessary. Verify the
lower end of the coil spring is contacting the strut’s
lower spring seat at the proper location using the fol­lowing figure (Fig. 68). The strut’s clevis bracket is
pointing straight outward to the 6 o’clock position.
For left side struts and springs, the lower coil spring
end should contact the strut’s lower spring seat at
the 7 o’clock position. For right side struts and
springs, the lower coil spring end should contact the
strut’s lower spring seat at the 5 o’clock position.

(12) Slowly release the tension from the coil spring
by backing off the compressor drive fully. As the ten­sion is relieved, make sure the upper mount, pivot
bearing and upper seat align properly. Remove the
clamp from the lower end of the coil spring and strut.
Push back the spring compressor upper and lower
hooks, then remove the strut assembly from the
spring compressor.

(13) Install strut assembly on the vehicle.

LOWER CONTROL ARM (BALL JOINT SEAL
BOOT)

DISASSEMBLY

(1) Using a screw driver or other suitable tool, pry
the seal boot off of the ball joint assembly (Fig. 69)

Fig. 68 Top View Lower Spring Seats

1 – LEFT STRUT
2 – CLEVIS BRACKET
3 – RIGHT STRUT
4 – COIL SPRING END
5 – LOWER SPRING SEAT
6 – COIL SPRING END

(10) Install the strut mount over the strut shaft
and onto the top of the pivot bearing and upper seat
as shown (Fig. 59). Loosely install the retaining nut
on the strut shaft.

(11) Install Strut Nut Socket (on the end of a
torque wrench), Special Tool 6864, on the strut shaft
retaining nut (Fig. 60). Next, install a 10 mm socket
on the hex on the end of the strut shaft. While hold­ing the strut shaft from turning, tighten the strut
shaft retaining nut to a torque of 94 N·m (70 ft. lbs.).

Fig. 69 Ball Joint Seal Boot Removal

1 – LOWER CONTROL ARM
2 – BALL JOINT STUD
3 – SEAL BOOT
4 – SCREW DRIVER
5 – BALL JOINT ASSEMBLY

ASSEMBLY

CAUTION: When installing the ball joint seal on the
ball joint/lower control arm, the shield (Fig. 70) on
the ball joint seal must be positioned as shown.

(1) Install a NEW seal boot by hand as far as pos­sible on the ball joint. Installation of the seal boot is
to be with the shield positioned as shown (Fig. 70).

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

NS SUSPENSION 2 - 37

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 70 Ball Joint Seal Boot Installed Position

1 – BALL JOINT SEAL BOOT
2 – BALL JOINT STUD
3 – LOWER CONTROL ARM
4 – SHIELD

(2) Place Installer, Special Tool 6758 over seal boot
and squarely align it with bottom edge of seal boot
(Fig. 71). Apply hand pressure to Special Tool 6758
until seal boot is pressed squarely against top surface
of lower control arm.

CAUTION: A replacement ball joint is not pre-lubri­cated. Properly lubricate the replacement ball joint
using Mopar Multi–Mile grease or an equivalent.
Lubricate ball joint after seal boot is installed but
prior to top of seal boot being pushed down below
notch in ball joint stud. Air must vent out of the
seal boot at notch when grease is pumped into ball
joint, failure to do so will balloon and damage seal
boot. Do not over grease the ball joint, this will pre­vent the seal boot from pushing down on the stud
of the ball joint.

Fig. 71 Installing Ball Joint Seal Boot

1 – SHIELD
2 – SPECIAL TOOL 6758
3 – LOWER CONTROL ARM
4 – BALL JOINT SEAL BOOT

LOWER CONTROL ARM (BALL JOINT)

NOTE: To perform the following procedure, the
lower control arm must be removed from the vehi­cle. Refer to Removal And Installation in this sec­tion for that procedure.

DISASSEMBLY

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

the seal boot off of the ball joint assembly (Fig. 72)

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

Fig. 72 Ball Joint Seal Boot Removal

1 – LOWER CONTROL ARM
2 – BALL JOINT STUD
3 – SEAL BOOT
4 – SCREW DRIVER
5 – BALL JOINT ASSEMBLY

2 - 38 SUSPENSION NS

DISASSEMBLY AND ASSEMBLY (Continued)

(2) Position receiving cup, Special Tool 6758 to
support lower control arm when removing ball joint
assembly (Fig. 73). Install Remover, Special Tool
6919 on top of the ball joint assembly (Fig. 73).

Fig. 74 Installation Position Of Ball Joint In Control

Arm

1 – NOTCH
2 – BALL JOINT STUD
3 – BALL JOINT

Fig. 73 Ball Joint Removal From Lower Control Arm

1 – ARBOR PRESS
2 – SPECIAL TOOL 6919
3 – BALL JOINT
4 – SPECIAL TOOL 6758
5 – LOWER CONTROL ARM

4 – LOWER CONTROL ARM

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

ASSEMBLY

NOTE: When installing ball joint in lower control
arm, position the ball joint in control arm so notch
in ball joint stud is in the direction shown (Fig. 74).
This will ease assembly of the ball joint to the
steering when installing pinch bolt.

(1) By hand, position ball joint into ball joint bore
of lower control arm. Be sure ball joint is not

cocked in the bore of the control arm, this will
cause the ball joint to bind when being pressed
into control arm.

(2) Position control arm with installed ball joint, in
an arbor press with Receiving Cup, Special Tool 6758
supporting the lower control arm (Fig. 75). Then cen­ter Installer, Special Tool 6908-4 on the bottom of the
ball joint (Fig. 75)

(3) Carefully align all pieces. Then press the ball
joint into the lower control arm until it is completely
seated against surface of lower control arm. The ball
joint is correctly installed when there is no gap
between the ball joint and the lower control arm (Fig.

76). Do not apply excessive force against the

ball joint or the lower control arm.

Fig. 75 Installing Ball Joint In Control Arm

1 – ARBOR PRESS
2 – SPECIAL TOOL 6908–4
3 – BALL JOINT
4 – LOWER CONTROL ARM

CAUTION: When installing the ball joint seal on the
ball joint/lower control arm, the shield (Fig. 77) on
the ball joint seal must be positioned as shown.

(4) Install a NEW seal boot by hand as far as pos­sible on the ball joint. Installation of the seal boot is
to be with the shield positioned as shown (Fig. 77).

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

NS SUSPENSION 2 - 39

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 76 Correctly Installed Lower Ball Joint

1 – SPECIAL TOOL 6908–4
2 – BALL JOINT
3 – BALL JOINT IS CORRECTLY INSTALLED WHEN NO GAP IS

PRESENT HERE

4 – LOWER CONTROL ARM

Fig. 77 Ball Joint Seal Boot Installed Position

1 – BALL JOINT SEAL BOOT
2 – BALL JOINT STUD
3 – LOWER CONTROL ARM
4 – SHIELD

Fig. 78 Installing Ball Joint Seal Boot

1 – SHIELD
2 – SPECIAL TOOL 6758
3 – LOWER CONTROL ARM
4 – BALL JOINT SEAL BOOT

CAUTION: A replacement ball joint is not pre-lubri­cated. Properly lubricate the replacement ball joint
using Mopar Multi–Mile grease or an equivalent.
Lubricate ball joint after seal boot is installed but
prior to top of seal boot being pushed down below
notch in ball joint stud (Fig. 74). Air must vent out
of the seal boot at notch when grease is pumped
into ball joint, failure to do so will balloon and dam­age seal boot. Do not over grease the ball joint, this
will prevent the seal boot from pushing down on
the stud of the ball joint.

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

(6) Reinstall lower control arm on vehicle.

LOWER CONTROL ARM (FRONT BUSHING)

(5) Place Installer, Special Tool 6758 over seal boot
and squarely align it with bottom edge of seal boot
(Fig. 78). Apply hand pressure to Special Tool 6758
until seal boot is pressed squarely against top surface
of lower control arm.

DISASSEMBLY

(1) Remove the lower control arm from the front
suspension cradle. Refer to Lower Control Arm in the
Removal And Installation Section in this section of
the service manual for the required procedure.

2 - 40 SUSPENSION NS

DISASSEMBLY AND ASSEMBLY (Continued)

(2) Securely mount the lower control arm in a vise.

(3) Assemble for removal of the front bushing, the
Bushing Receiver, Special Tool 6908–2, Bushing
Remover, Special Tool 6908–1, Nut, Special Tool
6908–3 thrust washer, threaded rod and small nut,
as shown in (Fig. 79) on the lower control arm and
front bushing.

Fig. 80 Installation Position Of Lower Control Arm

Front Bushing

1 – LOWER CONTROL ARM
2 – LOWER CONTROL ARM REAR BUSHING
3 – RUBBER BLOCKS
4 – LOWER CONTROL ARM FRONT BUSHING

Fig. 79 Tools Assembled For Removal Of Front

Bushing

1 – THRUST BEARING
2 – SPECIAL TOOL 6908–1
3 – LOWER CONTROL ARM
4 – NUT
5 – SPECIAL TOOL 6908–2
6 – FRONT BUSHING
7 – SPECIAL TOOL 6908–3
8 – THREADED ROD

(4) To remove front bushing from lower control
arm, hold the threaded rod stationary and tighten
the Nut, Special Tool 6908–3 (Fig. 79). This will force
the front bushing out of the lower control arm and
into Bushing Receiver, Special Tool 6908–2 (Fig. 79).

ASSEMBLY

(1) Securely mount the lower control arm in a vise.

NOTE: The lower control arm front bushing is a
directional bushing. It must be installed in the lower
control arm positioned as shown in (Fig. 80).

(2) Position the front bushing in the lower control
arm so that the 2 rubber blocks on the bushing are
positioned horizontally as shown in (Fig. 80).

(3) Assemble for installation of the front bushing,
the Bushing Receiver, Special Tool 6908–5, Bushing
Installer, Special Tool 6908–4, Nut, Special Tool
6908–3 thrust washer, threaded rod and small nut,
as shown in (Fig. 81) on the lower control arm and
front bushing.

Fig. 81 Tools Assembled For Installation Of Front

Bushing

1 – THRUST WASHER
2 – SPECIAL TOOL 6908–5
3 – LOWER CONTROL ARM
4 – FRONT BUSHING
5 – NUT
6 – SPECIAL TOOL 6908–4
7 – SPECIAL TOOL 6908–9
8 – THREADED ROD

(4) To install the front bushing in lower control
arm, hold the threaded rod stationary and tighten
the Nut, Special Tool 6908–3 (Fig. 81). This will pull
the front bushing into the lower control arm.

NS SUSPENSION 2 - 41

DISASSEMBLY AND ASSEMBLY (Continued)

(5) Continue pulling the bushing into the lower
control arm until bushing is seated squarely against
the lower control arm and there is no gap between
the bushing and the lower control arm (Fig. 82).

Fig. 83 Slit Lower Control Arm Rear Bushing

1 – LOWER CONTROL ARM REAR BUSHING
2 – SLIT CUT IN BUSHING
3 – LOWER CONTROL ARM

Fig. 82 Correctly Installed Lower Control Arm

Bushing

1 – WHEN BUSHING IS CORRECTLY INSTALLED NO GAP IS TO

BE VISIBLE BETWEEN BUSHING AND CONTROL ARM

HERE
2 – SPECIAL TOOL 6908–4
3 – BUSHING
4 – LOWER CONTROL ARM
5 – SPECIAL TOOL 6908–5

(1) Apply Mopar Silicone Spray Lube or an equiv­alent, to the hole in lower control arm rear bushing.
This will aid in the installation of the bushing on the
lower control arm.

(2) With the lower control arm held securely in a
vise, install bushing on lower control arm. Install
bushing by pushing and rocking the bushing until it
is fully installed on lower control arm. Be sure that

(6) Install the lower control arm on the front sus­pension cradle. Refer to Lower Control Arm in the
Removal And Installation Section in this group of the
service manual for the required procedure.

when bushing is installed it is past the upset on the
end of the lower control arm (Fig. 84).

(3) The rear bushing of the lower control arm,
when correctly installed, is to be positioned on the
lower control arm as shown (Fig. 84).

LOWER CONTROL ARM (REAR BUSHING)

DISASSEMBLY

(1) Remove the lower control arm from the front
suspension cradle. Refer to Lower Control Arm in the
Removal And Installation Section in this group of the
service manual for the required procedure.

(2) Mount the lower control arm in a vise without
using excessive clamping force.

(3) Using a sharp knife, (such as a razor) slit the
bushing lengthwise (Fig. 83) to allow its removal
from the lower control arm (Fig. 83).

(4) Remove the bushing from the lower control
arm.

ASSEMBLY

CAUTION: Do not apply grease or any other type of
lubricant other than the silicone lubricant specified
below to the control arm bushing.

Fig. 84 Correctly Installed Lower Control Arm

Bushing

1 – ROUND SURFACE OF BUSHING
2 – LOWER CONTROL ARM
3 – LOWER CONTROL ARM REAR BUSHING
4 – UPSET
5 – FLAT SURFACE OF BUSHING

2 - 42 SUSPENSION NS

DISASSEMBLY AND ASSEMBLY (Continued)

STABILIZER BAR BUSHING (FRONT)

If stabilizer bar to front suspension cradle bush­ings require replacement at time of inspection, install
new bushings before installing stabilizer bar back on
the vehicle.

DISASSEMBLY

(1) Stabilizer bar bushings are replaced by opening
the slit on the bushings and peeling them off the sta­bilizer bar.

ASSEMBLY

(1) Install new bushings on stabilizer bar by
spreading bushing at slit and forcing them onto sta­bilizer bar.

NOTE: Bushings must be installed on stabilizer bar
so the square corner of the bushing will be down
and slit in bushing will be facing the rear of the
vehicle when the stabilizer is installed (Fig. 85).

SPECIFICATIONS

FRONT SUSPENSION FASTENER TORQUES

DESCRIPTION TORQUE
Strut Assembly:

Strut Tower Attaching Nuts ........... 28N·m

(250 in. lbs.)

Steering Knuckle Attaching bolts ...... 88N·m

(65 ft. lbs.) Plus 1/4 Additional Turn

Strut Shaft Nut .......... 100N·m(75ft.lbs.)

Steering Knuckle:

Ball Joint Stud Nut/Bolt . . 145 N·m (105 ft. lbs.)

Disc Brake Caliper Bolts .... 41N·m(30ft.lbs.)

Wheel Stop .............. 95N·m(70ft.lbs.)

Hub And Bearing:

Mounting Bolts ........... 65N·m(45ft.lbs.)

HubNut............... 244N·m(180 ft. lbs.)

Wheel Mounting Lug Nuts . . 135 N·m (100 ft. lbs.)

Lower Control Arm:

Lower Control Arm Pivot Bolt ........ 185N·m

(137 ft. lbs.)

Lower Control Arm Rear Bushing

Retainer Bolt ............. 68N·m(50ft.lbs.)

Stabilizer Bar:

Bushing Retainer Cradle Attaching

Bolts ................... 70N·m(50ft.lbs.)

Attaching Link Nuts ....... 88N·m(65ft.lbs.)

Front Suspension Cradle:

Body Attaching Bolts ..... 163N·m(120 ft. lbs.)

Reinforcement Plate Attaching

Bolts M-12 .............. 108N·m(80ft.lbs.)

Reinforcement Plate Attaching

Bolts M-14 ............. 166N·m(123 ft. lbs.)

Fig. 85 Correctly Installed Stabilizer Bar To Cradle

Bushing

1 – SLIT IN SWAY BAR BUSHING.
2 – SQUARE CORNER
3–SWAYBAR
4 – SWAY BAR ISOLATOR BUSHING

SPECIAL TOOLS

FRONT SUSPENSION

Installer Ball Joint 6758

NS SUSPENSION 2 - 43

SPECIAL TOOLS (Continued)

Wrench Strut Rod Nut 6864

Remover Ball Joint 6919

Remover/Installer Control Arm Bushing 6908

Remover Tie Rod End MB–991113

2 - 44 SUSPENSION NS

REAR SUSPENSION

TABLE OF CONTENTS

page page

DESCRIPTION AND OPERATION

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

LEAF SPRING ...........................44

JOUNCE BUMPER........................45

SHOCK ABSORBERS .....................45

HUB AND BEARING (REAR) ................46

TRACK BAR (REAR) ......................46

STABILIZER BAR (REAR)...................47

DIAGNOSIS AND TESTING

HUB AND BEARING (REAR) ................47

REMOVAL AND INSTALLATION

LEAF SPRINGS (FWD).....................48

LEAF SPRINGS (AWD).....................50

DESCRIPTION AND OPERATION

REAR SUSPENSION

DESCRIPTION

The rear suspension design on this vehicle uses
leaf springs, and a tube and casting axle (Fig. 1) (Fig.

2). The leaf springs used on the rear suspension of
this vehicle are of either a mono-leaf or multi-leaf
design.

There are 3 different rear suspension designs
available:

• Front-Wheel-Drive

• All-Wheel-Drive

• Front-Wheel-Drive Commercial (fleet use only)

The rear axle used on Front-Wheel-Drive applica­tions of this vehicle is mounted to the rear leaf
springs using isolator bushings at the axle mounting
brackets.

The rear axle used on All-Wheel-Drive applications
of this vehicle is also mounted to the rear leaf
springs, but does not use isolator bushings between
the rear axle and the leaf springs.

The rear suspension used on the Front-Wheel­Drive commercial version of this vehicle is unique.
The leaf spring used on the commercial version of
this vehicle is a multi-leaf spring. The rear axle is
similar to the standard FWD axle, but is heavy duty.
It is mounted to the rear leaf springs, but unlike the
non-commercial application of this vehicle, does not
use any isolators between the spring and the axle.

Each side of the rear suspension consists of these
major components:

• Leaf spring

LEAF SPRING FRONT MOUNT ..............52

LEAF SPRING REAR MOUNT ...............52

SHOCK ABSORBER (REAR) ................53

STABILIZER BAR (REAR)...................54

TRACK BAR (REAR) ......................54

TRACK BAR MOUNT ......................55

JOUNCE BUMPER........................55

HUB AND BEARING (REAR) ................56

WHEEL MOUNTING STUDS (REAR) ..........61

DISASSEMBLY AND ASSEMBLY

SHOCK ABSORBER UPPER BUSHING (REAR) . . 62

SPECIFICATIONS

REAR SUSPENSION FASTENER TORQUES ....63

• Jounce bumper

• Shock absorber

• Hub and bearing

• Track bar

• Stabilizer bar

OPERATION

This rear suspension is designed to handle the var­ious load requirements of the vehicle yet allow for a
comfortable ride.

The rear leaf spring shackle angle’s provide
increasing suspension rates as the vehicle is loaded.
This provides a comfortable unloaded ride and also
ample rear suspension travel when the vehicle is
loaded.

The shock absorbers are mounted at an angle,
more parallel to the springs. This design provides
greater stability in addition to controlling ride
motion.

The rear wheel bearings used are similar to the
bearings used in the front suspension. A hub and
bearing assembly is used.

LEAF SPRING

DESCRIPTION

The leaf springs used on the rear suspension of
this vehicle are of either a mono-leaf or multi-leaf
design depending on model and options.

The leaf spring used on the commercial version of
this vehicle is a multi-leaf spring, but is a unique
design for the commercial application.

Since the rear springs come in various designs and
rates, be sure the correct spring is in use.

NS SUSPENSION 2 - 45

DESCRIPTION AND OPERATION (Continued)

Fig. 1 Front-Wheel-Drive Rear Suspension

1 – JOUNCE BUMPER
2 – TRACK BAR
3 – LEAF SPRINGS

OPERATION

The leaf spring controls ride quality and maintains

ride height.

JOUNCE BUMPER

DESCRIPTION

There are two jounce bumpers used in the rear
suspension. One mounts to each frame rail above the
rear axle.

OPERATION

The jounce bumper limits suspension travel and
metal-to-metal contact of the rear axle with the
frame under full jounce conditions.

SHOCK ABSORBERS

DESCRIPTION

There is one shock absorber on each side of the
rear suspension (Fig. 1). The top of each shock
absorber is bolted to the frame rail. The bottom of
each shock absorber is bolted to the rear axle.

4 – SHOCK ABSORBERS
5 – AXLE ASSEMBLY

This vehicle is available with either standard type
or load-leveling shock absorbers. On the exterior,
load-leveling shock absorbers are larger in diameter
than standard shock absorbers. The load-leveling
shock absorbers mount the same as the standard
shock absorbers, but use longer fasteners. Although
the fasteners are longer, the torque specifications
remain the same.

OPERATION

The shock absorber dampens jounce and rebound
motions of the spring and suspension.

Each load-leveling shock absorber is a self-leveling,
self-contained vehicle leveling system and shock
absorber combined. It does not require an external
compressor, hoses, or height leveling sensors. All the
height leveling sensors, hydraulic pump, etc., are
contained inside the shock absorber. It uses road
inputs (bumps, stops, starts, turns, acceleration,
deceleration, etc.) to activate pumping, which results
in the extension and compression of the shock
absorber.

2 - 46 SUSPENSION NS

DESCRIPTION AND OPERATION (Continued)

Fig. 2 All-Wheel-Drive Rear Suspension

1 – JOUNCE BUMPER
2 – DRIVESHAFT
3 – REAR DRIVELINE MODULE
4 – DRIVESHAFT
5 – JOUNCE BUMPER

HUB AND BEARING (REAR)

DESCRIPTION

The rear wheel bearing and rear wheel hub of this
vehicle are a one-piece sealed unit, or hub and bear­ing unit type assembly. The hub and bearing is
mounted to the center of the rear axle using 4
mounting bolts. It has five wheel mounting studs on
the hub flange.

All-Wheel-Drive vehicles have a hub and bearing
unit with a splined hole in the center of the hub for
rear driveshaft acceptance.

CAUTION: If a vehicle is equipped with antilock
brakes, the tone wheel for the rear wheel speed
sensor is pressed onto the hub and bearing. Make
sure any replacement bearing has the tone wheel
on it before installation.

OPERATION

The hub and bearing has internal bearings that
allow the hub to rotate with the tire and wheel assem-

6 – LEAF SPRING
7 – SHOCK ABSORBER
8 – AXLE
9 – SHOCK ABSORBER
10 – LEAF SPRING

bly (and driveshaft on All-Wheel-Drive vehicles). The
five wheel mounting studs mount the tire and wheel
assembly, and disc brake rotor to the vehicle.

On All-Wheel-Drive vehicles, the splined mating of
the driveshaft and hub allows the driveshaft to
rotate with the hub and wheel.

Front-Wheel-Drive vehicles equipped with antilock
brakes have a tone wheel mounted to the rear of the
hub and bearing that is used in conjunction with the
wheel speed sensor to measure wheel speed.

TRACK BAR (REAR)

DESCRIPTION

On front-wheel-drive applications of this vehicle
that are equipped with single leaf rear springs, a
track bar is used on the rear axle (Fig. 3).

The track bar connects the rear axle to the frame/
body of the vehicle. The track bar is isolated from the
body of the vehicle by an isolator bushing located in
each end of the track bar.

NS SUSPENSION 2 - 47

DESCRIPTION AND OPERATION (Continued)

Attachment to the rear axle tube, and rear frame
rails is through rubber-isolated bushings. All parts
are serviceable, and the stabilizer bar to axle bush­ings are split for easy removal and installation. The
split in the bushing should be positioned up when
the stabilizer bar is installed on the vehicle.

The 2 rubber isolated link arms are connected to
the rear frame rails by brackets. These brackets are
bolted to the bottom of the frame rails.

OPERATION

Jounce and rebound movements affecting one
wheel are partially transmitted to the opposite wheel
to reduce body roll.

Fig. 3 Rear Track Bar

1 – REAR TRACK BAR

OPERATION

The track bar (Fig. 3) prevents excessive side-to­side movement of the rear axle. The track bar is used
to keep the location of the axle in the correct position
for optimum handling and control of the vehicle.

STABILIZER BAR (REAR)

DESCRIPTION

The stabilizer bar (Fig. 4) interconnects both sides
of the rear axle and attaches to the rear frame rails
using 2 rubber isolated link arms.

DIAGNOSIS AND TESTING

HUB AND BEARING (REAR)

The condition of the hub and bearing assembly is
diagnosed using the inspection and testing procedure
detailed below.

The bearing contained in the hub and bearing
assembly will produce noise and vibration when worn
or damaged. The noise will generally change when
the bearings are loaded. A road test of the vehicle is
normally required to determine the location of a
worn or damaged bearing.

1 – BUSHINGS AND RETAINER
2 – REAR AXLE
3 – FRAME RAIL BRACKET

Fig. 4 Stabilizer Bar

4 – LINK ARM
5 – STABILIZER BAR

2 - 48 SUSPENSION NS

DIAGNOSIS AND TESTING (Continued)

Find a smooth level road surface and bring the
vehicle up to a constant speed. When vehicle is at a
constant speed, swerve the vehicle back and forth
from the left and to the right. This will load and
unload the bearings and change the noise level.
When bearing damage is slight, the noise is usually
not noticeable at speeds above 30 m.p.h..

REMOVAL AND INSTALLATION

LEAF SPRINGS (FWD)

REMOVAL

(1) Raise vehicle on frame contact hoist to a com­fortable working position.

(2) Support axle with a jack stand. Pad should just
contact axle.

(3) Begin removal of the shock absorber lower
mounting bolt (Fig. 5).

NOTE: If shock absorber bolt deflects upward dur­ing removal, raise axle by adjusting support jack. If
shock absorber bolt deflects downward during
removal, lower axle by adjusting support jack (or by
pulling on axle).

1 – AXLE PLATE

Fig. 6 Axle Plate Bolts

Fig. 5 Rear Shock Mounting Bolt

1 – SHOCK BOLT

(4) Using 2 jack stands positioned under the outer
ends of the axle, raise the axle enough to remove the
weight of the axle from the rear springs.

(5) Loosen and remove the axle plate bolts from
the rear axle (Fig. 6).

(6) Remove the axle plate from the rear axle and
the leaf spring (Fig. 7).

Fig. 7 Axle Plate

1 – AXLE PLATE

(7) Using the jack stands slowly lower the rear

axle, permitting the rear springs to hang free.

(8) Loosen and remove the 4 bolts (Fig. 8) from the

front mount of the leaf spring.

(9) Loosen and remove the nuts from the spring
hanger (Fig. 9) for the rear leaf spring. Then remove
the hanger plate from the hanger and remove the
spring from the spring hanger (Fig. 9).

(10) Remove the leaf spring from the vehicle (Fig.

10).

(11) Loosen and remove the pivot bolt from the
front mount of the rear leaf spring. (Fig. 11).

NS SUSPENSION 2 - 49

REMOVAL AND INSTALLATION (Continued)

Fig. 8 Leaf Spring Front Mount

1 – FRONT SPRING MOUNT

Fig. 9 Rear Spring Hanger

1 – SHACKLE PLATE
2 – SPRING HANGER

FRONT BUSHING REPLACEMENT

(1) Install leaf spring in a proper holding fixture.
(2) Install leaf spring press Special Tool C-4212–F.
(3) Install adapter Special Tool C-4212–3.
(4) Tighten leaf spring press until bushing is

extracted from leaf spring.

(5) Remove leaf spring press from leaf spring.
(6) Insert replacement bushing into the leaf spring

eye. Verify that the bushing flange is on the left

side of the leaf spring when leaf spring is in the
in vehicle installed position.

(7) Install leaf spring press Special Tool C-4212–F.
(8) Install adapter Special Tool C-4212–4.
(9) Tighten leaf spring press until bushing flange

bottoms solidly against leaf spring eye.

(10) Remove leaf spring press and adapter.

Fig. 10 Leaf Spring Remove/Install

1 – LEAF SPRING

Fig. 11 Leaf Spring Front Mount

1 – LEAF SPRING
2 – SPRING MOUNT

(11) Bend the bushing tabs so that they are con­tacting the leaf spring.

INSTALLATION

(1) Assemble front spring mount to front of spring
eye and install pivot bolt and nut. Do not tighten.

CAUTION: Pivot bolt must face inboard to prevent
structural damage during installation of spring.

(2) Raise front of spring and install four hanger
bolts, tighten to 61 N·m (45 ft. lbs.) torque.

(3) Install rear of spring onto rear spring shackle.
Install shackle plate. Do not tighten.

(4) Verify lower leaf spring isolator is in position.

2 - 50 SUSPENSION NS

REMOVAL AND INSTALLATION (Continued)

(5) Raise axle into correct position on leaf spring

with axle centered under spring locator post (Fig.

12).

Fig. 12 Leaf Spring Locator Post

1 – LEAF SPRING ISOLATOR
2 – LEAF SPRING
3 – LOCATOR POST

NOTE: If shock absorber bolt deflects upward dur­ing removal, raise axle by adjusting support jack. If
shock absorber bolt deflects downward during
removal, lower axle by adjusting support jack (or by
pulling on axle).

(4) Begin removal of the shock absorber lower
mounting bolt (Fig. 13).

(6) Verify that the leaf spring isolator is correctly

positioned in the axle plate.

(7) Install axle plate on the spring.
(8) Install axle plate bolts. Tighten bolts to 101

N·m (75 ft. lbs.) torque.

(9) Install shock absorber bolts. Do not tighten.
(10) Lower vehicle to floor so that the full curb

weight of vehicle is supported by the tires.

(11) Tighten component fasteners as follows:

• Front pivot bolt—156 N·m (115 ft. lbs.)

• Shackle nuts—61 N·m (45 ft. lbs.)

• Shock absorber bolts—101 N·m (75 ft. lbs.)

(12) If the vehicle is not equipped with antilock
brakes, raise vehicle and the connect the actuator for
the height sensing proportioning valve on the rear
leaf spring. Adjust the height sensing proportioning
valve. Refer to the Adjustment Section in this group
of the service manual for the required adjustment
procedure.

LEAF SPRINGS (AWD)

REMOVAL

(1) Raise vehicle on frame contact hoist to a com­fortable working position.

(2) Remove the driveshaft from the side of the
vehicle that requires the removal of the leaf spring.
Refer to Group 3 Driveline in this service manual for
the procedure covering the removal of the rear drive­shafts.

(3) Support axle with a jack stand. Pad should just
contact axle.

Fig. 13 Rear Shock Absorber Mounting Bolt

1 – SHOCK BOLT

(5) Using 2 jack stands positioned under the outer
ends of the axle, raise the axle enough to remove the
weight of the axle from the rear springs.

(6) Loosen and remove the axle plate bolts from
the rear axle (Fig. 14).

Fig. 14 Axle Plate Bolts

1 – LEAF SPRING
2 – AXLE PLATE BOLTS (4)
3 – AXLE PLATE
4 – AXLE

NS SUSPENSION 2 - 51

REMOVAL AND INSTALLATION (Continued)

(7) Using the jack stands slowly lower the rear

axle, permitting the rear springs to hang free.

(8) Loosen and remove the 4 bolts (Fig. 15) at the

front mount of the rear leaf spring.

Fig. 17 Leaf Spring Remove/Install

1 – LEAF SPRING

Fig. 15 Leaf Spring Front Mount

1 – FRONT SPRING MOUNT

(9) Loosen and remove the 2 bolts and the 2 nuts
from the spring hanger (Fig. 16) for the rear leaf
spring. Then remove the inner half of the spring
hanger from the outer half hanger of the spring
hanger and the spring. (Fig. 16).

Fig. 16 Rear Spring Hanger

1 – LEAF SPRING
2 – NUTS
3 – SPRING HANGER INNER HALF
4 – LEAF SPRING REAR HANGER
5 – SPRING HANGER OUTER HALF
6 – BOLTS

(10) Remove the rear leaf spring from the outer
half of the spring hanger

(11) Remove the leaf spring from the vehicle (Fig.

17).

(12) Loosen and remove the pivot bolt from the

front mount of the rear leaf spring. (Fig. 18).

Fig. 18 Leaf Spring Front Mount

1 – LEAF SPRING
2 – SPRING MOUNT

FRONT BUSHING REPLACEMENT

(1) Install leaf spring in a proper holding fixture.
(2) Install leaf spring press Special Tool C-4212–F.
(3) Install adapter Special Tool C-4212–3.
(4) Tighten leaf spring press until bushing is

extracted from leaf spring.

(5) Remove leaf spring press from leaf spring.

(6) Insert replacement bushing into the leaf spring
eye. Verify that the bushing flange is on the outboard
side of the leaf spring.

(7) Install leaf spring press Special Tool C-4212–F.

(8) Install adapter Special Tool C-4212–4.

(9) Tighten leaf spring press until bushing flange
bottoms solidly against leaf spring eye.

2 - 52 SUSPENSION NS

REMOVAL AND INSTALLATION (Continued)

(10) Remove leaf spring press and adapter.
(11) Bend the tabs on the bushing until they are

contacting the leaf spring.

INSTALLATION

CAUTION: Pivot bolt must face inboard to prevent
structural damage during installation of spring.

(1) Install the front of the rear leaf spring into the

spring mount (Fig. 18). Install the pivot bolt and nut.

Do not tighten the pivot bolt at this time.

(2) Position the front spring mount for the rear
leaf spring against the floor pan of the vehicle.
Install the 4 mounting bolts for the spring mount.
Tighten the 4 mounting bolts to a torque of 61 N·m
(45 ft. lbs.).

(3) Install the rear of the leaf spring onto the outer
half of the rear hanger. Install the inner half of the
rear hanger. Install the nut and bolts on the rear
hanger but do not tighten at this time.

(4) Raise axle assembly into correct position with
axle centered under spring locator post.

(5) Install axle plate bolts. Tighten bolts to 101
N·m (75 ft. lbs.) torque.

(6) Install shock absorber bolts. Do not tighten.

(7) Lower vehicle to floor and with full weight of
vehicle on wheels. Tighten component fasteners as
follows:

LEAF SPRING FRONT MOUNT

REMOVAL

(1) Loosen the pivot bolt attaching the front of the

leaf spring to the spring mount (Fig. 19).

(2) Install a jackstand under the side of the axle
having the leaf spring mount removed. Using the
jackstand support the weight of the axle and leaf
spring.

(3) Remove the lower mounting bolt from the
shock absorber.

(4) Remove the bolts attaching the leaf spring
front mount (Fig. 19) to the body of the vehicle.

(5) Lower the leaf spring and remove the front
mount from the spring.

CAUTION: The following sequence must be fol­lowed when tightening the pin nuts on the rear
hanger for the rear leaf spring. First the hanger pin
nuts must be tightened to the specified torque
shown below. Then tighten the retaining bolts for
the inner to outer half of the spring hanger to the
torque specification listed below. This sequence
must be followed to properly seat the bushings into
the springs and to avoid bending the spring hanger.

• Front pivot bolt-156 N·m (115 ft. lbs.)

• Rear spring hanger pin nuts-61 N·m (45 ft. lbs.)

• Rear spring hanger inner to outer half retaining

bolts-61 N·m (45 ft. lbs.)

• Shock absorber mounting bolt-101 N·m (75 ft.

lbs.)

(9) If the vehicle is not equipped with antilock
brakes, raise vehicle and connect the actuator for the
height sensing proportioning valve on the rear leaf
spring. Adjust the height sensing proportioning
valve. Refer to the Adjustment Section in this group
of the service manual for the required adjustment
procedure.

Fig. 19 Leaf Spring Front Mount

1 – LEAF SPRING FRONT MOUNT

INSTALLATION

(1) For installation, reverse removal procedure. Do
not tighten front pivot bolt fully until vehicle is low­ered and the full vehicle weight is applied to the rear
wheels. Tighten leaf spring front mount bolts to 61
N·m (45 ft. lbs.). Tighten leaf spring front pivot bolt
to 156 N·m (115 ft. lbs.).

LEAF SPRING REAR MOUNT

REMOVE

(1) Remove the attaching nuts and bolts from the
leaf spring rear shackle (Fig. 20) and (Fig. 21).

(2) Install a jackstand under the side of the axle
having the leaf spring mount removed. Using the
jackstand, support the weight of the axle and leaf
spring.

(3) Remove the lower mounting bolt from the
shock absorber.

(4) Remove the bolts attaching the leaf spring rear
mount to the body of the vehicle (Fig. 22).

NS SUSPENSION 2 - 53

REMOVAL AND INSTALLATION (Continued)

Fig. 20 Leaf Spring Shackle Nuts (FWD)

1 – SHACKLE PLATE

Fig. 21 Leaf Spring Shackle Nuts/Bolts (AWD)

1 – LEAF SPRING
2 – NUTS
3 – SPRING HANGER INNER HALF
4 – LEAF SPRING REAR HANGER
5 – SPRING HANGER OUTER HALF
6 – BOLTS

Fig. 22 Rear Spring Mount

1 – LEAF SPRING MOUNT

(1) For installation, reverse removal procedure. Do
not tighten rear spring shackle nuts fully until vehi­cle is lowered and the full vehicle weight is applied
to the rear wheels. Tighten rear spring mount bolts
to 61 N·m (45 ft. lbs.). Tighten shackle nuts to 61
N·m (45 ft. lbs.).

SHOCK ABSORBER (REAR)

REMOVAL

(1) Raise vehicle. Vehicle is to be raised and sup­ported on jackstands or on a frame contact type
hoist. See Hoisting in the Lubrication And Mainte­nance section of this service manual.

(2) Support the rear axle of the vehicle using 2
jackstands positioned at the outer ends of the axle.

NOTE: If the shock absorber lower mounting bolt
deflects upward during removal, raise axle by
adjusting the support jack. If the lower shock
absorber bolt deflects downward during removal,
lower the axle by adjusting the support jack.

(5) Lower the jackstand and the rear of the leaf
spring. Remove the shackle from the leaf spring
bushing.

INSTALL

CAUTION: The following sequence must be fol­lowed when tightening the pin nuts on the rear
hanger for the rear leaf spring. First the hanger pin
nuts must be tightened to the specified torque.
Then tighten the retaining bolts for the inner to
outer half of the spring hanger to the specified
torque. This sequence must be followed to avoid
bending the spring hanger.

(3) Remove the shock absorber lower mounting

bolt.

(4) While holding shock absorber, remove the
shock absorber upper mounting bolt and shock
absorber.

INSTALLATION

(1) While holding shock absorber in position
against the frame rail, install the shock absorber
upper mounting bolt.

(2) Install the shock absorber lower mounting bolt
securing the lower end of the shock absorber to the
axle.

(3) Remove the support jack.

2 - 54 SUSPENSION NS

REMOVAL AND INSTALLATION (Continued)

(4) Lower the vehicle to the ground so the full curb

weight of the vehicle is supported by the suspension.

(5) Tighten the upper and lower shock absorber

mounting bolt to a torque of 101 N·m (75 ft. lbs.).

STABILIZER BAR (REAR)

REMOVAL

(1) Raise vehicle. Vehicle is to be raised and sup­ported on jack stands or on a frame contact type
hoist. See Hoisting in the Lubrication and Mainte­nance section of this service manual.

(2) Remove the 2 lower bolts which hold the stabi­lizer bar to the link arm on each side of the vehicle.

(3) Loosen but do not fully remove the four bolts
that attach the stabilizer bar bushing retainers to
the rear axle brackets.

(4) While holding the stabilizer bar in place. Fully
remove the 4 bolts loosened in step 3.

(5) Remove the stabilizer bar from the vehicle.

(6) If the link arms need to be serviced, remove
the upper link arm to bracket bolt. Then remove link
arm from frame rail attaching bracket.

INSPECTION

Inspect for broken or distorted clamps, retainers,
and bushings. If bushing replacement is required, the
stabilizer bar to axle bushings can be removed from
the stabilizer bar by opening the split.

INSTALLATION

(1) Install the link arms onto the frame rail brack­ets. DO NOT TIGHTEN.

(2) Position the axle to stabilizer bar bushings on
the stabilizer bar with the slit in the bushings facing
up.

(3) Lift the stabilizer bar onto the rear axle and
install the retainers and the four mounting bolts. DO
NOT TIGHTEN.

(4) Install the two lower link arm bolts on the sta­bilizer bar. DO NOT TIGHTEN.

(5) Lower the vehicle so that the full weight of the
vehicle is on all four tires. With the vehicle at its
curb height, tighten all attaching bolts to the torques
listed below.

• Stabilizer bar bushing to axle bracket bolts 61

N·m (45 ft. lbs.)

• Link arm to frame rail bracket 61 N·m (45 ft.

lbs.)

• Stabilizer bar to link arm 61 N·m (45 ft. lbs.)

• Frame rail bracket to frame rail 61 N·m (45 ft.

lbs.)

TRACK BAR (REAR)

REMOVAL

(1) Remove the nut and bolt mounting the track

bar to the rear axle (Fig. 23).

Fig. 23 Track Bar Mounting To Axle

1 – LOWER TRACK BAR BOLT INSTALLATION

(2) Remove the nut and bolt attaching the track
bar to the track bar mount on the body of the vehicle.
Remove the track bar from the track bar mount.

INSTALLATION

(1) Install the track bar first into the body mount
for the track bar (Fig. 24). Install the track bar bolt
with the head of the bolt facing toward the rear of
the vehicle (Fig. 25). Do not tighten.

Fig. 24 Track Bar Installation

1 – TRACK BAR REPLACEMENT

NS SUSPENSION 2 - 55

REMOVAL AND INSTALLATION (Continued)

INSTALLATION

(1) For installation, reverse removal procedure.
Tighten bolts to 61 N·m (45 ft. lbs.).

JOUNCE BUMPER

There are two types of jounce bumpers available
depending on which suspension option the vehicle is
equipped with.

REMOVAL-STANDARD

The jounce bumper is serviced as an assembly. The
jounce bumper mounts to the frame rail at a weld
nut located on the frame rail (Fig. 27).

(1) Using the proper tool, remove the bolt attach­ing the jounce bumper to frame rail.

(2) Remove the jounce bumper from the frame rail.

Fig. 25 Track Bar Bolt Installation

1 – TRACK BAR BOLT

(2) Install the track bar into its mounting bracket
on the rear axle (Fig. 23). Install the track bar bolt
with the head of the bolt facing toward the rear of
the vehicle. Do not tighten.

(3) Lower the vehicle to the ground until the full
weight of the vehicle is supported by the wheels.
Tighten both track bar attaching bolts to a torque of
95 N·m (70 ft. lbs.).

TRACK BAR MOUNT

REMOVE

(1) Remove the track bar from the track bar
mount.

(2) Remove the three bolts attaching the track bar
mount to the body (Fig. 26).

Fig. 26 Track Bar Mount

1 – TRACK BAR MOUNT

Fig. 27 Jounce Bumper-Standard

1– JOUNCE BUMPER

INSTALLATION-STANDARD

(1) For installation, reverse the removal procedure.
Tighten the jounce bumper mounting bolt to a torque
of 33 N·m (290 in. lbs.).

REMOVAL-HEAVY DUTY

The jounce bumpers are serviced as an assembly.
The jounce bumpers screw into a weld nut located in
the frame rail (Fig. 28).

(1) Using slip-joint pliers grasp the base of the
jounce bumper. Turn the base counterclockwise (Fig.

29).

(2) Remove the jounce bumper from the frame rail.

INSTALLATION-HEAVY DUTY

(1) For installation, reverse the removal procedure.
Tighten the jounce bumper to a torque of 33 N·m
(290 in. lbs.).

2 - 56 SUSPENSION NS

REMOVAL AND INSTALLATION (Continued)

Fig. 28 Jounce Bumper-Heavy Duty

1 – JOUNCE BUMPERS

Fig. 29 Bumper Replacement

1 – BUMPER REPLACEMENT

HUB AND BEARING (REAR)

Fig. 30 Rear Wheel Speed Sensor

1 – BRAKE SUPPORT PLATE
2 – REAR AXLE
3 – TONE WHEEL
4 – WHEEL SPEED SENSOR
5 – MOUNTING BOLT

CAUTION: When working in the area of the rear
hub/bearing and when removing it from the rear
axle, care must be used so the teeth on the tone
wheel are not damaged. Damage to the teeth on the
tone wheel will result in false ABS cycling and cor­rosion of the tone wheel.

(5) Remove the 4 bolts (Fig. 31) attaching the hub/
bearing to the rear axle.

FRONT-WHEEL-DRIVE VEHICLES

REMOVAL

(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in the Lubri­cation and Maintenance section of this service man­ual for required lifting procedure.

(2) Remove wheel and tire.

(3) Remove brake drum from hub/bearing.

(4) Remove rear wheel speed sensor from rear hub/
bearing (Fig. 30). This will prevent damage to the
speed sensor during removal and installation of the
hub/bearing. The rear wheel speed sensor bolts

to the hub/bearing. It can not be removed
unless the speed sensor is removed first.

Fig. 31 Rear Hub/Bearing Mounting Bolts

1 – REAR AXLE FLANGE
2 – HUB/BEARING MOUNTING BOLTS (4)
3 – HUB/BEARING ASSEMBLY
4 – TONE WHEEL (WHEN ABS EQUIPPED)

NS SUSPENSION 2 - 57

REMOVAL AND INSTALLATION (Continued)

CAUTION: Corrosion may occur between the hub/
bearing and the axle. If this occurs the hub/bearing
will be difficult to remove from the axle. If the hub/
bearing will not come out of the axle by pulling on
it by hand, do not pound on the hub/bearing to
remove it from the axle. Pounding on the hub/bear­ing to remove it from the axle will damage the hub/
bearing. This damage will result in noise or failure
of the bearing.

(6) If hub/bearing cannot be removed from the axle
by hand, use Remover Special Tool 8214 (Fig. 32) and
following procedure to press the hub/bearing out of
the axle.

(a) Place Special Tool 8214-1 over tone wheel

and against cast flange of hub/bearing (Fig. 32)

Fig. 33 Removing Rear Hub/Bearing From Axle

1 – BRAKE SUPPORT PLATE
2 – HUB/BEARING ASSEMBLY

INSTALLATION

(1) Install the 4 hub/bearing to axle mounting

bolts into the holes in the flange of the rear axle.

(2) Install the rear brake support plate on the 4
mounting bolts installed in the flange of the rear
axle.

(3) Align the rear hub/bearing with the 4 mount­ing bolts and start mounting bolts into hub/bearing.
Tighten the 4 bolts in a criss-cross pattern until the
hub/bearing and brake support plate is fully and
squarely seated onto flange of rear axle.

Fig. 32 Special Tool 8214 Installed

1 – BRAKE SUPPORT PLATE
2 – SPECIAL TOOL 8214–1
3 – SPECIAL TOOL 8214–2
4 – AXLE PLATE

(b) Put a dab of grease in the bolt pilot hole on

the back of Special Tool 8214-1.

(c) Insert Special Tool 8214-2 into the hole in the
bottom of the end casting on the axle (Fig. 32).
Special Tool 8214-2 should be against and sup­ported by the axle plate (Fig. 32) when pressing
the wheel bearing out of the axle. If Special Tool

8214-2 will not fit into the hole in the end
casting, file or grind the flashing from the
hole until tool fits properly.

(d) Align bolt in Special Tool 8214-2 with pilot
hole in Special Tool 8214-1. Tighten bolt against
Special Tool 8214-1.

(e) Press hub/bearing out of axle by continuing
to tighten bolt in Special Tool 8214-2 against Spe­cial Tool 8214-1.
(7) Remove the hub/bearing from the rear axle and

brake support plate (Fig. 33).

(4) Tighten the 4 hub/bearing mounting bolts (Fig.

31) to a torque of 129 N·m (95 ft. lbs.)
(5) Install the rear wheel speed sensor on the rear

hub/bearing flange (Fig. 30). Install the speed sensor
attaching bolt and tighten to a torque of 12 N·m (105
in. lbs.).

(6) Install brake drum on hub/bearing.
(7) Install wheel and tire.
(8) Tighten the wheel stud nuts in the proper

sequence to a torque of 135 N·m (100 ft. lbs.).

(9) Adjust the rear brakes as necessary, Refer to

Adjustments in the Brake section in this service
manual.

ALL-WHEEL-DRIVE VEHICLES

REMOVAL

(1) Set the parking brake. The parking brake is

set to keep the hub/bearing and axle shaft from
rotating when loosening the hub nut.

(2) Raise vehicle. Vehicle is to be raised and sup-

ported on jackstands or on a frame contact type
hoist. See Hoisting in the Lubrication And Mainte­nance section of this service manual.

(3) Remove the wheel/tire assembly.

2 - 58 SUSPENSION NS

REMOVAL AND INSTALLATION (Continued)

(4) Remove the cotter pin and nut retainer (Fig.

34) from the stub shaft of the outer C/V joint.

Fig. 36 Hub Nut And Washer

Fig. 34 Cotter Pin And Nut Retainer

1 – CALIPER
2 – COTTER PIN
3 – ROTOR
4 – NUT RETAINER
5 – OUTER C/V JOINT

1 – CALIPER
2 – HUB NUT
3 – WASHER
4 – ROTOR
5 – ADAPTER

(5) Remove the spring washer (Fig. 35) from the

stub shaft of the outer C/V joint.

Fig. 35 Spring Washer

1 – HUB NUT
2 – STUB SHAFT
3 – ROTOR
4 – SPRING WASHER

(6) Remove the hub nut and washer (Fig. 36) from

the stub shaft of the outer C/V joint.

(7) Remove the 6 bolts (Fig. 37) mounting the
driveshaft inner joint to the output shaft of the rear
drive line module.

Fig. 37 Driveshaft Attachment To Driveline Module

1 – DRIVESHAFT
2 – BOLTS
3 – DRIVE LINE MODULE
4 – DRIVESHAFT INNER JOINT

(8) Remove the rear wheel speed sensor (Fig. 38)

from the rear hub/bearing.

(9) Release the parking brake.
(10) Remove the disc brake caliper to adapter

guide pin bolts (Fig. 39).

(11) Remove rear caliper from adapter using the
following procedure. First rotate rear of caliper up
from the adapter. Then pull the front of the caliper
and the outboard brake shoe anti-rattle clip out from
under the front abutment on the adapter (Fig. 40).

NS SUSPENSION 2 - 59

REMOVAL AND INSTALLATION (Continued)

Fig. 38 Wheel Speed Sensor

1 – MOUNTING BOLT
2 – WHEEL SPEED SENSOR

Fig. 39 Caliper Guide Pin Bolts

1 – STUD PIN BOLTS
2 – DISC BRAKE CALIPER
3 – DRIVESHAFT
4 – AXLE
5 – DISC BRAKE CALIPER ADAPTER

(12) Support caliper to prevent the weight of the

caliper from damaging the flexible brake hose (Fig.

41).
(13) Remove the rotor from the hub/bearing.
(14) Remove driveshaft from rear drive line mod-

ule and hub/bearing. Driveshaft is removed by first
compressing the inner joint on the driveshaft and
removing it from the drive line module. Then, slide
the outer joint of the driveshaft out of the hub/bear­ing.

Fig. 40 Removing / Installing Caliper

1 – LIFT THIS END OF CALIPER AWAY FROM ADAPTER FIRST
2 – DISC BRAKE CALIPER
3 – ADAPTER ABUTMENT
4 – OUTBOARD BRAKE SHOE HOLD DOWN CLIP
5 – OUTBOARD BRAKE SHOE
6 – ROTOR
7 – ADAPTER

Fig. 41 Correctly Supported Caliper

1 – WIRE
2 – CALIPER
3 – ADAPTER
4 – ROTOR
5 – INNER FENDER

2 - 60 SUSPENSION NS

REMOVAL AND INSTALLATION (Continued)

(15) Remove the hub/bearing to axle mounting

bolts (Fig. 42).

Fig. 43 Hub/Bearing Removal And Installation

1 – PARK BRAKE BRAKE SHOE

Fig. 42 Hub/Bearing Mounting Bolts

1 – HUB/BEARING
2 – AXLE
3 – MOUNTING BOLTS
4 – CALIPER ADAPTER

2 – HUB/BEARING
3 – PARK BRAKE BRAKE SHOE

CAUTION: Corrosion may occur between the hub/
bearing and the axle. If this occurs the hub/bearing
will be difficult to remove from the axle. If the hub/
bearing will not come out of the axle by pulling on
it by hand, do not pound on the hub/bearing to
remove it from the axle. Pounding on the hub/bear­ing to remove it from the axle will damage the hub/
bearing. This damage will result in noise or failure
of the hub/bearing. To remove a hub/bearing which
is corroded to the axle, lightly tap the disc brake
caliper adapter using a soft faced hammer. This will
remove both the disc brake caliper adapter and
hub/bearing from the axle. The hub/bearing will
then need to be removed from the caliper adapter.

(16) Remove the hub/bearing from the axle. (Fig.

43).
(17) If the disc brake caliper adapter and hub/

bearing were removed as an assembly from the axle
and the hub/bearing cannot be removed from the
adapter by hand, use the following procedure to
remove it from the adapter. With a helper supporting
the caliper adapter in his hands, position Remover,
Special Tool 8214-1 on the cast housing of hub/bear­ing (Fig. 44). Do not position special tool on
inner race of hub/bearing. Lightly strike Remover,
Special Tool 8214-1 with a hammer to remove the
hub/bearing from the caliper adapter.

INSTALLATION

(1) Install hub/bearing on end of axle. (Fig. 43).

Fig. 44 Hub/Bearing Removal From Caliper Adapter

1 – SPECIAL TOOL 8214-1
2 – PARK BRAKE CABLE
3 – DISC BRAKE CALIPER ADAPTER
4 – HUB/BEARING

(2) Install the hub/bearing mounting bolts. In a
progressive criss-cross pattern, tighten the 4 hub/
bearing mounting bolts (Fig. 42) until the disc brake
caliper adapter and hub/bearing are squarely seated
against the axle. Then tighten the hub/bearing
mounting bolts to a torque of 129 N·m (95 ft. lbs.).

(3) Install driveshaft in hub/bearing and on output
shaft of rear drive line module. Driveshaft is
installed by first sliding the outer joint of the drive­shaft into the hub/bearing and then compressing the
inner joint on the driveshaft and installing it on the
output shaft the drive line module.

(4) Install rotor on hub/bearing.

NS SUSPENSION 2 - 61

REMOVAL AND INSTALLATION (Continued)

(5) Carefully lower disc brake caliper and brake
shoes over rotor and onto caliper adapter by revers­ing the removal procedure (Fig. 40).

CAUTION: When installing guide pin bolts extreme
caution should be taken not to cross-thread the cal­iper guide pin bolts.

(6) Install the disc brake caliper guide pin bolts
(Fig. 39). Tighten the guide pin bolts to a torque of
22 N·m (192 in. lbs.).

(7) Clean all foreign material off the threads of the
outer C/V joint stub shaft. Install the washer and
hub nut (Fig. 36) on the stub shaft of the outer C/V
joint.

(8) Lower vehicle.

(9) Set the park brake. This is required to keep

the driveshaft from rotating when tightening
and torquing the hub nut and driveshaft inner
joint to driveline module mounting nuts.

(10) Raise vehicle.

(11) Tighten the driveshaft inner joint to drive line
module output shaft mounting bolts (Fig. 37) to a
torque of 61 N·m (45 ft. lbs.).

(12) Tighten the outer C/V joint hub nut (Fig. 36)
to a torque of 244 N·m (180 ft. lbs.).

(13) Install the spring washer (Fig. 35) on the stub
shaft of the outer C/V joint.

(14) Install the nut retainer and cotter pin (Fig.

34) on the stub shaft of the outer C/V joint.

(15) Install the wheel speed sensor on the hub/
bearing and adapter. Install the wheel speed sensor
attaching bolt (Fig. 38). Tighten the wheel speed sen­sor attaching bolt to a torque of 12 N·m (105 in. lbs).

(16) Install wheel and tire.

(17) Tighten the wheel mounting stud nuts in
proper sequence until all nuts are torqued to half
specification. Then repeat the tightening sequence to
the full specified torque of 135 N·m (100 ft. lbs.).

(18) Remove jackstands or lower hoist.

CAUTION: Before moving vehicle, pump the brake
pedal several times to insure the vehicle has a firm
brake pedal to adequately stop vehicle.

(19) Road test vehicle to ensure proper operation
of the brake system.

WHEEL MOUNTING STUDS (REAR)

REMOVAL

CAUTION: If a wheel attaching stud needs to be
replaced in the hub and bearing assembly the studs
cannot be hammered out of the hub flange. If a stud
is removed by hammering it out of the bearing
flange, damage to the hub and bearing assembly
will occur leading to premature hub and bearing
failure.

(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in the Lubri­cation and Maintenance section of this manual for
the required lifting procedure to for this vehicle.

(2) Remove the rear wheel and tire assembly.

(3) Remove the rear brake drum.

(4) Install a lug nut on the wheel stud to be
removed from the hub and bearing assembly (Fig. 45)
so the threads on stud are even with end of lug nut.
Install Remover, Special Tool C-4150A on hub and
bearing assembly flange and wheel stud (Fig. 45).

Fig. 45 Removing Wheel Stud From Hub And

Bearing

1 – HUB/BEARING ASSEMBLY
2 – LUG NUT
3 – WHEEL STUD
4 – SPECIAL TOOL C-4150–A

(5) Tightening down on special tool will push
wheel stud out of the hub and bearing assembly
flange. Remove lug nut from stud and remove wheel
stud from flange.

2 - 62 SUSPENSION NS

REMOVAL AND INSTALLATION (Continued)

INSTALLATION

(1) Install replacement wheel stud into flange of
hub and bearing assembly. Install washers on wheel
stud, then install a wheel lug nut on stud with flat
side of lug nut against washers (Fig. 46).

Fig. 46 Installing Wheel Stud Into Hub And Bearing

1 – LUG NUT
2 – HUB/BEARING ASSEMBLY
3 – WASHERS
4 – WHEEL STUD

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

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

(4) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting stud nuts in proper
sequence until all nuts are torqued to half specifica­tion. Then repeat the tightening sequence to the full
specified torque of 135 N·m (100 ft. lbs.).

(5) Lower vehicle to the ground.

(2) Install the Receiver, Special Tool 8526-1, into
the cup of the Ball Joint Press, Special Tool C-4212F,
and tighten the set screw. Install the Driver, Special
Tool 8526-2, on the tip of the Ball Joint Press screw
drive as shown (Fig. 47).

Fig. 47 Special Tools Positioned For Removal

1 – SCREW DRIVE

NOTE: It works well to place the Ball Joint Press,
Special Tool C-4212F, in a bench vise as shown
(Fig. 47) to perform this procedure.

(3) Place the shock absorber upper mounting eye
in the Receiver so the notch in the Receiver clears
the shock absorber body (Fig. 48).

DISASSEMBLY AND ASSEMBLY

SHOCK ABSORBER UPPER BUSHING (REAR)

NOTE: This procedure is to be used only on the
upper bushing of load-leveling shock absorbers.
The shock absorber lower bushing on load-leveling
shock absorbers is not serviceable.

DISASSEMBLY

(1) Remove the shock absorber from the vehicle.
Refer to REMOVAL AND INSTALLATION in this
section for the procedure.

Fig. 48 Removing Bushing From Shock Absorber

1 – SCREW DRIVE
2 – SHOCK ABSORBER
3 – NOTCH

NS SUSPENSION 2 - 63

DISASSEMBLY AND ASSEMBLY (Continued)

(4) Tighten the screw drive until the Driver con­tacts the outer circumference of the bushing evenly
(Fig. 48). Continue to tighten the screw drive until
the bushing is pressed completely out of the shock
absorber eye and into the Receiver.

(5) Back off the screw drive and remove the bush­ing from the Receiver.

ASSEMBLY

(1) Install the Receiver, Special Tool 8526-1, into
the cup of the Ball Joint Press, Special Tool C-4212F,
and tighten the set screw. Install the Driver, Special
Tool 8526-2, on the tip of the Ball Joint Press screw
drive as shown (Fig. 49). Position the Driver this way
to seat the bushing to its correct depth.

Fig. 50 Installing Bushing In Shock Absorber

1 – BUSHING
2 – SCREW DRIVE
3 – SHOCK ABSORBER
4 – NOTCH

Fig. 49 Special Tools Positioned For Installation

1 – SCREW DRIVE

(2) Place the shock absorber upper mounting eye
in the Receiver so the notch in the Receiver clears
the shock absorber body (Fig. 50).

(3) Position the bushing between the shock
absorber eye and the Driver (Fig. 50). Tighten the
screw drive until the Driver, bushing, and shock
absorber eye are touching and squarely aligned.

(4) Press the bushing into the shock absorber eye
until the Driver bottoms against the face of the eye.

(5) Back off the Ball Joint Press screw drive and
remove the shock absorber from the press.

(6) Install the shock absorber on the vehicle. Refer
to REMOVAL AND INSTALLATION in this section
for the procedure.

SPECIFICATIONS

REAR SUSPENSION FASTENER TORQUES

DESCRIPTION TORQUE
Shock Absorber:

Mounting Bolts (All) ........ 101N·m(75ft.lbs.)

Leaf Spring:

Spring Plate To Axle Attaching

Bolts .................. 101N·m(75ft.lbs.)

Rear Mount To Body Bolts .... 61N·m(45ft.lbs.)

Front Mount To Body Bolts .... 61N·m(45ft.lbs.)

To Front Hanger Mounting

Nut .................. 156N·m(115ft.lbs.)

Shackle Plate Nuts .......... 61N·m(45ft.lbs.)

Jounce Bumper:

Mounting Bolt ............ 33N·m(290 in. lbs.)

Track Bar:

Axle And Mounting Bracket Pivot

Bolt .................... 95N·m(70ft.lbs.)

Bracket To Body Attaching .... 61N·m(45ft.lbs.)

Stabilizer Bar:

Bushing Retainer To Axle Attaching

Bolts ................... 61N·m(45ft.lbs.)

Attaching Link Nuts ......... 61N·m(45ft.lbs.)

Frame Rail Bracket Mounting

Bolts ................... 61N·m(45ft.lbs.)

Link Arm To Frame Rail

Bracket ................. 61N·m(45ft.lbs.)

Hub And Bearing:

To Axle Mounting Bolts ...... 129N·m(95ft.lbs.)

Stub Axle Nut ............ 224N·m(180 ft. lbs.)

Wheel Mounting Lug Nut . . . 135 N·m (100 ft. lbs.)

NS/GS SUSPENSION 2 - 1

SUSPENSION

TABLE OF CONTENTS

page

SPECIFICATIONS

ALIGNMENT SPECIFICATIONS...............1

SPECIFICATIONS

ALIGNMENT SPECIFICATIONS

All alignment specifications are to be checked and

adjusted with the vehicle at its correct ride height.

ALIGNMENT ANGLE TIRE SIZES TIRE SIZES

* FRONT INDIVIDUAL CAMBER IN

DEGREES............................................

Front Side To Side Camber
Difference Not To

Exceed...................

** FRONT INDIVIDUAL CASTER IN

DEGREES............................................

Front Side To Side Caster Difference
Not To

Exceed.....................................

*** FRONT INDIVIDUAL TOE
RIGHT/

LEFT.........................................

FRONT TOTAL

TOE....................................................

Specified In Degrees
FRONT SIDE TO SIDE TOE

DIFFERENTIAL.....................................

****REAR INDIVIDUAL CAMBER IN

DEGREES............................................

REAR INDIVIDUAL TOE RIGHT/

LEFT........................................

**** REAR TOTAL TOE.....................

Specified In Degrees
TOE OUT: When Backed On
Alignment Rack Is TOE In When
Driving

****REAR THRUST

ANGLE................

STEERING WHEEL

ANGLE................

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

P205/75/R14 P215/70/R15
P215/65/R15 P215/65/R16

+0.15° +or- 0.40° +0.05° +or- 0.40°

0.00° - 0.50° MAX 0.00° - 0.50° MAX

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

0.00° - 1.00° MAX 0.00° - 1.00° MAX

+0.05°+or- 0.10° +0.05° +or- 0.10°

+0.10° +or- 0.20° +0.10° +or- 0.20°

0.00° - 0.06° MAX 0.00° - 0.06° MAX

+0.00° +or- 0.25° +0.00° +or- 0.25°

0.00° +or- 0.40° 0.00° +or- 0.40°

0.00° +or- 0.40° 0.00° +or- 0.40°

0.00° +or- 0.30° 0.00° +or- 0.30°

0.00° +or- 2.50° 0.00° +or- 2.50°

2 - 2 SUSPENSION NS/GS

SPECIFICATIONS (Continued)

ALIGNMENT ANGLE TIRE SIZES TIRE SIZES

FRONT RIDE HEIGHT (MEASURED
AT TOP OF FENDER WHEEL

OPENING)............................................

FRONT RIDE HEIGHT SIDE TO
SIDE

DIFFERENTIAL.....................................

*****REAR RIDE HEIGHT
(MEASURED AT TOP OF FENDER
WHEEL

OPENING)............................................

*****REAR RIDE HEIGHT SIDE TO
SIDE

DIFFERENTIAL.....................................

747.5 mm +or-10.0mm 753.5 mm +or-10.0mm

0.0 mm 12.5 mm MAX 0.0 mm 12.5 mm MAX

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

0.0 mm 12.5 mm MAX 0.0 mm 12.5 mm MAX

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

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

*** Toe-In is positive.

**** Toe, Camber and thrust angle are not
adjustable. If found to be out of specification
check for proper ride heights and damaged/
worn out suspension components and replace
as necessary.

***** When Measuring ride heights: 1) Ensure
that the tire pressures are correct. 2) Jounce
the vehicle at the bumper several times and
release at the bottom of the stroke. 3) Measure
from the ground to the outboard, lower, center
section of the fender wheel well opening. Ride
heights are not adjustable. If found to be out of
specification check for damaged and/or worn
out suspension components and replace as
necessary.

NS DIFFERENTIAL AND DRIVELINE 3 - 1

DIFFERENTIAL AND DRIVELINE

TABLE OF CONTENTS

page page

FRONT DRIVESHAFTS ...................... 1 DRIVELINE MODULE AND REAR

DRIVESHAFTS .......................... 17

FRONT DRIVESHAFTS

TABLE OF CONTENTS

page page

DESCRIPTION AND OPERATION

FRONT DRIVESHAFTS .....................1

DIAGNOSIS AND TESTING

DRIVESHAFT DIAGNOSIS ...................2

REMOVAL AND INSTALLATION

FRONT DRIVESHAFTS .....................3

DISASSEMBLY AND ASSEMBLY

DRIVESHAFT RECONDITIONING

PROCEDURE ...........................7

DESCRIPTION AND OPERATION

FRONT DRIVESHAFTS

Vehicles equipped with either an automatic or
manual transmission uses an unequal length drive­shaft system (Fig. 1).

Vehicles equipped with automatic transaxles use a
solid short interconnecting shaft on the left side. The
right side of the vehicle uses a longer solid intercon­necting shaft.

The left driveshaft uses a tuned rubber damper
weight. When replacing the left driveshaft, be sure
the replacement driveshaft has the same damper
weight as the original.

Both driveshaft assemblies use the same type of
inner and outer joints. The inner joint of both drive­shaft assemblies is a tripod joint, and the outer joint
of both driveshaft assemblies is a Rzeppa joint. Both
tripod joints and Rzeppa joints are true constant
velocity (C/V) joint assemblies. The inner tripod joint
allows for the changes in driveshaft length through
the jounce and rebound travel of the front suspen­sion.

INNER TRIPOD JOINT SEAL BOOT............8

OUTER C/V JOINT SEAL BOOT..............12

OUTER C/V JOINT BEARING SHIELD

SERVICE .............................15

SPECIFICATIONS

TORQUE SPECIFICATIONS.................16

SPECIAL TOOLS

DRIVESHAFT............................16

On vehicles equipped with ABS brakes, the outer
C/V joint is equipped with a tone wheel used to
determine vehicle speed for ABS brake operation.

The inner tripod joint of both driveshafts is splined
into the transaxle side gears. The inner tripod joints
are retained in the side gears of the transaxle using
a snap ring located in the stub shaft of the tripod
joint. The outer C/V joint has a stub shaft that is
splined into the wheel hub and retained by a steel
hub nut.

NOTE: This vehicle does not use a rubber lip bear­ing seal as on past front wheel drive cars, to pre­vent contamination of the front wheel bearing. It is
important though to thoroughly clean the outer C/V
joint and the wheel bearing area in the steering
knuckle before it is assembled after servicing.

3 - 2 DIFFERENTIAL AND DRIVELINE NS

DESCRIPTION AND OPERATION (Continued)

Fig. 1 Unequal Length Driveshaft System

1 – STUB AXLE
2 – OUTER C/V JOINT
3 – OUTER C/V JOINT BOOT
4 – TUNED RUBBER DAMPER WEIGHT
5 – INTERCONNECTING SHAFT
6 – OUTER C/V JOINT BOOT
7 – STUB AXLE

DIAGNOSIS AND TESTING

DRIVESHAFT DIAGNOSIS

VEHICLE INSPECTION

(1) Check for grease in the vicinity of the inboard
tripod joint and outboard C/V joint; this is a sign of
inner or outer joint seal boot or seal boot clamp dam­age.

(2) A light film of grease may appear on the right
inner tripod joint seal boot; this is considered normal
and should not require replacement of the seal boot.

NOISE AND/OR VIBRATION IN TURNS

A clicking noise and/or a vibration in turns could
be caused by one of the following conditions:

(1) Damaged outer C/V or inner tripod joint seal
boot or seal boot clamps. This will result in the loss
and/or contamination of the joint grease, resulting in
inadequate lubrication of the joint.

(2) Noise may also be caused by another compo­nent of the vehicle coming in contact with the drive­shafts.

8 – OUTER C/V JOINT
9 – RIGHT DRIVESHAFT
10 – INNER TRIPOD JOINT BOOT
11 – INNER TRIPOD JOINT
12 – INNER TRIPOD JOINT
13 – INNER TRIPOD JOINT BOOT
14 – INTERCONNECTING SHAFT LEFT DRIVESHAFT

CLUNKING NOISE DURING ACCELERATION

This noise may be a result of one of the following

conditions:

(1) A torn seal boot on the inner or outer joint of

the driveshaft assembly.

(2) A loose or missing clamp on the inner or outer

joint of the driveshaft assembly.

(3) A damaged or worn driveshaft C/V joint.

SHUDDER OR VIBRATION DURING ACCELERATION

This problem could be a result of:
(1) A worn or damaged driveshaft inner tripod

joint.

(2) A sticking tripod joint spider assembly (inner

tripod joint only).

(3) Improper wheel alignment. See Wheel Align­ment in this group for alignment checking and set­ting procedures and specifications.

VIBRATION AT HIGHWAY SPEEDS

This problem could be a result of:

(1) Foreign material (mud, etc.) packed on the
backside of the wheel(s).

(2) Out of balance front tires or wheels. See Group
22, Wheels And Tires for the required balancing pro­cedure.

NS DIFFERENTIAL AND DRIVELINE 3 - 3

DIAGNOSIS AND TESTING (Continued)

(3) Improper tire and/or wheel runout. See Group
22, Wheels And Tires for the required runout check­ing procedure.

REMOVAL AND INSTALLATION

FRONT DRIVESHAFTS

REMOVAL

(1) Raise vehicle on jack stands or centered on a
frame contact type hoist. Refer to Hoisting in the
Lubrication And Maintenance section of this manual
for the required lifting procedure to be used for this
vehicle.

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

1 – HUB/BEARING ASSEMBLY
2 – WAVE WASHER
3 – STUB AXLE

Fig. 3 Wave Washer

Fig. 2 Hub And Bearing To Stub Axle Retaining Nut

1 – HUB/BEARING
2 – NUT LOCK
3 – COTTER PIN
4 – STUB AXLE

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

(4) Remove the wave washer (Fig. 3) from the end
of the stub axle

CAUTION: Wheel bearing damage will result if after
loosening hub nut, vehicle is rolled on the ground
or the weight of the vehicle is allowed to be sup­ported by the tires.

(5) With the vehicle’s brakes applied to keep hub
from turning, loosen and remove the stub axle to
hub nut.

(6) Remove the two front disc brake caliper to

steering knuckle attaching bolts (Fig. 4).

Fig. 4 Front Disc Brake Caliper Attaching Bolts

1 – DISC BRAKE CALIPER ASSEMBLY
2 – STEERING KNUCKLE
3 – DISC BRAKE CALIPER MOUNTING BOLTS
4 – DRIVESHAFT

(7) Remove the disc brake caliper from the steer­ing knuckle. Caliper is removed by first rotating top
of caliper away from steering knuckle and then
removing bottom of caliper out from under machined
abutment on steering knuckle (Fig. 5).

3 - 4 DIFFERENTIAL AND DRIVELINE NS

REMOVAL AND INSTALLATION (Continued)

Fig. 5 Brake Caliper Mounting To Steering Knuckle

1 – CALIPER ASSEMBLY
2 – ROTOR
3 – STEERING KNUCKLE
4 – MACHINED ABUTMENT

(8) Support disc brake caliper assembly by using a
wire hook and suspending it from the strut assembly
(Fig. 6). Do not allow the brake caliper assembly

to hang by the brake flex hose.

Fig. 6 Correctly Supported Disc Brake Caliper

1 – STEERING KNUCKLE
2 – BRAKE FLEX HOSE
3 – CALIPER ASSEMBLY
4 – WIRE HANGER
5 – STRUT ASSEMBLY

(9) Remove the brake rotor from the hub and bear­ing assembly (Fig. 7).

(10) Remove nut attaching outer tie rod end to
steering knuckle (Fig. 8). Nut is to be removed

from tie rod end using the following procedure,
hold tie rod end stud with a 11/32 socket while
loosening and removing nut with a wrench.

Fig. 7 Remove/Install Brake Rotor

1 – HUB
2 – STEERING KNUCKLE
3 – BRAKING DISC (ROTOR)
4 – WHEEL MOUNTING STUD

Fig. 8 Removing Tie Rod End Attaching Nut

1 – TIE ROD END
2 – STEERING KNUCKLE
3 – WRENCH
4 – 11/32 SOCKET
5 – TIE ROD END STUD

(11) Remove tie rod end from steering knuckle

using Remover, Special Tool MB-991113 (Fig. 9).

(12) Remove the steering knuckle to ball joint
stud, clamping nut and bolt (Fig. 10) from the steer­ing knuckle.

NS DIFFERENTIAL AND DRIVELINE 3 - 5

REMOVAL AND INSTALLATION (Continued)

Fig. 9 Tie Rod End Removal From Steering Knuckle

Arm

1 – TIE ROD END
2 – SPECIAL TOOL MB-991113
3 – STUD
4 – STEERING KNUCKLE ARM

Fig. 10 Control Arm To Steering Knuckle

Attachment

1 – CLAMPING NUT/BOLT
2 – LOWER CONTROL ARM
3 – BALL JOINT
4 – STEERING KNUCKLE
5 – ROTOR

(13) Using a pry bar, separate steering knuckle

from ball joint stud (Fig. 11). Note: Use caution

when separating ball joint stud from steering
knuckle, so ball joint seal does not get cut.

NOTE: Care must be taken not to separate the
inner C/V joint during this operation. Do not allow
driveshaft to hang by inner C/V joint after removing
outer C/V Joint from the hub/bearing assembly in

Fig. 11 Separating Ball Joint Stud From Steering

Knuckle

1 – STEERING KNUCKLE
2 – BALL JOINT STUD
3 – BALL JOINT SEAL
4 – LOWER CONTROL ARM
5–PRYBAR

steering knuckle, end of driveshaft must be sup­ported.

(14) Pull steering knuckle assembly out and away
from the outer C/V joint of the driveshaft assembly
(Fig. 12).

Fig. 12 Steering Knuckle Separation From

Driveshaft

1 – DRIVESHAFT STUB AXLE
2 – HUB/BEARING ASSEMBLY
3 – LOWER CONTROL ARM
4 – BALL JOINT
5 – STEERING KNUCKLE

(15) Support the outer end of the driveshaft
assembly. Insert a pry bar between inner tripod joint

3 - 6 DIFFERENTIAL AND DRIVELINE NS

REMOVAL AND INSTALLATION (Continued)

and transaxle case (Fig. 13). Pry against inner tripod
joint, until tripod joint retaining snap ring is disen­gaged from transaxle side gear.

Fig. 14 Tripod Joint Removal from Transaxle

1 – INNER TRIPOD JOINT
2 – TRANSAXLE

Fig. 13 Disengaging Inner Tripod Joint From

Transaxle

1 – INNER TRIPOD JOINT
2 – TRANSAXLE CASE
3–PRYBAR

3 – SPLINE
4 – OIL SEAL
5 – SNAP RING
6 – INTERCONNECTING SHAFT

(16) Hold inner tripod joint and interconnecting
shaft of driveshaft assembly. Remove inner tripod
joint from transaxle, by pulling it straight out of
transaxle side gear and transaxle oil seal (Fig. 14).

When removing tripod joint, do not let spline or
snap ring drag across sealing lip of the tran­saxle to tripod joint oil seal.

INSTALLATION

(1) Thoroughly clean spline and oil seal sealing
surface, on tripod joint. Lightly lubricate oil seal
sealing surface on tripod joint with fresh clean trans­mission lubricant.

(2) Holding driveshaft assembly by tripod joint and
interconnecting shaft, install tripod joint into tran­saxle side gear as far as possible by hand (Fig. 14).

(3) Grasp inner tripod joint an interconnecting
shaft. Forcefully push the tripod joint into side gear
of transaxle, until snap ring is engaged with tran­saxle side gear. Test that snap ring is fully

engaged with side gear by attempting to
remove tripod joint from transaxle by hand. If
snap ring is fully engaged with side gear, tripod
joint will not be removable by hand.

(4) Clean all debris and moisture out of steering
knuckle, in the area were outer C/V joint will be
installed into steering knuckle.

(5) Ensure that front of outer C/V joint which fits
against the face of the hub and bearing is free of
debris and moisture before installing outer C/V joint
into hub and bearing assembly (Fig. 15).

Fig. 15 Outer C/V Joint Inspection

1 – OUTER C/V JOINT
2 – THIS AREA OF OUTER C/V JOINT MUST BE FREE OF ALL

DEBRIS AND MOISTURE, BEFORE INSTALLATION INTO
STEERING KNUCKLE.

(6) Slide drive shaft back into front hub and bear­ing assembly. Then install steering knuckle onto the
stud of the ball joint assembly (Fig. 12).

(7) Install a new steering knuckle to ball joint
clamping bolt and nut (Fig. 10). Tighten the clamp­ing bolt and nut to a torque of 135 N·m (100 ft. lbs.).

(8) Install tie rod end into steering knuckle. Start
attaching nut onto stud of tie rod end. While holding
stud of tie rod end stationary using a 11/32 socket,
(Fig. 8) tighten tie rod end to steering knuckle

NS DIFFERENTIAL AND DRIVELINE 3 - 7

REMOVAL AND INSTALLATION (Continued)

attaching nut. Then using a crowfoot and 11/32
socket (Fig. 16), tighten the tie rod end attaching nut
to a torque of 54 N·m (40 ft. lbs.).

Fig. 17 Torquing Front Stub Axle To Hub Nut

1 – TORQUE WRENCH

Fig. 16 Torquing Tie Rod End Attaching Nut

1 – STEERING KNUCKLE
2 – TIE ROD END
3 – CROWFOOT
4 – 11/32 SOCKET
5 – TORQUE WRENCH

(9) Install braking disc on hub and bearing assem-

bly (Fig. 7).

(10) Install disc brake caliper assembly on steering
knuckle. Caliper is installed by first sliding bottom of
caliper under abutment on steering knuckle, and
then rotating top of caliper against top abutment
(Fig. 5).

(11) Install disc brake caliper assembly to steering
knuckle attaching bolts (Fig. 4). Tighten the disc
brake caliper assembly attaching bolts to a torque of
22 N·m (195 in. lbs.).

(12) Clean all foreign matter from the threads of
the outer C/V joint stub axle. Install the washer and
stub axle to hub/bearing assembly nut on stub axle
and securely tighten nut.

(13) Install front wheel and tire assembly. Install
and tighten the wheel mounting stud nuts in proper
sequence until all nuts are torqued to half the
required specification. Then repeat the tightening
sequence to the full specified torque of 135 N·m (100
ft. lbs.).

(14) Lower vehicle.

(15) With the vehicle’s brakes applied to keep hub
from turning, tighten the hub nut to a torque of 244
N·m (180 ft. lbs.) (Fig. 17).

(16) Install the spring wave washer on the end of
the stub axle.

(17) Install the hub nut lock, and a new cotter pin
(Fig. 2). Wrap cotter pin prongs tightly around the
hub nut lock as shown in (Fig. 2).

(18) Check for correct fluid level in transaxle
assembly. Refer to Group 21, Transaxle for the cor­rect fluid level checking procedure for the type of
transaxle being checked.

(19) Set front toe on vehicle to required specifica­tion.

DISASSEMBLY AND ASSEMBLY

DRIVESHAFT RECONDITIONING PROCEDURE

CAUTION: The outer C/V joint used on this vehicle
uses a new design for retaining the cross to the
interconnecting shaft. These driveshafts incorpo­rate a slight twist (helical) in the spline on the inter­connecting shaft where the cross is installed. This
twist causes a interference fit between the intercon­necting shaft and the cross when the outer C/V
joint is installed on the interconnecting shaft. This
design eliminates the clearance between the cross
and the interconnecting shaft resulting in quieter
operation of the driveshaft assembly. This design
though eliminated the capability of removing the
outer C/V joint from the interconnecting shaft. For
this reason the driveshafts will be serviced as a
quarter shaft (outer C/V joint/sealing boot, intercon­necting shaft and vibration damper) in the event of
a outer C/V joint boot failure.

NOTE: The only service which is to be performed
on the driveshaft assemblies is the replacement of
the driveshaft seal boots on the inner tripod joints.

If any failure of internal driveshaft components is
diagnosed during a vehicle road test or disassembly
of the driveshaft, the driveshaft will need to be
replaced as an assembly.

3 - 8 DIFFERENTIAL AND DRIVELINE NS

DISASSEMBLY AND ASSEMBLY (Continued)

CAUTION: Lubricant requirements and quantities
are different for inner joints than for outer joints.
Use only the recommended lubricants in the
required quantities when servicing driveshaft
assemblies.

INNER TRIPOD JOINT SEAL BOOT

REMOVAL

To remove sealing boots from driveshafts, the
driveshaft assemblies must be removed from the
vehicle. See Driveshaft Removal and Installation for
the required driveshaft removal and replacement
procedure.

The inner tripod joints use no internal retention in
the tripod housing to keep the spider assembly in the
housing. Therefore, do not pull on the interconnect­ing shaft to disengage tripod housing from transmis­sion stub shaft. Removal in this manner will cause
damage to the inboard joint sealing boots.

(1) Remove the driveshaft requiring boot replace­ment from the vehicle. See Driveshaft Removal and
Installation for the required driveshaft removal pro­cedure.

(2) Remove large boot clamp which retains inner
tripod joint sealing boot to tripod joint housing and
discard. Remove small clamp which retains inner tri­pod joint sealing boot to interconnecting shaft and
discard. Remove the sealing boot from the tripod
housing and slide it down the interconnecting shaft.

Fig. 18 Spider Assembly Removal from Tripod Joint

Housing

1 – TRIPOD JOINT HOUSING
2 – SPIDER ASSEMBLY
3 – SEALING BOOT

CAUTION: When removing the tripod joint housing
from the spider assembly, hold the bearings in
place on the spider trunions to prevent the bearings
from falling away.

(3) Slide the tripod joint housing off the spider
assembly and the interconnecting shaft (Fig. 18).

(4) Remove snap ring which retains spider assem­bly to interconnecting shaft (Fig. 19). Remove the
spider assembly from interconnecting shaft. If spider
assembly will not come off interconnecting shaft by
hand, it can be removed by tapping spider assembly
with a brass drift (Fig. 20). Do not hit the outer

tripod bearings in an attempt to remove spider
assembly from interconnecting shaft.

(5) Slide sealing boot off interconnecting shaft.

(6) Thoroughly clean and inspect spider assembly,
tripod joint housing, and interconnecting shaft for
any signs of excessive wear. If any parts show

signs of excessive wear, the driveshaft assembly
will require replacement. Component parts of
these driveshaft assemblies are not serviceable.

Fig. 19 Spider Assembly Retaining Snap Ring

1 – INTERCONNECTING SHAFT
2 – SPIDER ASSEMBLY
3 – RETAINING SNAP RING

INSTALLATION

NOTE: The inner tripod joint sealing boots are
made from two different types of material. High
temperature applications use silicone rubber where
as standard temperature applications use hytrel
plastic. The silicone sealing boots are soft and pli­able. The Hytrel sealing boots are stiff and rigid.
The replacement sealing boot MUST BE the same
type of material as the sealing boot which was
removed.

NS DIFFERENTIAL AND DRIVELINE 3 - 9

DISASSEMBLY AND ASSEMBLY (Continued)

fully install on interconnecting shaft by hand, it can
be installed by tapping the spider body with a brass
drift (Fig. 23). Do not hit the outer tripod bear-

ings in an attempt to install spider assembly on
interconnecting shaft.

Fig. 20 Spider Assembly Removal from

Interconnecting Shaft

1 – SPIDER ASSEMBLY
2 – DO NOT HIT SPIDER ASSEMBLY BEARINGS WHEN

REMOVING SPIDER ASSEMBLY
3 – BRASS DRIFT
4 – INTERCONNECTING SHAFT

(1) Slide inner tripod joint seal boot retaining
clamp, onto interconnecting shaft. Then, slide the
replacement inner tripod joint sealing boot onto the
interconnecting shaft. Inner tripod joint seal boot

MUST be positioned on interconnecting shaft,
so the raised bead on the inside of the seal boot
is in groove on interconnecting shaft (Fig. 21).

Fig. 22 Spider Assembly Installation on

Interconnecting Shaft

1 – SPIDER ASSEMBLY
2 – INTERCONNECTING SHAFT

Fig. 21 Sealing Boot Installation on Interconnecting

Shaft

1 – SEALING BOOT
2 – RAISED BEAD IN THIS AREA OF SEALING BOOT
3 – GROOVE
4 – INTERCONNECTING SHAFT

(2) Install spider assembly onto interconnecting
shaft (Fig. 22). Spider assembly must be installed on
interconnecting shaft far enough to fully install spi­der retaining snap ring. If spider assembly will not

Fig. 23 Installing Spider Assembly on

Interconnecting Shaft

1 – DO NOT HIT BEARINGS WHEN INSTALLING THE SPIDER

ASSEMBLY
2 – SPIDER ASSEMBLY
3 – INTERCONNECTING SHAFT
4 – BRASS DRIFT

(3) Install the spider assembly to interconnecting
shaft retaining snap ring into groove on end of inter­connecting shaft (Fig. 24). Be sure the snap ring is
fully seated into groove on interconnecting shaft.

(4) Distribute 1/2 the amount of grease provided in
the seal boot service package (DO NOT USE ANY

3 - 10 DIFFERENTIAL AND DRIVELINE NS

DISASSEMBLY AND ASSEMBLY (Continued)

tool C-4975-A until jaws on tool are closed completely
together, face to face (Fig. 27).

Fig. 24 Spider Assembly Retaining Snap Ring

Installed

1 – INTERCONNECTING SHAFT
2 – SPIDER ASSEMBLY
3 – RETAINING SNAP RING

OTHER TYPE OF GREASE) into tripod housing. Put
the remaining amount into the sealing boot.

(5) Align tripod housing with spider assembly and
then slide tripod housing over spider assembly and
interconnecting shaft (Fig. 25).

Fig. 26 Crimping Tool Installed on Sealing Boot

Clamp

1 – SPECIAL TOOL C-4975A
2 – INTERCONNECTING SHAFT
3 – CLAMP
4 – SEALING BOOT

Fig. 25 Installing Tripod Housing on Spider

Assembly

1 – TRIPOD JOINT HOUSING
2 – SPIDER ASSEMBLY
3 – SEALING BOOT

(6) Install inner tripod joint seal boot to intercon­necting shaft clamp evenly on sealing boot.

(7) Clamp sealing boot onto interconnecting shaft
using crimper, Special Tool C-4975-A and the follow­ing procedure. Place crimping tool C-4975-A over
bridge of clamp (Fig. 26). Tighten nut on crimping

Fig. 27 Sealing Boot Retaining Clamp Installed

1 – CLAMP
2 – JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED

COMPLETELY TOGETHER HERE
3 – INTERCONNECTING SHAFT
4 – SEALING BOOT

CAUTION: Seal must not be dimpled, stretched or
out of shape in any way. If seal is NOT shaped cor­rectly, equalize pressure in seal and shape it by
hand.

(8) Position sealing boot into the tripod housing
retaining groove. Install seal boot retaining clamp
evenly on sealing boot.

NS DIFFERENTIAL AND DRIVELINE 3 - 11

DISASSEMBLY AND ASSEMBLY (Continued)

CAUTION: The following positioning procedure
determines the correct air pressure inside the inner
tripod joint assembly prior to clamping the sealing
boot to inner tripod joint housing. If this procedure
is not done prior to clamping sealing boot to tripod
joint housing sealing boot durability can be
adversely affected.

CAUTION: When venting the inner tripod joint
assembly, use care so inner tripod sealing boot
does not get punctured, or in any other way dam­aged. If sealing boot is punctured, or damaged in
any way while being vented, the sealing boot can
not be used.

(9) Insert a trim stick between the tripod joint and
the sealing boot to vent inner tripod joint assembly
(Fig. 28). When inserting trim stick between tri-

pod housing and sealing boot ensure trim stick
is held flat and firmly against the tripod hous­ing. If this is not done damage to the sealing
boot can occur. If inner tripod joint has a Hytrel

(hard plastic) sealing boot, be sure trim stick is
inserted between soft rubber insert and tripod hous­ing not the hard plastic sealing boot and soft rubber
insert.

tripod joint, preventing premature sealing boot
failure.

(11) Position trilobal boot to interface with the tri­pod housing. The lobes of the boot must be properly
aligned with the recess’s of the tripod housing.

(12) Clamp tripod joint sealing boot to tripod joint,
using required procedure for type of boot clamp
application.

CRIMP TYPE BOOT CLAMP

If seal boot uses crimp type boot clamp:

• Clamp sealing boot onto tripod housing using

Crimper, Special Tool C-4975-A.

• Place crimping tool C-4975-A over bridge of

clamp (Fig. 29).

• Tighten nut on crimping tool C-4975-A until
jaws on tool are closed completely together, face to
face (Fig. 30).

Fig. 28 Trim Stick Inserted for Venting Tripod Joint

1 – INNER TRIPOD JOINT SEALING BOOT
2 – SEALING BOOT CLAMP
3 – INNER TRIPOD JOINT HOUSING
4 – TRIM STICK

(10) With trim stick inserted between sealing boot
and tripod joint housing, position the interconnecting
shaft so it is at the center of its travel in the tripod
joint housing. Remove the trim stick from between
the sealing boot and the tripod joint housing. This

procedure will equalize the air pressure in the

Fig. 29 Crimping Tool Installed on Sealing Boot

Clamp

1 – CLAMP
2 – TRIPOD JOINT HOUSING
3 – SPECIAL TOOL C-4975A
4 – SEALING BOOT

LATCHING TYPE BOOT CLAMP

If seal boot uses low profile latching type boot

clamp:

• Clamp sealing boot onto tripod housing using
clamp locking tool, Snap-On YA3050 or an equiva­lent.

• Place prongs of clamp locking tool in the holes of
the clamp (Fig. 31).

• Squeeze tool together until top band of clamp is
latched behind the two tabs on lower band of clamp
(Fig. 32).

(13) Install the driveshaft back on the vehicle. See

Driveshaft Removal and Installation in this Group.

3 - 12 DIFFERENTIAL AND DRIVELINE NS

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 30 Sealing Boot Retaining Clamp Installed

1 – CLAMP
2 – TRIPOD HOUSING
3 – SPECIAL TOOL C-4975A
4 – JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED

COMPLETELY TOGETHER HERE

5 – SEALING BOOT

Fig. 31 Clamping Tool Installed on Sealing Boot

Clamp

1 – CLAMP
2 – SPECIAL TOOL YA3050
3 – SEALING BOOT

OUTER C/V JOINT SEAL BOOT

REMOVAL

To remove outer C/V joint sealing boot from a
driveshaft for replacement, the driveshaft assembly
must be removed from the vehicle. See Driveshaft
Removal and Installation for the required driveshaft
removal and replacement procedure.

(1) Remove driveshaft assembly requiring boot
replacement from vehicle.

Fig. 32 Sealing Boot Clamp Correctly Installed

1 – INNER TRIPOD JOINT HOUSING
2 – TOP BAND OF CLAMP MUST BE RETAINED BY TABS AS

SHOWN HERE TO CORRECTLY LATCH BOOT CLAMP

3 – SEALING BOOT

(2) Remove large boot clamp retaining C/V joint
sealing boot to C/V joint housing (Fig. 33) and dis­card. Remove small clamp that retains outer C/V
joint sealing boot to interconnecting shaft and dis­card. Remove sealing boot from outer C/V joint hous­ing and slide it down interconnecting shaft.

Fig. 33 Outer C/V Joint Seal Boot Clamps

1 – SMALL CLAMP
2 – SEALING BOOT
3 – OUTER C/V JOINT HOUSING
4 – LARGE CLAMP
5 – INTERCONNECTING SHAFT

(3) Wipe away grease to expose outer C/V joint to
interconnecting shaft retaining ring. Spread ears
apart on C/V joint assembly to interconnecting shaft
retaining snap ring (Fig. 34). Slide outer C/V joint
assembly off end of interconnecting shaft.

NS DIFFERENTIAL AND DRIVELINE 3 - 13

DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 34 Outer C/V Joint Removal From

Interconnecting Shaft

1 – SPREAD RETAINING RING EARS AND PULL JOINT OFF

SHAFT
2 – RETAINING SNAP RING
3 – RETAINING RING
4 – OUTER C/V JOINT ASSEMBLY
5 – INTERCONNECTING SHAFT

(4) Slide failed sealing boot off interconnecting

shaft.

(5) Thoroughly clean and inspect outer C/V joint
assembly and interconnecting joint for any signs of
excessive wear. If any parts show signs of exces-

sive wear, the driveshaft assembly will require
replacement. Component parts of these drive­shaft assemblies are not serviceable.

INSTALLATION

(1) Slide a new seal boot to interconnecting shaft
retaining clamp, onto the interconnecting shaft. Then
slide the replacement outer C/V joint assembly seal­ing boot onto the interconnecting shaft.

(2) Install outer C/V joint assembly onto intercon­necting shaft. Joint is installed on interconnecting
shaft, by pushing interconnecting shaft into outer
C/V joint, until retaining snap ring is seated in
groove on interconnecting shaft (Fig. 35). Verify the
snap ring is fully seated into groove on interconnect­ing shaft.

(3) Distribute 1/2 the amount of grease provided in
seal boot service package (DO NOT USE ANY
OTHER TYPE OF GREASE) into outer C/V joint
assembly housing. Put the remaining amount into
the sealing boot.

(4) Install outer C/V joint seal boot retaining
clamp, onto interconnecting shaft. Install replace­ment outer C/V joint sealing boot onto interconnect­ing shaft. Outer C/V joint seal boot MUST be

positioned on interconnecting shaft, so only the

Fig. 35 Outer C/V Joint Installed On Interconnecting

Shaft

1 – INTERCONNECTING SHAFT
2 – RETAINING SNAP RING
3 – OUTER C/V JOINT ASSEMBLY

thinnest (sight) groove on interconnecting shaft
is visible (Fig. 36).

Fig. 36 Seal Boot Correctly Positioned On

Interconnecting Shaft

1 – SEALING BOOT
2 – INTERCONNECTING SHAFT THINNEST GROOVE
3 – INTERCONNECTING SHAFT
4 – BOOT CLAMP

(5) Clamp sealing boot onto interconnecting shaft
using crimper, Special Tool C-4975-A and the follow­ing procedure. Place crimping tool C- 4975-A over
bridge of clamp (Fig. 37). Tighten nut on crimping
tool C- 4975-A until jaws on tool are closed com­pletely together, face to face (Fig. 38).

3 - 14 DIFFERENTIAL AND DRIVELINE NS

DISASSEMBLY AND ASSEMBLY (Continued)

lowing procedure. Place crimping tool C- 4975-A over
bridge of clamp (Fig. 39). Tighten nut on crimping
tool C- 4975-A until jaws on tool are closed com­pletely together, face to face (Fig. 40).

Fig. 37 Crimping Tool Installed on Sealing Boot

Clamp

1 – SPECIAL TOOL C-4975A
2 – INTERCONNECTING SHAFT
3 – CLAMP
4 – SEALING BOOT

Fig. 39 Crimping Tool Installed on Sealing Boot

Clamp

1 – CLAMP
2 – TRIPOD JOINT HOUSING
3 – SPECIAL TOOL C-4975A
4 – SEALING BOOT

Fig. 38 Sealing Boot Retaining Clamp Installed

1 – CLAMP
2 – JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED

COMPLETELY TOGETHER HERE
3 – INTERCONNECTING SHAFT
4 – SEALING BOOT

CAUTION: Seal must not be dimpled, stretched, or
out–of–shape in any way. If seal is NOT shaped cor­rectly, equalize pressure in seal and shape it by
hand.

(6) Position outer C/V joint sealing boot into its
retaining groove on outer C/V joint housing. Install
sealing boot to outer C/V joint retaining clamp evenly
on sealing boot.

(7) Clamp sealing boot onto outer C/V joint hous­ing using Crimper, Special Tool C-4975-A and the fol-

Fig. 40 Sealing Boot Retaining Clamp Installed

1 – CLAMP
2 – TRIPOD HOUSING
3 – SPECIAL TOOL C-4975A
4 – JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED

COMPLETELY TOGETHER HERE

5 – SEALING BOOT

(8) Install the driveshaft requiring boot replace­ment back on the vehicle. See Driveshaft Removal
and Installation in this Group for the required drive­shaft installation procedure.