Chrysler GS 2000 Workshop Manual

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Page 1

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

Page 2

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.

Page 3

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.

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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.

Page 5

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.

Page 6

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.)

Page 7

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.

Page 8

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

Page 9

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.

Page 10

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.

Page 11

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.

Page 12

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

Page 13

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.

Page 14

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.

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

Page 15

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.

Page 16

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.

Page 17

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.

Page 18

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.

Page 19

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.

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.

Page 20

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.

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.

Page 21

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.

Page 22

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

Page 23

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

Page 24

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

Page 25

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-

Page 26

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.

Page 27

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.

Page 28

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.

Page 29

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°

Page 30

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.

Page 31

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

Page 32

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

Page 33

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.

Page 34

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.

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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

Page 36

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.)

Page 37

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.

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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

Page 39

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

Page 40

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.).

Page 41

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.).

Page 42

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

Page 43

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

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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

Page 45

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

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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.

Page 47

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.

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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

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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

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.

(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.

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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.).

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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

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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).

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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.

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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).

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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

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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.

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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

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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).

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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.

(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.

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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.

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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

Page 62

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

Page 63

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

Page 64

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.

Page 65

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.

Page 66

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.

Page 67

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

Page 68

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).

Page 69

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.

Page 70

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

(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

Page 71

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.

Page 72

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).

Page 73

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.

Page 74

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

Page 75

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.).

Page 76

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)

Page 77

NS SUSPENSION 2 - 57

REMOVAL AND INSTALLATION (Continued)

(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.

Page 78

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).

Page 79

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

Page 80

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.

Page 81

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.

(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.

Page 82

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

(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

Page 83

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.)

Page 84

Page 85

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- 0.30° 0.00° +or- 0.30°

0.00° +or- 2.50° 0.00° +or- 2.50°

Page 86

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.

Page 87

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.

Page 88

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.

Page 89

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

(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

Page 90

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.

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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

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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

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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.

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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.

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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

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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.

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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.

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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.

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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).

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3 - 14 DIFFERENTIAL AND DRIVELINE NS

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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.