Page 1
8A
8B
8E
8F
8G
8H
8I
8J
8L
8M
8N
8O
8P
8Q
8R
8T
8W
11
13
14
19
21
22
23
24
25
GROUP TAB LOCATOR
Introduction
Lubrication & Maintenance
0
Suspension
2
Differential & Driveline
3
Brakes
5
Cooling
7
Audio
Chime/Buzzer
Electronic Control Modules
Engine Systems
Heated Systems
Horn
Ignition Control
Instrument Cluster
Lamps
Message Systems
Power Systems
Restraints
Speed Control
Vehicle Theft Security
Wipers/Washers
Navigation/Telecommunication
Wiring
Engine
9
Exhaust System
Frame & Bumpers
Fuel System
Steering
Transmission/Transaxle
Tires/Wheels
Body
Heating & Air Conditioning
Emissions Control
Component and System Index
Service Manual Comment Forms (Rear of Manual)
Page 2
RS INTRODUCTION 1
INTRODUCTION
TABLE OF CONTENTS
page page
BODY CODE PLATE
DESCRIPTION ..........................1
FASTENER IDENTIFICATION
DESCRIPTION ..........................2
FASTENER USAGE
DESCRIPTION
FASTENER USAGE .....................5
THREADED HOLE REPAIR ...............5
INTERNATIONAL SYMBOLS
DESCRIPTION ..........................5
METRIC SYSTEM
DESCRIPTION ..........................6
BODY CODE PLATE
DESCRIPTION
The Body Code Plate (Fig. 1) is located in the
engine compartment on the radiator closure panel
crossmember. There are seven lines of information on
the body code plate. Lines 4, 5, 6, and 7 are not used
to define service information. Information reads from
left to right, starting with line 3 in the center of the
plate to line 1 at the bottom of the plate.
TORQUE REFERENCES
DESCRIPTION ..........................8
VEHICLE IDENTIFICATION NUMBER
DESCRIPTION ..........................9
VEHICLE CERTIFICATION LABEL
DESCRIPTION .........................11
E-MARK LABEL
DESCRIPTION .........................11
VECI LABEL
DESCRIPTION .........................11
MANUFACTURER PLATE
DESCRIPTION .........................11
BODY CODE PLATE – LINE 3
DIGITS 1 THROUGH 12
Vehicle Order Number
DIGITS 13 THROUGH 17
Open Space
DIGITS 18 AND 19
Vehicle Shell Line
• RS
DIGIT 20
Carline
FWD
• K = Dodge
• Y = Chrysler
Fig. 1 BODY CODE PLATE
1 - PRIMARY PAINT
2 - SECONDARY PAINT
3 - VINYL ROOF
4 - VEHICLE ORDER NUMBER
5 - CAR LINE SHELL
6 - PAINT PROCEDURE
7 - ENGINE
8 - TRIM
9 - TRANSMISSION
10 - MARKET
11 - VIN
AWD
• C = Chrysler
• D = Dodge
Page 3
2 INTRODUCTION RS
BODY CODE PLATE (Continued)
DIGIT 21
Price Class
• H = Highline
• L = Lowline
• P = Premium
• S = Luxury
• X = Premium
DIGITS 22 AND 23
Body Type
• 52 = Short Wheel Base
• 53 = Long Wheel Base
BODY CODE PLATE LINE 2
DIGITS 1, 2 AND 3
Paint Procedure
DIGIT 4
Open Space
DIGITS 5 THROUGH 7
Primary Paint (Refer to 23 - BODY/PAINT - SPECIFICATIONS).
DIGIT 8 AND 9
Open Space
DIGITS 10 THROUGH 12
Secondary Paint
DIGIT 13 AND 14
Open Space
BODY CODE PLATE LINE 1
DIGITS 1, 2, AND 3
Transaxle Codes
• DGC = 31TH 3-Speed Automatic Transaxle
• DGL = 41AE/TE 4-Speed Electronic Automatic
• DDR = T850 5-Speed Manual Transaxle
DIGIT 4
Open Space
DIGIT 5
Market Code
• C = Canada
• B = International
• M = Mexico
• U = United States
DIGIT 6
Open Space
DIGITS 7 THROUGH 23
Vehicle Identification Number
• Refer to Vehicle Identification Number (VIN)
paragraph for proper breakdown of VIN code.
IF TWO BODY CODE PLATES ARE REQUIRED
The last code shown on either plate will be followed by END. When two plates are required, the
last code space on the first plate will indicate (CTD)
When a second plate is required, the first four
spaces of each line will not be used due to overlap of
the plates.
DIGITS 15 THROUGH 18
Interior Trim Code
DIGIT 19
Open Space
DIGITS 20, 21, AND 22
Engine Code
• EDZ = 2.4L 4 cyl. 16-Valve DOHC Gasoline
(MPI)
• EGA = 3.3L 6 cyl. Gasoline (SMPI)
• EGH = 3.8L 6 cyl. Gasoline (SMPI)
• EGM = 3.3L 6 cyl. Ethanol Flexible Fuel
• ENJ = 2.5L 4 cyl. 16-Valve Turbo Diesel
DIGIT 23
Open Space
FASTENER IDENTIFICATION
DESCRIPTION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 10.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts.
Page 4
RS INTRODUCTION 3
FASTENER IDENTIFICATION (Continued)
FASTENER IDENTIFICATION
Page 5
4 INTRODUCTION RS
FASTENER IDENTIFICATION (Continued)
FASTENER STRENGTH
Page 6
RS INTRODUCTION 5
FASTENER USAGE
DESCRIPTION
FASTENER USAGE
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PERSONAL INJURY.
Fasteners and torque specifications references in
this Service Manual are identified in metric and SAE
format.
During any maintenance or repair procedures, it is
important to salvage all fasteners (nuts, bolts, etc.)
for reassembly. If the fastener is not salvageable, a
fastener of equivalent specification must be used.
THREADED HOLE REPAIR
Most stripped threaded holes can be repaired using
a Helicoilt. Follow the vehicle or Helicoilt recommendations for application and repair procedures.
INTERNATIONAL SYMBOLS
DESCRIPTION
The graphic symbols illustrated in the following
International Control and Display Symbols Chart are
used to identify various instrument controls. The
symbols correspond to the controls and displays that
are located on the instrument panel.
INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Wind screen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
Page 7
6 INTRODUCTION RS
METRIC SYSTEM
DESCRIPTION
The metric system is based on quantities of one,
ten, one hundred, one thousand and one million.
CONVERSION FORMULAS AND EQUIVALENT VALUES
MULTIPLY BY TO GET MULTIPLY BY TO GET
in-lbs x
0.11298
ft-lbs x
1.3558
Inches Hg (60° F) x 3.377 = Kilopascals (kPa) kPa x
psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x
Feet x
0.3048
Yards x
0.9144
mph x
1.6093
Feet/Sec x
0.3048
mph x
0.4470
Kilometers/Hr. (Km/h) x
0.27778
= Newton Meters
(N·m)
= Newton Meters
(N·m)
= Meters (M) M x 3.281 = Feet
= Meters M x
= Kilometers/Hr.
(Km/h)
= Meters/Sec (M/S) M/S x 3.281 = Feet/Sec
= Meters/Sec (M/S) M/S x 2.237 = mph
= Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr.
The following chart will assist in converting metric
units to equivalent English and SAE units, or vise
versa.
N·m x 8.851 = in-lbs
N·m x
0.7376
0.2961
0.03937
1.0936
Km/h x
0.6214
= ft-lbs
= Inches Hg
= Inches
= Yards
= mph
(Km/h)
COMMON METRIC EQUIVALENTS
1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters
1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter
1 Mile = 1.6 Kilometers
Refer to the Metric Conversion Chart to convert
torque values listed in metric Newton- meters (N·m).
Also, use the chart to convert between millimeters
(mm) and inches (in.).
Page 8
RS INTRODUCTION 7
METRIC SYSTEM (Continued)
METRIC CONVERSION CHART
Page 9
8 INTRODUCTION RS
TORQUE REFERENCES
DESCRIPTION
TORQUE SPECIFICATIONS
Page 10
RS INTRODUCTION 9
TORQUE REFERENCES (Continued)
Individual Torque Charts appear within many or
the Groups. Refer to the Standard Torque Specifications Chart for torque references not listed in the
individual torque charts.
VEHICLE IDENTIFICATION NUMBER
DESCRIPTION
The Vehicle Identification Number (VIN) can be
viewed through the windshield at the upper left corner of the instrument panel, near the left windshield
pillar (Fig. 2). The VIN consists of 17 characters in a
combination of letters and numbers that provide specific information about the vehicle. Refer to VIN
Code Breakdown Chart for decoding information.
To protect the consumer from theft and possible
fraud the manufacturer is required to include a
Check Digit at the ninth position of the vehicle identification number. The check digit is used by the
manufacturer and government agencies to verify the
authenticity of the vehicle and official documenta-
tion. The formula to use the check digit is not
released to the general public.
Fig. 2 VEHICLE IDENTIFICATION NUMBER (VIN)
1 - DEFROSTER OUTLET
2 - VEHICLE IDENTIFICATION NUMBER
3 - HEATED WINDSHIELD GRID
VIN CODE BREAKDOWN CHART
POSITION INTERPRETATION CODE = DESCRIPTION
Country of Origin 1 = Manufactured By DaimlerChrysler Corporation
1
2 = Manufactured By DaimlerChrysler Canada Inc.
2 Make D = Dodge
C = Chrysler
Vehicle Type 4 = Multipurpose Pass. Vehicle Less Side Air Bags
3
8 = Multipurpose Pass. Vehicle With Side Air Bags
4 Gross Vehicle Weight Rating G = 2268 - 2721 kg. (5001 - 6000 lbs.)
1 = Chrysler Caravan - FWD
P = Chrysler, Town & Country - FWD
P = Dodge, Caravan/Grand Caravan - FWD
P = Dodge, Caravan C/V, Grand Caravan C/V - FWD
T = Chrysler, Town & Country - AWD
5 Car Line
T = Dodge, Grand Caravan - AWD
J = Chrysler, Voyager/Grand Voyager - FWD
Y = Voyager/Grand Voyager - FWD Left Hand Drive
C = Voyager/Grand Voyager - AWD Left Hand Drive
H = Voyager/Grand Voyager - FWD Right Hand Drive
K = Voyager/Grand Voyager - AWD Left Hand Drive
Page 11
10 INTRODUCTION RS
VEHICLE IDENTIFICATION NUMBER (Continued)
POSITION INTERPRETATION CODE = DESCRIPTION
2 = Low Line
3 = Medium
6 Series
6 - Export Series B = 4-Speed Automatic Transaxle
4 = High Line
5 = Premium
6 = Sport
7 = Special
N = 5-Speed Manual Transaxle
1 = Van - Caravan C/V
7 Body Style
7 - Export Body Style
8 Engine
3 = Extended Van - Grand Caravan C/V
4 = Extended Wagon - Grand Caravan/Town & Country
5 = Wagon - Caravan, Voyager, Town & Country
1 = EURO Wagon - Long Wheelbase (RG - 53 - S Series)
2 = EURO Wagon - Short Wheelbase (RG - 52 - H Series)
3 = EURO Wagon - Short Wheelbase (RG - 52 - P Series)
4 = EURO Wagon - Long Wheelbase (RG - 53 - P Series)
5 = EURO Wagon - Long Wheelbase (RG - 53 - H Series)
6 = Commercial Van - Short Wheelbase (with- Sales Code -
CYX Less AS8)
7 = Commercial Van - Short Wheelbase (with Sales Code -
AS8)
8 = Commercial Van-Long Wheelbase (H - Series with Sales
Code - CYX)
9 = Commercial Van - Long Wheelbase (P - Series with
Sales Code - CYX)
B = 2.4L I4 Cyl. 16-Valve Gasoline DOHC (MPI)
E = 3.3L V6 Cyl. OHV Flex Fuel
L = 3.8L V6 Cyl. Gasoline (SMPI)
R = 3.3L V6 Cyl. OHV Gasoline
5 = 2.8L I4 Cyl. Turbo Diesel
7 = 2.5L I4 Cyl. 16 Valve Turbo Diesel
9 Check Digit See explanation in this section.
10 Model Year 5 = 2005
11 Assembly Plant B = St. Louis Assembly South
R = Windsor Assembly
U = Eurostar Gesellschaftz Assembly
12 through 17 Sequence Number A six digit number assigned by assembly plant.
Page 12
RS INTRODUCTION 11
VEHICLE CERTIFICATION LABEL
DESCRIPTION
A vehicle certification label is attached to the rear
shutface of the driver’s door (Fig. 3). This label indicates date of manufacture (month and year), Gross
Vehicle Weight Rating (GVWR), Gross Axle Weight
Rating (GAWR) front, Gross Axle Weight Rating
(GAWR) rear and the Vehicle Identification Number
(VIN). The Month, Day and Hour of manufacture is
also included.
All communications or inquiries regarding the
vehicle should include the Month-Day-Hour and
Vehicle Identification Number.
1 - COUNTRY CODE
2 - REGULATION NUMBER
3 - APPROVAL NUMBER
4 - AMENDMENT NUMBER
Fig. 4 E-MARK LABEL
VECI LABEL
Fig. 3 VEHICLE CERTIFICATION LABEL - TYPICAL
E-MARK LABEL
DESCRIPTION
An E-mark Label (Fig. 4) is located on the rear
shut face of the driver’s door. The label contains the
following information:
• Date of Manufacture
• Month-Day-Hour (MDH)
• Vehicle Identification Number (VIN)
• Country Codes
• Regulation Number
• Regulation Amendment Number
• Approval Number
DESCRIPTION
All models have a Vehicle Emission Control Information (VECI) Label. Chrysler permanently attaches
the label in the engine compartment. It cannot be
removed without defacing information and destroying
the label.
The label contains the vehicle’s emission specifications and vacuum hose routings. All hoses must be
connected and routed according to the label.
MANUFACTURER PLATE
DESCRIPTION
The Manufacturer Plate (Fig. 5) is located in the
engine compartment on the passenger side rear corner of the hood. The plate contains five lines of information:
1. Vehicle Identification Number (VIN)
2. Gross Vehicle Mass (GVM)
3. Gross Train Mass (GTM)
4. Gross Front Axle Rating (GFAR)
5. Gross Rear Axle Rating (GRAR)
Fig. 5 MANUFACTURER PLATE
Page 13
Page 14
RS LUBRICATION & MAINTENANCE 0-1
LUBRICATION & MAINTENANCE
TABLE OF CONTENTS
page page
INTERNATIONAL SYMBOLS
DESCRIPTION ..........................1
FLUID TYPES
DESCRIPTION
DESCRIPTION - ENGINE OIL AND
LUBRICANTS .........................1
DESCRIPTION - ENGINE COOLANT ........3
DESCRIPTION - FLEXIBLE FUEL ENGINE
OIL .................................3
DESCRIPTION - AUTOMATIC/MANUAL
TRANSAXLE FLUID .....................4
DESCRIPTION - FUEL REQUIREMENTS .....4
DESCRIPTION - FUEL REQUIREMENTS -
DIESEL ENGINE .......................6
DESCRIPTION - ENGINE OIL - DIESEL
ENGINES ............................6
DESCRIPTION - AWD REAR DRIVELINE
MODULE FLUIDS ......................6
DESCRIPTION - AWD POWER TRANSFER
UNIT FLUID ...........................6
INTERNATIONAL SYMBOLS
DESCRIPTION
DaimlerChrysler Corporation uses international
symbols to identify engine compartment lubricant
and fluid inspection and fill locations (Fig. 1).
FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES .......6
FLUID FILL/CHECK LOCATIONS
DESCRIPTION ..........................7
LUBRICATION POINTS
DESCRIPTION ..........................7
MAINTENANCE SCHEDULES
DESCRIPTION
DESCRIPTION ........................7
DESCRIPTION - EXPORT ...............13
DESCRIPTION - DIESEL ENGINES -
EXPORT ............................21
HOISTING
STANDARD PROCEDURE - HOISTING .......24
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING . 25
TOWING
STANDARD PROCEDURE - TOWING ........26
FLUID TYPES
DESCRIPTION
DESCRIPTION - ENGINE OIL AND LUBRICANTS
Fig. 1 INTERNATIONAL SYMBOLS
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
When service is required, DaimlerChrysler Corporation recommends that only Mopart brand parts,
lubricants and chemicals be used. Mopart provides
the best engineered products for servicing
DaimlerChrysler Corporation vehicles.
Only lubricants bearing designations defined by
the following organization should be used.
Page 15
0 - 2 LUBRICATION & MAINTENANCE RS
FLUID TYPES (Continued)
• Society of Automotive Engineers (SAE)
• American Petroleum Institute (API)
• National Lubricating Grease Institute (NLGI)
API CERTIFICATION AND LICENSE SYMBOL
Use an engine oil that is API Certified (GF-3) and
Licensed to display the certification mark (Fig. 2).
MOPARt provides engine oils that meet or exceed,
Material Standard MS-6395 requirement.
Fig. 2 API Certification Mark
SAE VISCOSITY
SAE 5W-20 and SAE 5W-30 engine oils are recommended for all operating temperatures.
These engine oils are designed to improve low
temperature starting and vehicle fuel economy.
Refer to the engine oil filler cap for the preferred engine oil viscosity grade for each vehicle (Fig. 3). SAE viscosity grades are used to specify
the correct viscosity oil for an engine. Use only MultiViscosity oils such as SAE 5W-20 or 5W-30. These
are specified with a dual SAE viscosity grade which
indicates the cold (5W) to hot (20, 30) temperature
performance range of the oil.
that do not display the “Mark” on the front of the
container should not be used (Fig. 2).
DiamlerChrysler only recommends API Certified
engine oils that meet the requirements of Material
Standard MS-6395. Use Mopar or an equivalent oil
meeting the specification MS-6395.
SYNTHETIC ENGINE OILS
There are a number of engine oils being promoted
as either synthetic or semi-synthetic. If you chose to
use such a product, use only those oils that are certified by the American Petroleum Institute (API) to
display the “Certification Mark” and show SAE viscosity grade recommended for each vehicle. Follow
the service schedule that describes your driving type.
ENGINE OIL ADDITIVES/SUPPLEMENTS
The manufacturer does not recommend the addition of any engine oil additives/supplements to the
specified engine oil. Engine oil additives/supplements
should not be used to enhance engine oil performance. Engine oil additives/supplements should not
be used to extend engine oil change intervals. No
additive is known to be safe for engine durability and
can degrade emission components. Additives can contain undesirable materials that harm the long term
durability of engines by:
• Increasing the level of Phosphorus and Sulfur in
the engine oil. The API Certified Engine Oils control
the Phosphorus and Sulfur contents of the oil to levels that reduce the contamination effect on the vehicles emission control system.
• Altering the viscosity characteristics of the
engine oil so that it no longer meets the requirements of the specified viscosity grade.
• Creating potential for an undesirable additive
compatibility interaction in the engine crankcase.
The engine oils contain a performance additive system carefully developed to optimize the oils performance in the engine. The addition of supplements
may cause the oil to thicken prematurely, cause
excessive deposit build up and potentially shorten
engine life.
Fig. 3 5W-30 Oil Filler Cap
CONTAINER IDENTIFICATION
The Engine Oil Certificarion Mark was developed
and trademarked by the API to refer customers to
those engine oils preferred by the automobile manufacturers. This symbol means that the oil has been
certified and licensed by the American Petroleum
Institute (API). This certification mark will only be
found on the front of the oil containers. Those oils
AXLE LUBRICANTS
SAE ratings also apply to multigrade gear lubricants. In addition, API classification defines the
lubricants usage. Such as API GL-5 and SAE 75W-
90.
LUBRICANTS AND GREASES
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 4) on the label. At the bottom of the
NLGI symbol is the usage and quality identification
letters. Wheel bearing lubricant is identified by the
Page 16
RS LUBRICATION & MAINTENANCE 0-3
FLUID TYPES (Continued)
letter “G”. Chassis lubricant is identified by the letter
“L”. The letter following the usage letter indicates
the quality of the lubricant. The following symbols
indicate the highest quality.
Fig. 4 NLGI SYMBOL
1 - WHEEL BEARINGS
2 - CHASSIS LUBRICATION
3 - CHASSIS AND WHEEL BEARINGS
SPECIALIZED LUBRICANTS AND OILS
Some maintenance or repair procedures may
require the use of specialized lubricants or oils. Consult the appropriate sections in this manual for the
correct application of these lubricants.
DESCRIPTION - ENGINE COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF
GLYCOL BASE COOLANT PROPERLY, CONTACT
YOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN
RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene Glycol based coolants
is not recommended, as they provide less freeze
protection and less boiling protection.
radiator where the tube/fin radiator can transfer the
heat to the air.
The use of aluminum cylinder blocks, cylinder
heads, and water pumps requires special corrosion
protection. Mopart Antifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene glycol base coolant with hybrid organic
corrosion inhibitors (called HOAT, for Hybrid Organic
Additive Technology) is recommended. This coolant
offers the best engine cooling without corrosion when
mixed with 50% Ethylene Glycol and 50% distilled
water to obtain a freeze point of -37°C (-35°F). If it
loses color or becomes contaminated, drain, flush,
and replace with fresh properly mixed coolant solution.
The green coolant MUST NOT BE MIXED with
the orange or magenta coolants. When replacing coolant the complete system flush must be performed
before using the replacement coolant.
CAUTION: MoparT Antifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769) may not be
mixed with any other type of antifreeze. Doing so
will reduce the corrosion protection and may result
in premature water pump seal failure. If non-HOAT
coolant is introduced into the cooling system in an
emergency, it should be replaced with the specified
coolant as soon as possible.
DESCRIPTION - FLEXIBLE FUEL ENGINE OIL
The information in this section is for Flexible Fuel
Vehicles (FFV) only. These vehicles can be identified
by the unique Fuel Filler Door Label that states
Ethanol (E-85) or Unleaded Gasoline Only. This section only covers those subjects that are unique to
these vehicles. Please refer to the other sections of
this manual for information on features that are
common between Flexible Fuel and gasoline only
powered vehicles.
ETHANOL FUEL (E-85)
E-85 is a mixture of approximately 85% fuel ethanol and 15% unleaded gasoline.
WARNING: Ethanol vapors are extremely flammable
and could cause serious personal injury. Never
have any smoking materials lit in or near the vehicle when removing the fuel filler tube cap (gas cap)
or filling the tank. Do not use E-85 as a cleaning
agent and never use it near an open flame.
The cooling system is designed around the coolant.
The coolant must accept heat from engine metal, in
the cylinder head area near the exhaust valves and
engine block. Then coolant carries the heat to the
FUEL REQUIREMENTS
The vehicle will operate on both unleaded gasoline
with an octane rating of 87, or E-85 fuel, or any mixture of these two.
Page 17
0 - 4 LUBRICATION & MAINTENANCE RS
FLUID TYPES (Continued)
For best results, a refueling pattern that alternates
between E-85 and unleaded gasoline should be
avoided. When you do switch fuels, it is recommended that
• you do not switch when the fuel gauge indicates
less than 1/4 full
• you do not add less than 5 gallons when refuel-
ing
• you operate the vehicle immediately after refuel-
ing for a period of at least 5 minutes
Observing these precautions will avoid possible
hard starting and/or significant deterioration in
driveability during warm up.
FFV STARTING
The characteristics of E-85 fuel make it unsuitable
for use when ambient temperatures fall below 0°F. In
the range of 0°F to 32°F, you may experience an
increase in the time it takes for your engine to start,
and a deterioration in driveability (sags and/or hesitations) until the engine is fully warmed up.
Engine Operating on E-85 Fuel
If vehicle operates on E-85 fuel either full or parttime, use only Mopart Flexible Fuel 5W-30 engine oil
or an equivalent that meets DaimlerChrysler Standard MS-9214. Equivalent commercial Flexible Fuel
engine oils may be labeled as Multi-Fuel, Variable
Fuel, Flexible Fuel, etc. These engine oils may be
satisfactory if they meet the DaimlerChrysler Standard.
SAE 5W-30 engine oil is preferred for use in Flexible Fuel engines.
TRANSMISSION FLUID
Mopart ATF+4 (Automatic Transmission Fluid) is
required in the 4XTE automatic and T850 manual
transaxles. Substitute fluids can induce transmission
problems and/or failure.
Mopart ATF+4 (Automatic Transmission Fluid)
when new is red in color. The ATF is dyed red so it
can be identified from other fluids used in the vehicle
such as engine oil or antifreeze. The red color is not
permanent and is not an indicator of fluid condition.
As the vehicle is driven, the ATF will begin to look
darker in color and may eventually become brown.
This is normal. ATF+4 also has a unique odor that
may change with age. Consequently, odor and color
cannot be used to indicate the fluid condition
or the need for a fluid change.
FLUID ADDITIVES
DaimlerChrysler strongly recommends against the
addition of any fluids to the transmission, other than
those automatic transmission fluids listed above.
Exceptions to this policy are the use of special dyes
to aid in detecting fluid leaks.
Various “special” additives and supplements exist
that claim to improve shift feel and/or quality. These
additives and others also claim to improve converter
clutch operation and inhibit overheating, oxidation,
varnish, and sludge. These claims have not been supported to the satisfaction of DaimlerChrysler and
these additives must not be used. The use of transmission “sealers” should also be avoided, since they
may adversely affect the integrity of transmission
seals.
CAUTION: If Flexible Fuel engine oil is not used
when using E-85 fuel, engine wear or damage may
result.
CRUISING RANGE
Because E-85 fuel contains less energy per gallon
than gasoline, you will experience an increase in fuel
consumption. You can expect your MPG and your
driving range to decrease by about 30% compared to
gasoline operation.
DESCRIPTION - AUTOMATIC/MANUAL TRANSAXLE FLUID
NOTE: Refer to the maintenance schedules for the
recommended maintenance (fluid/filter change)
intervals for these transaxles.
NOTE: All transaxles have a common transmission
and differential sump. Filling the transaxle accommodates the differential as well.
DESCRIPTION - FUEL REQUIREMENTS
Your engine is designed to meet all emissions regulations and provide excellent fuel economy and performance when using high quality unleaded gasoline
having an octane rating of 87. The use of premium
gasoline is not recommended. The use of premium
gasoline will provide no benefit over high quality regular gasoline, and in some circumstances may result
in poorer performance.
Light spark knock at low engine speeds is not
harmful to your engine. However, continued heavy
spark knock at high speeds can cause damage and
immediate service is required. Engine damage resulting from operation with a heavy spark knock may
not be covered by the new vehicle warranty.
Poor quality gasoline can cause problems such as
hard starting, stalling and hesitations. If you experience these symptoms, try another brand of gasoline
before considering service for the vehicle.
Over 40 auto manufacturers world-wide have
issued and endorsed consistent gasoline specifications
(the Worldwide Fuel Charter, WWFC) to define fuel
Page 18
RS LUBRICATION & MAINTENANCE 0-5
FLUID TYPES (Continued)
properties necessary to deliver enhanced emissions,
performance and durability for your vehicle. We recommend the use of gasolines that meet the WWFC
specifications if they are available.
REFORMULATED GASOLINE
Many areas of the country require the use of
cleaner burning gasoline referred to as “reformulated” gasoline. Reformulated gasoline contain oxygenates, and are specifically blended to reduce
vehicle emissions and improve air quality.
We strongly support the use of reformulated gasoline. Properly blended reformulated gasoline will provide excellent performance and durability for the
engine and fuel system components.
GASOLINE/OXYGENATE BLENDS
Some fuel suppliers blend unleaded gasoline with
oxygenates such as 10% ethanol, MTBE, and ETBE.
Oxygenates are required in some areas of the country
during the winter months to reduce carbon monoxide
emissions. Fuels blended with these oxygenates may
be used in your vehicle.
CAUTION: DO NOT use gasoline containing METHANOL. Gasoline containing methanol may damage
critical fuel system components.
adversely affected. Gasoline sold outside of California
is permitted to have higher sulfur levels which may
affect the performance of the vehicle’s catalytic converter. This may cause the Malfunction Indicator
Lamp (MIL), Check Engine or Service Engine Soon
light to illuminate. We recommend that you try a different brand of unleaded gasoline having lower sulfur
to determine if the problem is fuel related prior to
returning your vehicle to an authorized dealer for
service.
CAUTION: If the Malfunction Indicator Lamp (MIL),
Check Engine or Service Engine Soon light is flashing, immediate service is required; see on-board
diagnostics system section.
MATERIALS ADDED TO FUEL
All gasoline sold in the United States and Canada
are required to contain effective detergent additives.
Use of additional detergents or other additives is not
needed under normal conditions.
FUEL SYSTEM CAUTIONS
CAUTION: Follow these guidelines to maintain your
vehicle’s performance:
MMT IN GASOLINE
MMT is a manganese-containing metallic additive
that is blended into some gasoline to increase octane.
Gasoline blended with MMT provide no performance
advantage beyond gasoline of the same octane number without MMT. Gasoline blended with MMT
reduce spark plug life and reduce emission system
performance in some vehicles. We recommend that
gasoline free of MMT be used in your vehicle. The
MMT content of gasoline may not be indicated on the
gasoline pump; therefore, you should ask your gasoline retailer whether or not his/her gasoline contains
MMT.
It is even more important to look for gasoline without MMT in Canada because MMT can be used at
levels higher than allowed in the United States.
MMT is prohibited in Federal and California reformulated gasoline.
SULFUR IN GASOLINE
If you live in the northeast United States, your
vehicle may have been designed to meet California
low emission standards with Cleaner-Burning California reformulated gasoline with low sulfur. If such
fuels are not available in states adopting California
emission standards, your vehicles will operate satisfactorily on fuels meeting federal specifications, but
emission control system performance may be
• The use of leaded gas is prohibited by Federal
law. Using leaded gasoline can impair engine performance, damage the emission control system, and
could result in loss of warranty coverage.
• An out-of-tune engine, or certain fuel or ignition
malfunctions, can cause the catalytic converter to
overheat. If you notice a pungent burning odor or
some light smoke, your engine may be out of tune or
malfunctioning and may require immediate service.
Contact your dealer for service assistance.
• When pulling a heavy load or driving a fully
loaded vehicle when the humidity is low and the temperature is high, use a premium unleaded fuel to
help prevent spark knock. If spark knock persists,
lighten the load, or engine piston damage may result.
• The use of fuel additives which are now being
sold as octane enhancers is not recommended. Most
of these products contain high concentrations of
methanol. Fuel system damage or vehicle performance problems resulting from the use of such fuels
or additives is not the responsibility of
DaimlerChrysler Corporation and may not be covered
under the new vehicle warranty.
NOTE: Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
Page 19
0 - 6 LUBRICATION & MAINTENANCE RS
FLUID TYPES (Continued)
DESCRIPTION - FUEL REQUIREMENTS DIESEL ENGINE
WARNING: DO NOT USE ALCOHOL OR GASOLINE
AS A FUEL BLENDING AGENT. THEY CAN BE
UNSTABLE UNDER CERTAIN CONDITIONS AND
HAZARDOUS OR EXPLOSIVE WHEN MIXED WITH
DIESEL FUEL.
Use good quality diesel fuel from a reputable supplier. For most year-round service, number 2 diesel
fuel meeting DIN EN 590 (Class0-4)will provide
good performance. If the vehicle is exposed to
extreme cold (below -18°C/0°F) or is required to operate at colder than normal conditions for prolonged
periods, use climatize No. 2 diesel fuel or dilute the
No. 2 diesel fuel with 50% No. 1 diesel fuel as long as
it meets ASTM D 975: 1D and 2D and the quality of
lubrication behavior is in accordance with DIN EN
590. This will provide better protection from fuel gelling or wax plugging of the fuel filters.
Diesel fuel is seldom completely free of water. To
prevent fuel system trouble, including fuel line freezing in winter, drain the accumulated water from the
fuel/water separator using the fuel/water separator
drain provided. If you buy good quality fuel and follow
the cold weather advice above, fuel conditioners should
not be required in your vehicle. If available in your
area, a high cetane “premium” diesel fuel may offer
improved cold starting and warm up performance.
DESCRIPTION - 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.
To assure of properly formulated engine oils, it is
recommended that SAE Grade 10W-40 engine oils
that meet Chrysler material standard MS-6395, be
used in accordance to ACEA B3, B4 specification.
European Grade 10W-40 oils are also acceptable.
Oils of the SAE 5W-40 grade number are preferred
when minimum temperatures consistently fall below
-15°C.
DESCRIPTION - AWD REAR DRIVELINE MODULE FLUIDS
The AWD Rear Driveline Module Assembly consists
of two subassemblies, the Overrunning Clutch Housing (front) and the Differential Carrier (rear).
The recommended lubricant for the Overrunning
Clutch Housing is Mopart ATF+4. The recommended
lubricant for the Differential Carrier is Mopart
80W-90 Gear and Axle Lubricant.
DESCRIPTION - AWD POWER TRANSFER UNIT FLUID
The recommended lubricant for the AWD Power
Transfer Unit is Mopart Gear and Axle Lubricant
80W-90.
FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES
DESCRIPTION SPECIFICATION
Fuel Tank (Gas) 75 L (20 gal.)
Fuel Tank (Diesel) 75 L (20 gal.)
Engine Oil* - 2.4 L 4.7 L (5.0 qts.)
Engine Oil* - 3.3/3.8 L 4.7 L (5.0 qts.)
Engine Oil* - 2.5 L
(Diesel)
Cooling System** - 2.4 L 10.7 L (11.4 qts.)
Cooling System** - 2.5 L
Turbo Diesel with
Auxiliary Heater
Cooling System** -
3.3/3.8 L without Auxiliary
Heater
Cooling System** -
3.3/3.8 L with Auxiliary
Heater
Automatic Transaxle -
Service Fill
Automatic Transaxle -
4XTE Overhaul Fill
Manual Transaxle (T850
5-Speed)
AWD Power Transfer Unit 1.15 L (2.4 pts.)
Power Steering 1.2 L (2.5 pts.)
AWD Bi-directional
Overrunning Clutch
AWD Rear Carrier 0.7 L (1.48 pts.)
* (includes oil filter)
** (includes heater and recovery/reserve bottle)
6.0 L (6.3 qts.)
13.8 L (14.6 qts.)
12.6 L (13.4 qts.)
15.4 L (16.3 qts.)
3.8 L (4.0 qts.)
9.2 L (9.7 qts.)
2.4-2.7 L (2.5-2.9 qts.)
0.575 L (1.22 pts.)
Page 20
RS LUBRICATION & MAINTENANCE 0-7
FLUID FILL/CHECK LOCATIONS
DESCRIPTION
The fluid check/fill point locations are located in
each applicable service manual section.
LUBRICATION POINTS
DESCRIPTION
Lubrication point locations are located in each
applicable Sections.
MAINTENANCE SCHEDULES
DESCRIPTION
DESCRIPTION
There are two maintenance schedules that show
the required service for your vehicle.
First is Schedule “B”. It is for vehicles that are
operated under the conditions that are listed below
and at the beginning of the schedule.
• Day or night temperatures are below 32° F (0°
C).
• Stop and go driving.
• Extensive engine idling.
• Driving in dusty conditions.
• Short trips of less than 10 miles (16 km).
• More than 50% of your driving is at sustained
high speeds during hot weather, above 90° F (32° C).
• Trailer towing.L
• Taxi, police, or delivery service (commercial ser-
vice).L
• Off-road or desert operation.
NOTE: Most vehicles are operated under the conditions listed for Schedule (B(.
Second is Schedule “A”. It is for vehicles that are
not operated under any of the conditions listed under
Schedule 9B9.
Use the schedule that best describes your driving
conditions. Where time and mileage are listed, follow
the interval that occurs first.
At Each Stop for Fuel
• Check the engine oil level about 5 minutes after
a fully warmed engine is shut off. Checking the oil
level while the vehicle is on level ground will
improve the accuracy of the oil level reading. Add oil
only when the level is at or below the ADD or MIN
mark.
• Check the windshield washer solvent and add if
required.
Once a Month
• Check tire pressure and look for unusual wear
or damage.
• Inspect the battery and clean and tighten the
terminals as required.
• Check the fluid levels of coolant reservoir, brake
master cylinder and transmission, add as needed.
• Check all lights and all other electrical items for
correct operation.
At Each Oil Change
• Change the engine oil filter.
• Inspect the exhaust system.
• Inspect the brake hoses.
• Inspect the CV joints and front suspension com-
ponents.
• Check the automatic transmission fluid level.
• Check the coolant level, hoses, and clamps.
SCHEDULE B
Follow schedule “B” if you usually operate your
vehicle under one or more of the following conditions.
Change the automatic transmission fluid and filter
every 60,000 miles (96 000 km) if the vehicle is usually operated under one or more of the conditions
marked with an L.
• Day or night temperatures are below 32° F (0°
C).
• Stop and go driving.
• Extensive engine idling.
• Driving in dusty conditions.
• Short trips of less than 10 miles (16 km).
• More than 50% of your driving is at sustained
high speeds during hot weather, above 90° F (32° C).
• Trailer towing.L
• Taxi, police, or delivery service (commercial ser-
vice).L
• Off-road or desert operation.
CAUTION: Failure to perform the required maintenance items may result in damage to the vehicle.
Page 21
0 - 8 LUBRICATION & MAINTENANCE RS
MAINTENANCE SCHEDULES (Continued)
Miles 3, 000 6, 000 9, 000 12, 000 15, 000 18, 000
(Kilometers) (5 000 ) (10 000 ) (14 000) (19 000) (24 000) (29 000)
Change engine oil and engine
oil filter.
Rotate Tires X X X
Inspect the brake linings. X X
Inspect the engine air cleaner
filter, replace if necessary. *
Replace the engine air
cleaner filter. *
Replace the air conditioning
filter.
Miles 21, 000 24, 000 27, 000 30, 000 33, 000 36, 000
(Kilometers) (34 000) (38 000) (43 000) (48 000) (53 000) (58 000)
Change engine oil and engine
oil filter.
Rotate Tires X X X
Inspect the brake linings. X X
Inspect the engine air cleaner
filter, replace if necessary. *
Replace the engine air
cleaner filter.
Inspect the tie rod ends and
boot seals.
Inspect the PCV valveand
replace as necessary.*
Replace the air conditioning
filter.
XXXXXX
XXXX X
X
X
XXXXXX
XXX XX
X
X
X
XX
Miles 39, 000 42, 000 45, 000 48, 000 51, 000 54, 000
(Kilometers) (62 000) (67 000) (72 000) (77 000) (82 000) (86 000)
Change engine oil and engine
oil filter.
Rotate Tires X X X
Inspect the brake linings. X X
Inspect the engine air cleaner
filter, replace if necessary. *
Replace the engine air
cleaner filter. *
Replace the air conditioning
filter.
XXXXXX
XX XXX
X
X
Page 22
RS LUBRICATION & MAINTENANCE 0-9
MAINTENANCE SCHEDULES (Continued)
Miles 57, 000 60, 000 63, 000 66, 000 69, 000 72, 000
(Kilometers) (91 000) (96 000) (101 000) (106 000) (110 000) (115 000)
Change engine oil and engine
oil filter.
Rotate Tires X X X
Inspect the brake linings. X X
Inspect the engine air cleaner
filter, replace if necessary. *
Replace the engine air
cleaner filter.
Inspect the tie rod ends and
boot seals.
Inspect the PCV valve and
replace if necessary.*
Inspect the serpentine drive
belt on 3.3 liter and 3.8 liter
engines, replace if necessary.
‡
Change the automatic
transmission fluid and filter. L
Replace the air conditioning
filter.
XXXXXX
X XXXX
X
X
X
X
X
XX
Miles 75, 000 78, 000 81, 000 84, 000 87, 000 90, 000
(Kilometers) (120 000) (125 000) (130 000) (134 000) (139 000) (144 000)
Change engine oil and engine
oil filter.
Rotate Tires X X X
Inspect the brake linings. X X
Inspect the engine air cleaner
filter, replace if necessary. *
Replace the engine air
cleaner filter
Replace the spark plugs on
3.3 liter and 3.8 liter engines.
Replace the ignition cables
3.3 liter and 3.8 liter engines.
Inspect the tie rod ends and
boot seals.
Check the PCV valve and
replace if necessary. Not
required if previously
changed.*
Inspect the serpentine drive
belt on 3.3 liter and 3.8 liter
engines, replace if necessary. ‡
Replace the air conditioning
filter.
XXXXXX
XXXX
XX
X
X
X
X
XX
X
Page 23
0 - 10 LUBRICATION & MAINTENANCE RS
MAINTENANCE SCHEDULES (Continued)
Miles 93, 000 96, 000 99, 000 100, 000 102, 000 105, 000
(Kilometers) (149 000) (154 000) (158 000) (160 000) (163 000) (168 000)
Change engine oil and
engine oil filter.
Rotate Tires X X
Inspect the brake linings. X
Inspect the engine air cleaner
filter, replace if necessary. *
Replace the engine air
cleaner filter *
Inspect the serpentine drive
belt on 3.3 liter and 3.8 liter
engines, replace if necessary.
‡
Flush and replace the engine
coolant at 60 months or
100,000 miles.
Replace the air conditioning
filter.
XXX XX
X X XXX
X
X
X
X
Miles 108, 000 111, 000 114, 000 117, 000 120, 000
(Kilometers) (173 000) (178 000) (182 000) (187 000) (192 000)
Change engine oil and engine oil filter. XXXXX
Rotate Tires X X X
Inspect the brake linings. X X
Inspect the engine air cleaner filter, replace
if necessary. *
Replace the engine air cleaner filter. X
Inspect the tie rod ends and boot seals. X
Inspect the PCV valve and replace as
necessary.*
Inspect the serpentine drive belt on 3.3 liter
and 3.8 liter engines, replace if necessary. ‡
Change the automatic transmission fluid
and filter. L
Replace the air conditioning filter. X X
* This maintenance is recommended by the manufacture to the owner but is not required to maintain
the emissions warranty.
‡ This maintenance is not required if previously
replaced.
XXXX
X
X
X
L This maintenance is required only for police,
taxi, limousine type operation, or trailer towing.
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
Retain all receipts.
Page 24
RS LUBRICATION & MAINTENANCE 0-11
MAINTENANCE SCHEDULES (Continued)
SCHEDULE A
Miles 6, 000 12, 000 18, 000 24, 000 30, 000 36, 000
(Kilometers) (10 000) (19 000) (29 000) (38 000 ) (48 000) (58 000)
[Months] [6] [12] [18] [24] [30] [36]
Change engine oil and engine
oil filter.
Rotate Tires X X X X X X
Inspect the brake linings. X X
Inspect the engine air cleaner
filter, replace if necessary. *
Replace the engine air
cleaner filter.
Inspect the tie rod ends and
boot seals.
Replace the air conditioning
filter.
XXXXXX
XXX X X
X
X
XX X
Miles 42, 000 48, 000 54, 000 60, 000 66, 000 72, 000
(Kilometers) (67 000) (77 000) (86 000) (96 000) (106 000) (115 000)
[Months] [42] [48] [54] [60] [66] [72]
Change engine oil and engine
oil filter.
Rotate Tires X XXXXX
Inspect the brake linings. X X
Inspect the engine air cleaner
filter, replace if necessary. *
Replace the engine air
cleaner filter.
Inspect the tie rod ends and
boot seals.
Check the PCV valve and
replace, if necessary.*
Inspect the serpentine drive
belt on 3.3 liter and 3.8 liter
engines, replace if necessary.
‡
Flush and replace the engine
coolant at 60 months,
regardless of mileage.
Replace the air conditioning
filter.
XXXXXX
XXX XX
X
X
X
XX
X
XXX
Page 25
0 - 12 LUBRICATION & MAINTENANCE RS
MAINTENANCE SCHEDULES (Continued)
Miles 78, 000 84, 000 90, 000 96, 000 100, 000
(Kilometers) (125 000) (134 000) (144 000) (154 000) (160 000)
[Months] [78] [84] [90] [96]
Change engine oil and engine oil filter. XXXX
Rotate Tires XXXX
Inspect the brake linings. X
Inspect the engine air cleaner filter, replace
if necessary. *
Replace the engine air cleaner filter. X
Inspect the tie rod ends and boot seals. X
Check and replace the PCV valve,if
necessary.*
Inspect the serpentine drive belt on 3.3 liter
and 3.8 liter engines, replace if 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.
Flush and replace the engine coolant at
100,000 miles, if not done at 60 months.
Replace the air conditioning filter. X X
XX XX
X
X
X
X
X
Miles 102, 000 108, 000 114, 000 120, 000
(Kilometers) (163 000) (173 000) (182 000) (192 000)
[Months] [102] [108] [114] [120]
Change engine oil and engine oil filter. X X X X
Rotate Tires X X X X
Inspect the brake linings. X
Inspect the engine air cleaner filter, replace if necessary. * X X X
Replace the engine air cleaner filter. X
Inspect the tie rod ends and boot seals. X
Check the PCV valve and replace, if necessary.* X
Inspect the serpentine drive belt on 3.3 liter and 3.8 liter
engines, replace if necessary. ‡
Flush and replace the engine coolant at 120 months, if
not done at 100,000 miles (160 000 km).
Replace the air conditioning filter. X X
* This maintenance is recommended by the manufacture to the owner but is not required to maintain
the emissions warranty.
‡ This maintenance is not required if previously
replaced.
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
Retain all receipts.
XX
X
WARNING: You can be badly injured working on or
around a motor vehicle. Do only that service work
for which you have the knowledge and the right
equipment. If you have any doubt about your ability
to perform a service job, take your vehicle to a
competent mechanic.
Page 26
RS LUBRICATION & MAINTENANCE 0-13
MAINTENANCE SCHEDULES (Continued)
DESCRIPTION - EXPORT
There are two maintenance schedules that show
the required service for your vehicle.
First is Schedule “A”. It is for vehicles that are not
operated under any of the conditions listed under
Schedule 9B9.
Second is Schedule “B”. It is for vehicles that are
operated under the conditions that are listed below
and at the beginning of the schedule.
• Day or night temperatures are below 0° C (32°
F).
• Stop and go driving.
• Extensive engine idling.
• Driving in dusty conditions.
• Short trips of less than 16 km (10 miles).
• More than 50% of your driving is at sustained
high speeds during hot weather, above 32° C (90° F).
• Trailer towing.L
• Taxi, police, or delivery service (commercial ser-
vice).L
• Off-road or desert operation.
NOTE: Most vehicles are operated under the conditions listed for Schedule (B(.
Use the schedule that best describes your driving
conditions. Where time and mileage are listed, follow
the interval that occurs first.
CAUTION: Failure to perform the required maintenance items may result in damage to the vehicle.
At Each Stop for Fuel
• Check the engine oil level about 5 minutes after
a fully warmed engine is shut off. Checking the oil
level while the vehicle is on level ground will
improve the accuracy of the oil level reading. Add oil
only when the level is at or below the ADD or MIN
mark.
• Check the windshield washer solvent and add if
required.
Once a Month
• Check tire pressure and look for unusual wear
or damage.
• Inspect the battery and clean and tighten the
terminals as required.
• Check the fluid levels of coolant reservoir, brake
master cylinder and transmission, add as needed.
• Check all lights and all other electrical items for
correct operation.
At Each Oil Change
• Change the engine oil filter.
• Inspect the exhaust system.
• Inspect the brake hoses.
• Inspect the CV joints and front suspension com-
ponents.
• Check the automatic transmission fluid level.
• Check the manual transmission fluid level.
• Check the coolant level, hoses, and clamps.
SCHEDULE A - EXPORT ONLY
Kilometers 12 000 24 000 36 000 48 000 60 000 72 000
(Miles) (7,500) (15,000) (22,500 (30,000) (37,500) (45,000)
[Months] [6] [12] [18] [24] [30] [36]
Change engine oil and engine
oil filter.
Rotate Tires X XXXXX
Inspect the brake linings. X X
Inspect the engine air cleaner
filter, replace if necessary. *
Replace the engine air
cleaner filter.
Replace the spark plugs on
2.4 liter engines.
Inspect the tie rod ends and
boot seals.
Replace the air conditioning
filter.
XXXXXX
XXX XX
X
X
X
XXX
Page 27
0 - 14 LUBRICATION & MAINTENANCE RS
MAINTENANCE SCHEDULES (Continued)
Kilometers 84 000 96 000 108 000 120 000 132 000 144 000
(Miles) (52,500) (60,000) (67,500) (75,000) (82,500) (90,000)
[Months] [42] [48] [54] [60] [66] [72]
Change engine oil and engine
oil filter.
Rotate Tires X XXXXX
Inspect the brake linings. X X
Inspect the engine air cleaner
filter, replace if necessary. *
Replace the engine air
cleaner filter.
Replace the spark plugs on
2.4 liter engines.
Replace the ignition cables
on 2.4 liter engines.
Inspect and adjust the power
steering pump belt tension on
2.4 liter engines.
Inspect the tie rod ends and
boot seals.
Inspect the generator belt on
2.4 liter engines, replace if
necessary.
Check the PCV valve and
replace, if necessary.*
Inspect the serpentine drive
belt on 3.3 liter engines,
replace if necessary. ‡
Flush and replace the engine
coolant at 60 months,
regardless of mileage.
Replace the air conditioning
filter.
XXXXXX
X XXX
XX
XX
X
XX
XX
XX
XX
XXX
X
XXX
Kilometers 156 000 160 000 168 000 180 000 192 000
(Miles) (97,500) (100,000) (105,000) (112,500) (120,000)
[Months] [78] [84] [90] [96]
Change engine oil and engine oil filter. X X X X
Rotate Tires X X X X
Inspect the brake linings. X
Inspect the engine air cleaner filter, replace
if necessary. *
Replace the engine air cleaner filter. X
Replace the spark plugs on 2.4 liter
engines.
Replace the ignition cables on 2.4 liter
engines.
XXXX
X
X
Page 28
RS LUBRICATION & MAINTENANCE 0-15
MAINTENANCE SCHEDULES (Continued)
Kilometers 156 000 160 000 168 000 180 000 192 000
(Miles) (97,500) (100,000) (105,000) (112,500) (120,000)
[Months] [78] [84] [90] [96]
Inspect the tie rod ends and boot seals. X
Inspect and adjust the power steering pump
belt tension on 2.4 liter engines.
Inspect the generator belt on 2.4 liter
engines, replace if necessary.
Check and replace the PCV valve,if
necessary.*
Inspect the serpentine drive belt on 3.3 liter
engines, replace if necessary. ‡
Replace the spark plugs 3.3 liter engines. X
Replace the ignition cables 3.3 liter
engines.
Flush and replace the engine coolant at
100,000 miles, if not done at 60 months.
Replace the engine timing belt on 2.4 liter
engines only.
Replace the air conditioning filter. X
X
X
XX
XX
X
XX
X
* This maintenance is recommended by the manufacture to the owner but is not required to maintain
the emissions warranty.
‡ This maintenance is not required if previously
replaced.
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
Retain all receipts.
Page 29
0 - 16 LUBRICATION & MAINTENANCE RS
MAINTENANCE SCHEDULES (Continued)
SCHEDULE B - EXPORT ONLY
Follow schedule “B” if you usually operate your
vehicle under one or more of the following conditions.
Change the automatic transmission fluid and filter
every 96 000 km (60,000 miles) if the vehicle is usually operated under one or more of the conditions
marked with an L.
•
Day or night temperatures are below 0° C (32° F).
• Stop and go driving.
Kilometers 5 000 10 000 14 000 19 000 24 000 29 000
(Miles) (3,000 ) (6,000 ) (9,000) (12,000) (15,000) (18,000)
Change engine oil and engine
oil filter.
Rotate Tires X X X
Inspect the brake linings. X X
Inspect the engine air cleaner
filter, replace if necessary. *
Replace the engine air
cleaner filter. *
Inspect and adjust the power
steering pump belt tension on
2.4 liter engines.
Inspect the generator belt on
2.4 liter engines, replace if
necessary.
Change the All Wheel Drive
(AWD) power transfer unit
fluid. (See note at the end of
this chart)
Replace the air conditioning
filter.
XXXXXX
XXXX X
• Extensive engine idling.
• Driving in dusty conditions.
• Short trips of less than 16 km (10 miles).
• More than 50% of your driving is at sustained
high speeds during hot weather, above 32° C (90° F).
• Trailer towing.L
• Taxi, police, or delivery service (commercial ser-
vice).L
• Off-road or desert operation.
X
X
X
X
X
Kilometers 34 000 38 000 43 000 48 000 53 000 58 000
(Miles) (21,000) (24,000) (27,000) (30,000) (33,000) (36,000)
Change engine oil and engine
oil filter.
Rotate Tires X X X
Inspect the brake linings. X X
Inspect the engine air cleaner
filter, replace if necessary. *
Replace the engine air
cleaner filter.
Replace the spark plugs 2.4
liter engines.
Inspect the tie rod ends and
boot seals.
Inspect and adjust the power
steering pump belt tension on
2.4 liter engines.
XXXXXX
XXX XX
X
X
X
X
Page 30
RS LUBRICATION & MAINTENANCE 0-17
MAINTENANCE SCHEDULES (Continued)
Kilometers 34 000 38 000 43 000 48 000 53 000 58 000
(Miles) (21,000) (24,000) (27,000) (30,000) (33,000) (36,000)
Inspect the generator belt on
2.4 liter engines, replace if
necessary.
Inspect the PCV valveand
replace as necessary.*
Change the manual
transmission fluid.
Change the All Wheel Drive
(AWD) power transfer unit
fluid. (See note at the end of
this chart)
Change the All Wheel Drive
(AWD) overrunning clutch and
rear carrier fluid. (See the
note at the end of this chart)
Replace the air conditioning
filter.
X
X
X
X
X
X
Kilometers 62 000 67 000 72 000 77 000 82 000 86 000
(Miles) (39,000) (42,000) (45,000) (48,000) (51,000) (54,000)
Change engine oil and engine
oil filter.
Rotate Tires X X X
Inspect the brake linings. X X
Inspect the engine air cleaner
filter, replace if necessary. *
Replace the engine air
cleaner filter. *
Inspect and adjust the power
steering pump belt tension on
2.4 liter engines.
Inspect the generator belt on
2.4 liter engines, replace if
necessary.
Change the manual
transmission fluid.
Change the All Wheel Drive
power transfer unit fluid. (See
the note at the end of this chart.)
Change the All Wheel Drive
(AWD) overrunning clutch and
rear carrier fluid. (See note at
the end of this chart)
Replace the air conditioning
filter.
XXXXXX
XX XXX
X
X
X
X
X
X
X
Page 31
0 - 18 LUBRICATION & MAINTENANCE RS
MAINTENANCE SCHEDULES (Continued)
Kilometers 91 000 96 000 101 000 106 000 110 000 115 000
(Miles) (57,000) (60,000) (63,000) (66,000) (69,000) (72,000)
Change engine oil and engine
oil filter.
Rotate Tires X X X
Inspect the brake linings. X X
Inspect the engine air cleaner
filter, replace if necessary. *
Replace the engine air
cleaner filter.
Replace the spark plugs on
2.4 liter engines.
Replace the ignition cables
on 2.4 liter engines.
Inspect the tie rod ends and
boot seals.
Inspect and adjust the power
steering pump belt tension on
2.4 liter engines.
Inspect the generator belt on
2.4 liter engines, replace if
necessary.
Inspect the PCV valve and
replace if necessary.*
Inspect the serpentine drive
belt on 3.3 liter engines,
replace if necessary.
Change the automatic
transmission fluid and filter. L
Change the manual
transmission fluid.
Change the All Wheel Drive
(AWD) power transfer unit
fluid. (See note at the end of
this chart)
Change the All Wheel Drive
(AWD) overrunning clutch and
rear carrier fluid. (See note at
the end of this chart)
Replace the air conditioning
filter.
XXXXXX
X XXXX
X
X
X
X
X
X
X
X
X
X
XX
X
X
Page 32
RS LUBRICATION & MAINTENANCE 0-19
MAINTENANCE SCHEDULES (Continued)
Kilometers 120 000 125 000 130 000 134 000 139 000 144 000
(Miles) (75,000) (78,000) (81,000) (84,000) (87,000) (90,000)
Change engine oil and engine
oil filter.
Rotate Tires X X X
Inspect the brake linings. X X
Inspect the engine air cleaner
filter, replace if necessary. *
Replace the engine air
cleaner filter
Replace the spark plugs on
3.3 liter engines.
Replace the ignition cables
on 3.3 liter engines.
Replace the spark plugs on
2.4 liter engines.
Inspect and adjust the power
steering pump belt tension on
2.4 liter engines.
Inspect the generator belt on
2.4 liter engines, replace if
necessary.
Inspect the tie rod ends and
boot seals.
Inspect engine accessory
drive belts on 3.3 liter
engines, replace if necessary.
‡
Change the manual
transmission fluid.
Check the PCV valve and
replace if necessary. Not
required if previously
changed.*
Change the All Wheel Drive
power transfer unit fluid. (See
the note at the end of this
chart.)
Change the All Wheel Drive
(AWD) overrunning clutch and
rear carrier fluid. (See note at
the end of this chart)
Replace the engine timing
belt on 2.4 liter engines. *
Replace the air conditioning
filter.
XXXXXX
XXXX
XX
X
X
X
XX
XX
X
XX
X
X
XX
X
X
XX
Page 33
0 - 20 LUBRICATION & MAINTENANCE RS
MAINTENANCE SCHEDULES (Continued)
Kilometers 149 000 154 000 158 000 160 000 163 000 168 000
(Miles) (93,000) (96,000) (99,000) (100,000) (102,000) (105,000)
Change engine oil and engine
oil filter.
Rotate Tires X X
Inspect the brake linings. X
Inspect the engine air cleaner
filter, replace if necessary. *
Replace the engine air
cleaner filter *
Inspect and adjust the power
steering pump belt tension on
2.4 liter engines.
Inspect the generator belt on
2.4 liter engines, replace if
necessary.
Inspect engine accessory
drive belts on 3.3 liter
engines, replace if necessary.
‡
Change the manual
transmission fluid.
Change the All Wheel Drive
(AWD) power transfer unit,
overrunning clutch and rear
carrier fluid. (See note at the
end of this chart)
Flush and replace the engine
coolant at 60 months or
100,000 miles.
Replace the air conditioning
filter.
XXX XX
XXXXX
X
X
X
X
X
X
X
X
Kilometers 173 000 178 000 182 000 187 000 192 000
(Miles) (108,000) (111,000) (114,000) (117,000) (120,000)
Change engine oil and engine oil filter. XXXXX
Rotate Tires X X X
Inspect the brake linings. X X
Inspect the engine air cleaner filter, replace
if necessary. *
Replace the engine air cleaner filter. X
Replace the spark plugs on 2.4 liter
engines.
Replace the ignition cables on 2.4 liter
engines.
Inspect and adjust the power steering pump
belt tension on 2.4 liter engines.
XXXX
X
X
X
Page 34
RS LUBRICATION & MAINTENANCE 0-21
MAINTENANCE SCHEDULES (Continued)
Kilometers 173 000 178 000 182 000 187 000 192 000
(Miles) (108,000) (111,000) (114,000) (117,000) (120,000)
Inspect the generator belt on 2.4 liter
engines, replace if necessary.
Inspect engine accessory drive belts on 3.3
liter engines, replace if necessary. ‡
Inspect the tie rod ends and boot seals. X
Inspect the PCV valve and replace as
necessary.*
Change the automatic transmission fluid
and filter. L
Change the All Wheel Drive (AWD) power
transfer unit fluid. (See note at the end of
this chart)
Replace the air conditioning filter. X
X
X
X
X
X
* This maintenance is recommended by the manufacture to the owner but is not required to maintain
the emissions warranty.
‡ This maintenance is not required if previously
replaced.
L This maintenance is required only for police,
taxi, limousine type operation, or trailer towing.
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
Retain all receipts.
NOTE: The AWD power transfer unit fluid and the
AWD overrunning clutch/ rear carrier fluid must be
changed at the intervals shown in schedule B if the
vehicle is operated under any of the conditions
noted by a diamond at the beginning of the schedule.
WARNING: You can be badly injured working on or
around a motor vehicle. Do only that service work
for which you have the knowledge and the right
equipment. If you have any doubt about your ability
to perform a service job, take your vehicle to a
competent mechanic.
DESCRIPTION - DIESEL ENGINES - EXPORT
There are two maintenance schedules that show
the required service for your vehicle.
First is Schedule “A”. It is for vehicles that are not
operated under any of the conditions listed under
Schedule 9B9.
Second is Schedule “B”. It is for vehicles that are
operated under the conditions that are listed below
and at the beginning of the schedule.
• Extensive engine idling.
• Driving in dusty conditions.
• More than 50% of your driving is at sustained
high speeds during hot weather, above 32° C (90° F).
• Trailer towing.
• Taxi, police, or delivery service (commercial ser-
vice).
Most vehicles are operated under the conditions
listed for Schedule 9B9.
Use the schedule that best describes your driving
conditions. Where time and mileage are listed, follow
the interval that occurs first.
Failure to perform the required maintenance items
may result in damage to the vehicle.
At Each Stop for Fuel
• Check the engine oil level about 5 minutes after
a fully warmed engine is shut off. Checking the oil
level while the vehicle is on level ground will
improve the accuracy of the oil level reading. Add oil
only when the level is at or below the ADD or MIN
mark.
• Check the windshield washer solvent and add if
required.
Once a Month
• Check the tire pressure and look for unusual
wear or damage.
• Inspect the battery and clean and tighten the
terminals as required.
• Check the fluid levels of coolant deaeration bottle, brake master cylinder and transmission, add as
needed.
• Check all lights and all other electrical items for
correct operation.
Page 35
0 - 22 LUBRICATION & MAINTENANCE RS
MAINTENANCE SCHEDULES (Continued)
At Each Oil Change
• Change the engine oil filter.
• Inspect the exhaust system.
• Inspect the brake hoses.
• Inspect the CV joints and front suspension com-
ponents.
• Check the manual transmission fluid level.
• Check the coolant level, hoses, and clamps.
• Inspect engine accessory drive belts. Replace as
necessary.
• Inspect for the presence of water in the fuel filter/water separator unit.
SCHEDULE A - DIESEL ENGINES
Kilometers 20 000 km 40 000 km 60 000 km 80 000 km 100 000
km
Change engine oil and engine oil filter. XXXXX
Rotate Tires XXXXX
Replace engine air filter element XXXXX
Replace fuel filter/water separator unit. XXXXX
Inspect timing belt tensioner. ‡ X
Replace the engine timing belt and idler
pulleys.
Check front end alignment. X X
Inspect the tie rod ends and boot seals. X X
Inspect the brake linings. XXXXX
X
Kilometers 120 000
km
Change engine oil and engine oil filter. XXXXX
Rotate Tires XXXXX
Inspect accessory drive belts and replace if
necessary.
Replace engine air filter element XXXXX
Replace fuel filter/water separator unit. XXXXX
Replace the timing belt, idler pulleys and
timing belt tensioner.
Flush and replace engine coolant. X
Check front end alignment. X X X
Inspect the tie rod ends and boot seals. X X X
Inspect the brake linings. XXXXX
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
Retain all receipts.
140 000
km
‡ Replace if there is superficial wear, bearing clear-
ance, or evident grease leakage.
160 000
km
180 000
km
X
200 000
km
X
Page 36
RS LUBRICATION & MAINTENANCE 0-23
MAINTENANCE SCHEDULES (Continued)
SCHEDULE B - DIESEL ENGINES
Follow schedule “B” if you usually operate your
vehicle under one or more of the following conditions.
• Extensive engine idling.
• Driving in dusty conditions.
Kilometers 10 000 km 20 000 km 30 000 km 40 000 km 50 000 km
Change engine oil and engine oil filter. XXXXX
Rotate Tires X X
Replace engine air filter element XXXXX
Replace engine accessory drive belt. X
Replace the engine timing belt and idler
pulleys.
Inspect timing belt tensioner. ‡ X
Replace fuel filter/water separator unit. X X
Check front end alignment. X X
Change the manual transaxle fluid. X
Inspect the tie rod ends and boot seals. X
Inspect the brake linings. XXXXX
• More than 50% of your driving is at sustained
high speeds during hot weather, above 32° C (90° F).
• Trailer towing.
• Taxi, police, or delivery service (commercial ser-
vice).
X
Kilometers 60 000 km 70 000 km 80 000 km 90 000 km 100 000
km
Change engine oil and engine oil filter. XXXXX
Rotate Tires X X X
Replace engine air filter element XXXXX
Replace fuel filter/water separator unit. X X X
Replace engine accessory drive belt. X
Replace engine timing belt, idler pulleys
and timing belt tensioner.
Check front end alignment. X X
Change the manual transaxle fluid. X X
Inspect the tie rod ends and boot seals. X
Inspect the brake linings. XXXXX
Kilometers 110 000
km
Change engine oil and engine
oil filter.
Rotate Tires X X X
Replace engine air filter
element
Replace engine accessory
drive belt.
Replace the engine timing
belt and idler pulleys.
Inspect timing belt tensioner.
‡
XXXXXX
XXXXX X
120 000
km
130 000
km
140 000
km
150 000
km
X
X
X
X
160 000
km
Page 37
0 - 24 LUBRICATION & MAINTENANCE RS
MAINTENANCE SCHEDULES (Continued)
Kilometers 110 000
km
Replace fuel filter/water
separator unit.
Flush and replace engine
coolant.
Check front end alignment. X X X
Inspect the tie rod ends and
boot seals.
Inspect the brake linings. X XXXXX
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
Retain all receipts.
‡ Replace if there is superficial wear, bearing clearance, or evident grease leakage.
WARNING: You can be badly injured working on or
around a motor vehicle. Do only that service work
for which you have the knowledge and the right
equipment. If you have any doubt about your ability
to perform a service job, take your vehicle to a
competent mechanic.
HOISTING
STANDARD PROCEDURE - HOISTING
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 VEHICLE. 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.
120 000
km
XXX
XX
130 000
km
CAUTION: Do not position hoisting device on any
suspension component, including the front suspension crossmember, the rear leaf springs, and the
rear axle. Do not hoist on the front and rear
bumpers, the lower liftgate crossmember, the lower
radiator crossmember, the down standing flanges
on the sill or the front engine mount.
FOR PROPER HOIST PLACEMENT REFER
TO (Fig. 5).
The hoisting points are identified by S.A.E.
inverted triangle hoisting symbols (Fig. 5). The front
hoisting points are at the bottom of the font rail
below the hoisting symbol approximately 250 mm
behind the front suspension crossmember. When
using outboard lift hoists, verify that the hoist lift
pads have been properly adjusted to eliminate contact between the hoist arm and the down standing
flange on the sill. The rear hoisting points are the
leaf spring front mounting brackets. The hoist pad
must be positioned to pick up the flanges on the
bracket, not the leaf spring.
When servicing the leaf springs or the leaf spring
mounting brackets, special provisions are required to
support the rear of the vehicle. Position the rear
hoist pads under the horizontal surface on the bottom of the sill, inboard adjacent to the flange and
centered fore/aft between the jacking indicator tabs
on the lower flange. DO NOT HOIST ON THE
FLANGE. Place a soft pad between the hoist and the
painted surface on the sill to avoid scratching the finish.
140 000
km
150 000
km
160 000
km
X
Page 38
RS LUBRICATION & MAINTENANCE 0-25
HOISTING (Continued)
WARNING: REMOVE METALLIC JEWELRY WORN
ON HANDS OR WRISTS TO AVOID INJURY BY
ACCIDENTAL ARCING OF BATTERY CURRENT.
WARNING: WHEN USING A HIGH OUTPUT BOOSTING DEVICE, DO NOT ALLOW BATTERY VOLTAGE
TO EXCEED 16 VOLTS.
WARNING: REFER TO INSTRUCTIONS PROVIDED
WITH DEVICE BEING USED.
CAUTION: DO NOT ATTEMPT TO PUSH OR TOW
THE VEHICLE TO START IT. THE VEHICLE CANNOT
BE STARTED THIS WAY. PUSHING WITH ANOTHER
VEHICLE MAY DAMAGE THE TRANSAXLE OR THE
REAR OF THE VEHICLE.
(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
• Battery cable clamp condition, clean if necessary.
• Frozen battery.
• Clear or bright color test indicator, if equipped.
• Generator drive belt condition and tension.
Fig. 5 HOISTING AND JACKING POINTS
1- DRIVE ON LIFT
2 - FRAME CONTACT LIFT (SINGLE POST)
2 - CHASSIS LIFT (NON-AXLE DUAL POST)
2 - OUTBOARD LIFT (DUAL POST)
2 - FLOOR JACK
3 - S.A.E. HOISTING SYMBOLS
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BATTERY - STANDARD PROCEDURE).
WARNING: DO NOT JUMP START A FROZEN BATTERY, PERSONAL INJURY CAN RESULT.
WARNING: DO NOT JUMP START WHEN MAINTENANCE FREE BATTERY INDICATOR DOT IS BRIGHT
COLOR.
WARNING: DO NOT ALLOW JUMPER CABLE
CLAMPS TO TOUCH EACH OTHER WHEN CONNECTED TO A BOOSTER SOURCE.
WARNING: DO NOT USE OPEN FLAME NEAR BATTERY
• 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
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. 6).
(Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BATTERY - STANDARD PROCEDURE).
(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.
Page 39
0 - 26 LUBRICATION & MAINTENANCE RS
JUMP STARTING (Continued)
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.
Fig. 6 JUMPER CABLE CLAMP CONNECTIONS
1 - BATTERY NEGATIVE TERMINAL
2 - POSITIVE JUMPER CABLE
3 - TEST INDICATOR (IF EQUIPPED)
4 - BATTERY POSITIVE TERMINAL
5 - BATTERY
6 - NEGATIVE JUMPER CABLE
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter may overheat and could fail.
(7) 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.
RECOMMENDED TOWING EQUIPMENT
To avoid damage to bumper fascia and air dams
use:
• FWD vehicles, use of a flat bed towing device or
a wheel lift is recommended (Fig. 7).
• AWD vehicles, a flat bed towing device or a
wheel lift and towing dolly is recommended (Fig. 7).
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.
TOWING
STANDARD PROCEDURE - TOWING
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.
Fig. 7 RECOMMENDED TOWING
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 front end of
the vehicle and lower the front end closer to the
Page 40
RS LUBRICATION & MAINTENANCE 0-27
TOWING (Continued)
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.
• AWD models should not be flat towed. For additional information, refer to RECOMMENDED TOW-
ING EQUIPMENT in this section.
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 rear sway bar have brackets at this
location.
TOWING – FRONT WHEEL LIFT
If the vehicle is being towed from the front, whenever possible ensure at least 10 inches road clearance
to the tires.
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.
• 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 41
Page 42
RS SUSPENSION 2-1
SUSPENSION
TABLE OF CONTENTS
page page
FRONT SUSPENSION .....................1
REAR SUSPENSION ......................26
FRONT SUSPENSION
TABLE OF CONTENTS
page page
FRONT SUSPENSION
DESCRIPTION - FRONT SUSPENSION .......2
OPERATION - FRONT SUSPENSION .........2
STANDARD PROCEDURE - LUBRICATION ....2
SPECIFICATIONS
FRONT SUSPENSION FASTENER TORQUE . . 3
SPECIAL TOOLS
FRONT SUSPENSION ...................3
BUSHINGS
REMOVAL - STABILIZER BAR CUSHION ......4
INSTALLATION - STABILIZER BAR CUSHION . . . 4
HUB / BEARING
DESCRIPTION ..........................5
OPERATION ............................5
DIAGNOSIS AND TESTING - HUB AND
BEARING ............................5
REMOVAL .............................5
INSTALLATION ..........................5
KNUCKLE
DESCRIPTION ..........................6
OPERATION ............................7
REMOVAL - STEERING KNUCKLE ...........7
INSPECTION - STEERING KNUCKLE .........9
INSTALLATION - STEERING KNUCKLE .......9
LOWER BALL JOINT
DESCRIPTION .........................10
OPERATION ...........................10
DIAGNOSIS AND TESTING - LOWER BALL
JOINT ..............................10
LOWER BALL JOINT SEAL BOOT
DESCRIPTION - EXPORT .................10
REMOVAL
REMOVAL ...........................11
REMOVAL - EXPORT ...................11
WHEEL ALIGNMENT .....................47
INSTALLATION
INSTALLATION .......................11
INSTALLATION - EXPORT ...............11
LOWER CONTROL ARM
DESCRIPTION .........................12
OPERATION ...........................12
REMOVAL - LOWER CONTROL ARM ........12
DISASSEMBLY
DISASSEMBLY - LOWER CONTROL ARM
(REAR BUSHING - STANDARD) ..........13
DISASSEMBLY - LOWER CONTROL ARM
(REAR BUSHING - HYDRO) .............13
INSPECTION - LOWER CONTROL ARM ......14
ASSEMBLY
ASSEMBLY - LOWER CONTROL ARM
(REAR BUSHING - STANDARD) ..........14
ASSEMBLY - LOWER CONTROL ARM
(REAR BUSHING - HYDRO) .............15
INSTALLATION - LOWER CONTROL ARM ....15
STABILIZER BAR
DESCRIPTION .........................16
OPERATION ...........................16
REMOVAL .............................17
INSPECTION ..........................17
INSTALLATION .........................17
STRUT
DESCRIPTION - STRUT ASSEMBLY .........19
OPERATION - STRUT ASSEMBLY ..........19
DIAGNOSIS AND TESTING - STRUT
ASSEMBLY ..........................20
REMOVAL - STRUT ASSEMBLY ............20
DISASSEMBLY - STRUT ASSEMBLY ........21
ASSEMBLY - STRUT ASSEMBLY ...........23
INSTALLATION - STRUTASSEMBLY ........25
Page 43
2 - 2 FRONT SUSPENSION RS
FRONT SUSPENSION
DESCRIPTION - FRONT SUSPENSION
This vehicle has a MacPherson Strut type front
suspension (Fig. 1).
OPERATION - FRONT SUSPENSION
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.
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.
STANDARD PROCEDURE - LUBRICATION
There are no serviceable lubrication points on the
front suspension. The ball joints are sealed-for-life
and require no maintenance. The lower ball joints
have special grease fitting caps that prevent normal
grease gun attachment. This has been done to eliminate the possibility of over-filling, damaging the nonvented seal. Do not attempt to remove the special
grease fitting cap and replace it with a normal grease
zirc fitting.
CAUTION: No attempt should be made to replace
the ball joint grease fitting cap with a normal zirc
fitting or fill the ball joint with grease. Damage to
the grease seal can result.
Fig. 1 Front Suspension
1 - TOWER
2 - CROSSMEMBER TAPPING PLATES
3 - LEFT STRUT ASSEMBLY
4 - LEFT STEERING KNUCKLE (WITH HUB AND BEARING)
5 - STABILIZER BAR LINK
6 - STABILIZER BAR
7 - LEFT LOWER CONTROL ARM
8 - CRADLE/CROSSMEMBER
9 - CRADLE/CROSSMEMBER REINFORCEMENT
10 - BALL JOINT
11 - ISOLATOR BUSHING
12 - STEERING GEAR TIE ROD
13 - RIGHT STEERING KNUCKLE
14 - RIGHT HUB AND BEARING
15 - RIGHT STRUT ASSEMBLY
Page 44
RS FRONT SUSPENSION 2-3
FRONT SUSPENSION (Continued)
SPECIFICATIONS
FRONT SUSPENSION FASTENER TORQUE
DESCRIPTION N·m
Ball Joint Nut 108 80 —
Cradle Crossmember
Mounting Bolts
Cradle Crossmember
Reinforcement Bolts - Size
M-14
Cradle Crossmember
Reinforcement Bolt - Size
M-12
Cradle Crossmember
Reinforcement Bolts - Size
M-10
Disc Brake Adapter
Mounting Bolts
Hub And Bearing Mounting
Bolts
Hub And Bearing Axle Hub
Nut
Lower Control Arm Pivot
Bolt
Stabilizer Bar Bushing
Retainer Bolts
Stabilizer Bar Link Nuts 88 65 —
Strut Body/Tower Mounting
Nuts
Strut Clevis-to-Knuckle Nuts 81 +
Strut Shaft Nut 100 75 —
Tie Rod Adjuster Jam Nut 75 55 —
Tie Rod Steering Arm Nut 75 55 —
Wheel Mounting (Lug) Nuts 135 100 —
163 120 —
153 113 —
106 78 —
61 45 —
169 125 —
65 45 —
244 180 —
183 135 —
68 50 —
28 21 250
90°
turn
Ft.
Lbs.
60 +
90°
turn
SPECIAL TOOLS
FRONT SUSPENSION
In.
Lbs.
Puller C-3894A
Press, Ball Joint C-4212F
Installer, Ball Joint 6758
—
Wrench, Strut Rod Nut 6864
Page 45
2 - 4 FRONT SUSPENSION RS
FRONT SUSPENSION (Continued)
REMOVER/INSTALLER, BUSHING 8460
Fig. 2 Front Stabilizer Bar Cushion Retainers
1 - STEERING GEAR
2 - STABILIZER BAR
3 - RAISED BEAD
4 - FRONT CRADLE CROSSMEMBER
5 - RETAINERS
REMOVER/INSTALLER, BALL JOINT 8490
BUSHINGS
REMOVAL - STABILIZER BAR CUSHION
(1) Raise Vehicle. Refer to Hoisting in Lubrication
and Maintenance.
(2) Remove the 2 bolts fastening the emission leak
detection pump to the cradle crossmember reinforcement.
(3) Move the leak detection pump to the side
allowing access to the stabilizer bar cushion retainers.
(4) Remove the nut and bolt securing each stabilizer bar cushion retainer to the cradle crossmember
(Fig. 2) and remove the retainers.
(5) Remove each stabilizer bar cushion from the
stabilizer bar by opening the slit in the cushion and
peeling it off the stabilizer bar.
INSTALLATION - STABILIZER BAR CUSHION
(1) Install each new cushion on stabilizer bar by
spreading cushion at slit and forcing it onto stabilizer
bar.
NOTE: Cushions must be installed on stabilizer bar
so the square corner of the bushing will be down
and slit in cushion will be facing the rear of the
vehicle when the stabilizer bar is installed (Fig. 3).
Fig. 3 Correctly Installed Stabilizer Bar Cushion
1 - SLIT IN SWAY BAR BUSHING.
2 - SQUARE CORNER
3-SWAYBAR
4 - SWAY BAR ISOLATOR BUSHING
(4) Install each mounting bolt from rear of cradle
crossmember through retainer. Install the two nuts
and tighten to 68 N·m (50 ft. lbs.) torque.
(5) Reattach emission leak detection pump to cradle crossmember reinforcement with two mounting
bolts.
(6) Lower the vehicle.
(2) Place stabilizer bar into mounted position with
cushions properly aligned.
(3) Hook each retainer into cradle crossmember
mounting hole and over cushion.
Page 46
RS FRONT SUSPENSION 2-5
HUB / BEARING
DESCRIPTION
The front wheel bearing and front wheel hub of
this vehicle are a hub and bearing unit type assembly (Unit III). 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 inboard side of the steering knuckle. The
hub flange has five wheel mounting studs.
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.
DIAGNOSIS AND TESTING - HUB AND BEARING
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.
When bearing damage is slight, the noise is sometimes noticeable at lower speeds and at other times
is more noticeable at speeds above 105 km/h (65
mph).
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 vehicle to allow the hub/bearing assembly to be
pressed out of the steering knuckle. (Refer to 2 SUSPENSION/FRONT/KNUCKLE - REMOVAL)
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCEDURE)
(2) Remove wheel lug nuts, and front tire and
wheel assembly.
(3) Remove the cotter pin, nut lock and spring
washer from the stub axle (Fig. 4).
Fig. 4 Hub Nut
1 - HUB NUT
2 - NUT LOCK
3 - COTTER PIN
4 - SPRING WASHER
(4) With aid of a helper applying the brakes to
keep the front hub from turning, remove the hub nut
(Fig. 4).
(5) Remove disc brake caliper and adapter as an
assembly from knuckle as shown (Fig. 5). Hang
assembly out of the way using a bungee cord or wire.
Do not allow caliper hang by brake hose.
(6) Remove brake rotor from hub and bearing (Fig.
5).
(7) Push in on end of driveshaft stub shaft, pushing its splines out of the hub splines.
(8) Remove the four hub and bearing mounting
bolts from the rear of steering knuckle (Fig. 6). Use
care not to come in contact with and damage
the ABS tone wheel on the driveshaft stub shaft
upon bolt removal.
(9) Remove the hub and bearing assembly from
the steering knuckle.
INSTALLATION
CAUTION: Hub and bearing assembly mounting
surfaces on the steering knuckle and stub axle (Fig.
7) must be smooth and completely free of foreign
material or nicks prior to installing hub and bearing
assembly.
Page 47
2 - 6 FRONT SUSPENSION RS
HUB / BEARING (Continued)
Fig. 5 Front Brake Mounting
1 - BRAKE ROTOR
2 - HUB AND BEARING
3 - STEERING KNUCKLE
4 - ADAPTER MOUNTING BOLTS
5 - BRAKE CALIPER
6 - ADAPTER
7 - CLIP
Fig. 6 Hub And Bearing Mounting Bolts
1 - HUB
2 - STEERING KNUCKLE
3 - MOUNTING BOLTS (4)
4 - DRIVESHAFT
CAUTION: When installing hub and bearing into
steering knuckle, be careful not to damage the
bearing seal (Fig. 7) on the outer C/V joint.
Fig. 7 Mounting Surfaces (Typical)
1 - BEARING SEAL
2 - STUB AXLE
3 - THESE SURFACES MUST BE CLEAN AND FREE OF NICKS
BEFORE INSTALLING BEARING ASSEMBLY
4 - STEERING KNUCKLE
steering knuckle. Tighten mounting bolts to a torque
of 65 N·m (45 ft. lbs.)
(3) Install the brake rotor on the hub and bearing
(Fig. 5).
(4) Install brake caliper and adapter assembly
back over brake rotor and align with mounting holes
on steering knuckle (Fig. 5). Install the mounting
bolts and tighten to 169 N·m (125 ft. lbs.) torque.
(5) Install the hub nut on the end of the stub axle
(Fig. 4). With aid of a helper applying the brakes to
keep the front hub from turning, tighten the hub nut
to Install the mounting bolts and tighten to 244 N·m
(180 ft. lbs.) torque.
(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 135 N·m (100 ft. lbs.).
(7) Lower vehicle to the ground.
(8) Check the front wheel alignment toe setting
and reset if not within specifications. (Refer to 2 SUSPENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE)
KNUCKLE
(1) Install hub and bearing onto stub axle and into
steering knuckle until squarely seated on the face of
the steering knuckle.
(2) Install the 4 hub and bearing mounting bolts
from the rear of the knuckle. Equally tighten all 4
mounting bolts in a criss-cross pattern until hub/
bearing assembly is squarely seated against front of
DESCRIPTION
The steering knuckle is a single aluminum casting with legs machined for attachment of the strut
assembly, steering linkage, disc brake caliper
adapter, lower control arm ball joint and steering
linkage (Fig. 1). The hub and bearing assembly is
mounted in the center of the steering knuckle using
Page 48
RS FRONT SUSPENSION 2-7
KNUCKLE (Continued)
4 bolts. The driveshaft’s constant velocity (C/V) stub
axle is splined through the center of the hub and
bearing and is held in place using a nut, nut lock and
cotter pin.
Service replacement of the front hub and bearing
assembly can be done with the steering knuckle
remaining on the vehicle.
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.
Fig. 9 Front Brake Mounting
REMOVAL - STEERING KNUCKLE
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCEDURE)
(2) Remove the wheel and tire assembly from the
vehicle.
(3) Remove the cotter pin, nut lock and spring
washer from the end of the stub axle and hub nut
(Fig. 8).
1 - BRAKE ROTOR
2 - HUB AND BEARING
3 - STEERING KNUCKLE
4 - ADAPTER MOUNTING BOLTS
5 - BRAKE CALIPER
6 - ADAPTER
7 - CLIP
Fig. 8 Hub Nut
1 - HUB NUT
2 - NUT LOCK
3 - COTTER PIN
4 - SPRING WASHER
(4) Have a helper apply the vehicle’s brakes to
keep hub from turning, loosen and remove the hub
nut (Fig. 8).
(5) Remove disc brake caliper and adapter as an
assembly from knuckle as shown (Fig. 9). Hang
assembly out of the way using a bungee cord or wire
(Fig. 10). Do not allow caliper to hang by brake
hose.
(6) Remove nut attaching outer tie rod end to
steering knuckle by holding the tie rod end stud
Fig. 10 Caliper And Driveshaft Suspended
1 - HANGER SUSPENDING CALIPER
2 - HANGER SUSPENDING DRIVESHAFT
3 - DRIVESHAFT
4 - BRAKE CALIPER
while loosening and removing nut with a wrench
(Fig. 11).
Page 49
2 - 8 FRONT SUSPENSION RS
KNUCKLE (Continued)
(8) If equipped with antilock brakes, remove the
front wheel speed sensor from the steering knuckle
(Fig. 13).
Fig. 11 Removing Tie Rod End Attaching Nut
1 - TIE ROD END
2 - STEERING KNUCKLE
3 - WRENCH
4 - SOCKET
5 - TIE ROD END STUD
(7) Remove tie rod end from steering knuckle
using Remover, Special Tool C-3894–A (Fig. 12).
1 - MOUNTING BOLT
2 - WHEEL SPEED SENSOR
3 - STEERING KNUCKLE
(9) Remove the two steering knuckle-to-strut clevis
bracket attaching bolts.
(10) Tip the knuckle outward and remove the
driveshaft stub axle from the hub and bearing. Suspend driveshaft straight outward using a bungee
cord or wire (Fig. 10). Do not allow driveshaft to
hang by inner joint.
(11) Remove ball joint nut using a power impact
wrench. Because the tapered stud is held sufficiently
in the knuckle at this time, it is not necessary to
hold the stud stationary to remove the nut.
(12) Reinstall the ball joint nut until the top of the
nut is even with the top of the ball joint stud. This
will keep the stud from distorting while the stud is
released from the knuckle in the following step.
Fig. 13 Front Wheel Speed Sensor
Fig. 12 Tie Rod Removal With Tool C-3894-A
1 - OUTER TIE ROD
2 - SPECIAL TOOL C-3894-A
3 - STEERING KNUCKLE
CAUTION: Do not remove ball joint stud from steering knuckle using a hammer. Damage to the Aluminum knuckle, ball joint or control arm will result.
(13) Release ball joint stud from steering knuckle
using Remover, Special Tool C-4150A, as shown (Fig.
14). To ease Remover installation and use, it may
help to rotate the knuckle around so the inside of the
knuckle faces outward.
(14) Remove the nut from the top of the ball joint
stud.
(15) Remove the steering knuckle from the vehicle.
(16) If the hub and bearing needs to be transferred, remove the four bolts attaching the hub and
bearing to the knuckle, then remove the hub and
bearing.
Page 50
RS FRONT SUSPENSION 2-9
KNUCKLE (Continued)
damage to the knuckle can occur. Use a clean shop
cloth with MoparT Brake Parts Cleaner applied to it
for proper cleaning. Do not spray the stud directly.
(2) Place the knuckle on the ball joint stud.
(3) Install a NEW steering knuckle to ball joint
stud nut. Tighten the nut by holding ball joint stud
with hex wrench while turning nut with a wrench
(Fig. 15). Using a crowsfoot wrench on a torque
wrench, tighten the nut to a torque of 108 N·m (80 ft.
lbs.).
Fig. 14 Using C-4150A To Release Ball Joint
1 - ALUMINUM KNUCKLE
2 - SPECIAL TOOL C-4150A
3 - LOWER CONTROL ARM
4 - NUT INSTALLED ON BALL JOINT STEM
INSPECTION - STEERING KNUCKLE
Inspect the knuckle for the following:
• Cracks or breaks
• Dents or damage
• Stress marks indicating a bend
The front suspension knuckle is not a repairable
component of the vehicles front suspension. If bent,
broken or damaged in any way, do not attempt to
straighten or repair the steering knuckle. It must be
replaced.
If inspection leads to the hub and bearing, (Refer
to 2 - SUSPENSION/FRONT/HUB / BEARING DIAGNOSIS AND TESTING)
INSTALLATION - STEERING KNUCKLE
(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 four mounting bolts and tighten them to a torque
of 65 N·m (45 ft. lbs.).
CAUTION: Before installing the knuckle on the ball
joint stud, wipe the ball joint stud and knuckle contact area free of any grease or debris, otherwise
Fig. 15 Ball Joint Nut Installation
1 - KNUCKLE
2 - BALL JOINT STUD
3 - LOWER CONTROL ARM
(4) Slide driveshaft stub axle into hub and bearing
assembly.
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 knuckle.
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. 16).
NOTE: The strut clevis-to-steering knuckle bolts are
installed differently on each side. Left hand side
bolts are to be installed from vehicle rear to front.
Right side bolts are to be installed from vehicle
front to rear.
(5) Install steering knuckle in clevis bracket of
strut damper assembly. Install the strut clevis-tosteering knuckle attaching bolts. Tighten both bolts
to a torque of 81 N·m (60 ft. lbs.) plus an additional
1/4 (90°) turn.
Page 51
2 - 10 FRONT SUSPENSION RS
KNUCKLE (Continued)
LOWER BALL JOINT
DESCRIPTION
The ball joint is an integral part of the lower control arm (Fig. 1). The ball joint has a tapered stud
that is pressed into the aluminum knuckle. The ball
joint stud is threaded on the end for a retainer nut.
The ball joint has a non-vented seal boot. The seal
boot has an integrated heat shield.
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
lubricated-for-life during the manufacturing process.
A special fitting cap is installed on the fill port. This
cap must not be removed and replaced with a com-
Fig. 16 Correctly Installed Eccentric Attaching Bolt
1 - STEERING KNUCKLE
2 - FLANGED BOLT IN TOP HOLE
3 - CAM BOLT IN BOTTOM HOLE
4 - STRUT CLEVIS BRACKET
(6) Install tie rod end into knuckle steering arm.
Start nut onto stud of tie rod end. While holding stud
of tie rod end stationary using a socket (Fig. 11),
tighten tie rod end to steering knuckle attaching nut.
Tighten the tie rod end nut to a torque of 75 N·m (55
ft. lbs.).
(7) If equipped with antilock brakes, install wheel
speed sensor and mounting bolt on steering knuckle
(Fig. 13). Tighten the speed sensor bolt to a torque of
7 N·m (60 in. lbs.).
(8) Install brake rotor on hub and bearing (Fig. 9).
(9) Install disc brake caliper and adapter assembly
on steering knuckle. Install adapter amounting bolts
and tighten to 169 N·m (125 ft. lbs.).
(10) Clean any debris from the threads of the
outer C/V joint stub axle.
(11) Install the washer and hub nut on stub axle.
(12) Have a helper apply the vehicle’s brakes to
keep hub from turning, then tighten hub nut to a
torque of 244 N·m (180 ft. lbs.).
(13) Install the spring wave washer on the end of
the stub axle.
(14) Install the hub nut lock, and a new cotter pin
(Fig. 8). Wrap cotter pin prongs tightly around the
hub nut lock.
(15) Install wheel and tire assembly. Install and
tighten the wheel mounting 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.).
(16) Lower vehicle.
(17) Set front wheel alignment camber and toe as
necessary. (Refer to 2 - SUSPENSION/WHEEL
ALIGNMENT - STANDARD PROCEDURE)
mon zirc fitting. The special cap is there 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.
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.
DIAGNOSIS AND TESTING - LOWER BALL JOINT
With the weight of the vehicle resting on the road
wheels, grasp the special fitting cap 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 control arm is recommended.
LOWER BALL JOINT SEAL BOOT
DESCRIPTION - EXPORT
The lower ball joint seal boot is a two piece unit. It
consists of the seal boot, plus a separate shield that
is located in a groove at the top of the seal boot.
NOTE: The seal boot should only be replaced if
damaged during vehicle service. The entire lower
control arm should be replaced if the joint has been
contaminated.
Page 52
RS FRONT SUSPENSION 2-11
LOWER BALL JOINT SEAL BOOT (Continued)
REMOVAL
REMOVAL
(1) Remove steering knuckle from vehicle. (Refer
to 2 - SUSPENSION/FRONT/KNUCKLE REMOVAL)
(2) Using a screwdriver or other suitable tool, pry
seal boot off of ball joint (Fig. 17).
(2) Install a NEW seal boot by hand as far as possible on ball joint. Ensure seal boot shield is positioned outward from control arm as shown (Fig. 18).
Fig. 18 Ball Joint Seal Boot Installed Position
1 - BALL JOINT STUD
2 - LOWER CONTROL ARM
3 - SEAL BOOT SHIELD
Fig. 17 Ball Joint Seal Boot Removal
1 - BALL JOINT STUD
2 - SCREWDRIVER
3 - SEAL BOOT
(3) Inspect ball joint for evidence of dirt or water
intrusion and wipe clean as necessary. If dirt or
water intrusion is extreme and joint cannot be properly cleaned, lower control arm will need to be
replaced. (Refer to 2 - SUSPENSION/FRONT/
LOWER CONTROL ARM - REMOVAL)
REMOVAL - EXPORT
(1) Remove steering knuckle from vehicle. (Refer
to 2 - SUSPENSION/FRONT/KNUCKLE REMOVAL)
(2) Remove shield from seal boot by gently pulling
on it.
(3) Using a screw driver or other suitable tool, pry
seal boot off lower ball joint.
INSTALLATION
INSTALLATION
(1) Place a liberal dab of Mopart Wheel Bearing
Grease around base of ball joint stud at socket.
CAUTION: Do not use an arbor press to install seal
boot on ball joint. Damage to seal boot will occur if
excessive pressure is applied while it is being
installed.
(3) Place Installer, Special Tool 6758, over top of
seal boot and squarely align it with bottom edge of
seal boot (Fig. 19). Apply hand pressure (or gently
tap with a hammer if necessary) to top of Installer
until seal boot is pressed squarely down against top
surface of lower control arm.
(4) Wipe any grease off ball joint stem using a
clean shop towel with Mopart Brake Parts Cleaner
applied to it.
CAUTION: Do not attempt to install a normal grease
zirc in ball joint in an effort to lubricate joint
through zirc fitting.
(5) Install steering knuckle on vehicle. (Refer to 2 SUSPENSION/FRONT/KNUCKLE - INSTALLATION)
INSTALLATION - EXPORT
(1) Place a liberal dab of Mopart Wheel Bearing
Grease around the base of the ball joint stem at the
socket.
(2) Install a NEW seal boot by hand as far as possible on the ball joint.
Page 53
2 - 12 FRONT SUSPENSION RS
LOWER BALL JOINT SEAL BOOT (Continued)
(5) Place the shield over the top of the seal boot
and stretch it into the groove at the top of the seal
boot.
CAUTION: Do not attempt to install a normal grease
zirc in the ball joint and lubricate the joint through
the zirc fitting.
(6) Reinstall steering knuckle on vehicle. (Refer to
2 - SUSPENSION/FRONT/KNUCKLE - INSTALLATION)
LOWER CONTROL ARM
DESCRIPTION
The lower control arm is mounted to the front suspension crossmember using a pivot bolt through the
center of the front pivot bushing, and the front sus-
Fig. 19 Installer Positioned On Ball Joint Seal Boot
1 - INSTALLER 6758
2 - LOWER CONTROL ARM
3 - SEAL BOOT SHIELD
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.
(3) Place Installer, Special Tool 6758, over seal
boot and squarely align it with bottom edge of seal
boot (Fig. 20). Apply hand pressure to Special Tool
6758 until seal boot is pressed squarely against top
surface of lower control arm.
pension cradle crossmember reinforcement traps the
rear bushing in the crossmember (Fig. 1).
The lower control arm is an iron casting with two
rubber bushings and a ball joint. The lower control
arm front bushing is the spool type and is pressed
into the lower control arm. The standard (Low-line,
High-line) lower control arm rear bushing is a
push-on bushing that is pushed over a stem on the
rear of the lower control arm. The lower control arm
rear bushing used on all other models is a hydrobushing that is pressed on. It has liquid filled voids
that provide more effective dampening than the standard bushing. Vehicles with rear hydro-bushings utilize a different lower control arm than vehicles with
standard bushings. They have a straight slightly
tapered round stem where the hydro-bushing is
mounted whereas the standard arm has a straight
stem with a squared knob on the end to retain the
bushing.
The lower control arm ball joint is pressed into the
outer end of the arm. The ball joint has a tapered
stud and retainer nut for fastening it to the steering
knuckle.
Fig. 20 Installing Ball Joint Seal Boot (Typical)
1 - SHIELD (NOT ON RG VEHICLE)
2 - SPECIAL TOOL 6758
3 - LOWER CONTROL ARM
4 - BALL JOINT SEAL BOOT
(4) Wipe any grease off the ball joint stem.
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.
REMOVAL - LOWER CONTROL ARM
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCEDURE)
(2) Remove wheel and tire assembly.
(3) Remove the steering knuckle. (Refer to 2 SUSPENSION/FRONT/KNUCKLE - REMOVAL)
Page 54
RS FRONT SUSPENSION 2-13
LOWER CONTROL ARM (Continued)
(4) Remove the bolts fastening the power steering
cooler to the front suspension cradle crossmember
reinforcement (Fig. 21).
Fig. 21 Power Steering Cooler
1 - CRADLE CROSSMEMBER REINFORCEMENT
2 - POWER STEERING COOLER
(5) Remove the lower control arm rear bushing
retainer bolts located on each side of each lower control arm rear bushing.
NOTE: The bolts fastening the cradle crossmember
reinforcement are of three different thread sizes.
Note the location of the various sizes.
(6) Remove the bolts attaching the cradle crossmember reinforcement to the front suspension cradle
crossmember (Fig. 22). Remove the 2 bolts fastening
the reinforcement and rear of cradle crossmember to
the body of the vehicle. Remove the reinforcement.
(7) Remove the pivot bolt attaching the front bushing of the lower control arm to the front suspension
cradle crossmember.
(8) Remove the lower control arm.
DISASSEMBLY
DISASSEMBLY - LOWER CONTROL ARM (REAR BUSHING - STANDARD)
(1) Remove the lower control arm from the front
suspension cradle. (Refer to 2 - SUSPENSION/
FRONT/LOWER CONTROL ARM - REMOVAL)
(2) Mount the lower control arm in a vise without
using excessive clamping force.
Fig. 22 Cradle Crossmember Reinforcement
Attachment
1 - STEERING GEAR
2 - RIGHT LOWER CONTROL ARM
3 - LEFT LOWER CONTROL ARM
4 - CRADLE CROSSMEMBER REINFORCEMENT
5 - REAR CRADLE CROSSMEMBER ISOLATOR BUSHING
6 - STABILIZER BAR
7 - CRADLE CROSSMEMBER
(3) Using a sharp knife (such as a razor), slit the
bushing lengthwise (Fig. 23) to allow its removal
from the lower control arm (Fig. 23).
(4) Remove the bushing from the lower control
arm.
DISASSEMBLY - LOWER CONTROL ARM (REAR BUSHING - HYDRO)
(1) Remove the lower control arm from the front
suspension cradle. (Refer to 2 - SUSPENSION/
FRONT/LOWER CONTROL ARM - REMOVAL)
(2) Mount the lower control arm in a vise without
using excessive clamping force.
(3) Install Remover, Special Tool 8460, on hydrobushing as shown (Fig. 24). Removal Pin, Special
Tool 8460–3, must extend though hole in center of
bushing rear.
(4) Tighten forcing screw of Bridge (Special Tool
8460–1), removing bushing from lower control arm.
Page 55
2 - 14 FRONT SUSPENSION RS
LOWER CONTROL ARM (Continued)
SION/FRONT/LOWER BALL JOINT - DIAGNOSIS
AND TESTING)
ASSEMBLY
ASSEMBLY - LOWER CONTROL ARM (REAR BUSHING - STANDARD)
CAUTION: Do not apply grease or any other type of
lubricant other than the silicone lubricant specified
below to the control arm bushing.
(1) Apply Mopar Silicone Spray Lube or an equivalent, to the hole in lower control arm rear bushing.
Fig. 23 Slit Lower Control Arm Rear Bushing
1 - REAR BUSHING
2 - SLIT CUT IN BUSHING
3 - LOWER CONTROL ARM
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
when bushing is installed it is past the upset on the
end of the lower control arm (Fig. 25).
(3) The rear bushing of the lower control arm,
when correctly installed, is to be positioned on the
lower control arm as shown (Fig. 25).
Fig. 24 HYDRO-BUSHING REMOVAL
1 - REMOVAL PIN (8460-3)
2 - BRIDGE (8460-1)
3 - HYDRO-BUSHING
4 - LOWER CONTROL ARM
INSPECTION - 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.
Inspect both lower control arm isolator bushings
for severe deterioration, and replace as required.
Inspect the rear hydro-bushing for seepage. Both
type rear bushings are serviceable. If the front bushing fails, the lower control arm must be replaced.
Inspect and test the ball joint per the procedure
listed in Lower Ball Joint. (Refer to 2 - SUSPEN-
Fig. 25 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
(4) Install lower control arm on vehicle. (Refer to 2
- SUSPENSION/FRONT/LOWER CONTROL ARM INSTALLATION)
Page 56
RS FRONT SUSPENSION 2-15
LOWER CONTROL ARM (Continued)
ASSEMBLY - LOWER CONTROL ARM (REAR BUSHING - HYDRO)
CAUTION: Do not apply grease or any other type of
lubricant to the arm stem where the bushing is to
be mounted. Such action will reduce proper bushing adhesion to arm.
(1) Secure lower control arm in a vise.
NOTE: Hydro bushings and grooves on control arm
stems are unique for right and left sides. Left side
bushing master spline and control arm groove are
on the top (when mounted on vehicle). Right side
bushing master spline and control arm groove are
on the bottom (when mounted on vehicle).
(2) Align master spline on bushing inner sleeve
with groove on lower control arm rear bushing stem
(Fig. 26). Start bushing on stem by hand.
Fig. 27 HYDRO-BUSHING INSTALLATION
1 - LOWER CONTROL ARM FLANGE
2 - INSTALLER CUP (8460-2)
3 - BRIDGE (8460-1)
4 - HYDRO-BUSHING
Fig. 26 BUSHING MASTER SPLINE LINED UP WITH
GROOVE (RIGHT SIDE SHOWN)
1 - GROOVE
2 - HYDRO-BUSHING
3 - MASTER SPLINE
(3) Install Remover/Installer, Special Tool 8460,
over bushing and lower control arm as shown (Fig.
27). Engage flange on lower control arm with tips of
Bridge, Special Tool 8460–1 as shown (Fig. 27). The
contoured side of Installer Cup, Special Tool 8460–2,
should be fitted up against rear of the bushing.
(4) Begin to tighten forcing screw. As bushing
nears lower control arm flange, place Spacer Plate,
Special Tool 8460–4 between flange and bushing
inner sleeve, straddling the stem as shown (Fig. 28).
(5) Install bushing up against Spacer Plate, tightening the bridge forcing screw with a torque wrench
until approximately 50 N·m (37 ft. lbs.) torque is
reached. This will properly space bushing on the
stem in relation to the flange.
Fig. 28 SPACER PLATE POSITIONED
1 - SPACER PLATE (8460-4)
2 - LOWER CONTROL ARM FLANGE
3 - BRIDGE (8460-1)
4 - INSTALLER CUP (8460-2)
5 - HYDRO-BUSHING
(6) Back off the forcing screw and remove tool.
(7) Install lower control arm on vehicle. (Refer to 2
- SUSPENSION/FRONT/LOWER CONTROL ARM INSTALLATION)
INSTALLATION - LOWER CONTROL ARM
(1) Position lower control arm assembly into front
suspension cradle crossmember guiding bushings into
mounting position (Fig. 22).
(2) Install NEW pivot bolt attaching front bushing
of lower control arm to front suspension cradle crossmember (Fig. 29). Do not tighten or torque pivot
bolt at this time.
Page 57
2 - 16 FRONT SUSPENSION RS
LOWER CONTROL ARM (Continued)
Fig. 29 Lower Control Arm Bushing Pivot Bolt
Correctly Installed
1 - PIVOT BOLT
2 - LOWER CONTROL ARM
3 - FRONT SUSPENSION CRADLE CROSSMEMBER
(3) Install the reinforcement on the front suspension cradle crossmember and install the bolts attaching the reinforcement to the cradle crossmember
(Fig. 22). Tighten the M-14 size bolts to a torque of
153 N·m (113 ft. lbs.). Tighten the M-12 size bolts to
a torque of 106 N·m (78 ft. lbs.).
(4) Install the lower control arm rear bushing
retainer bolts through reinforcement on each side of
each lower control arm rear bushing. Tighten these
M-10 size bolts to a torque of 61 N·m (45 ft. lbs.).
(5) Install the two bolts and bushings attaching
the reinforcement and rear of cradle crossmember to
body of vehicle (Fig. 22). Tighten bolts to a torque of
163 N·m (120 ft. lbs.).
(6) Install the power steering cooler (Fig. 21).
Tighten bolts to a torque of 11 N·m (100 in. lbs.).
(7) Reinstall steering knuckle, brake rotor and caliper. (Refer to 2 - SUSPENSION/FRONT/KNUCKLE
- INSTALLATION)
CAUTION: When locating jack stands under lower
control arms, do not place the jack stands under
the ball joints (Fig. 30).
(8) Position jack stands under the lower control
arms as close to the ball joints as possible (Fig. 30).
Lower the vehicle onto the jack stands until the jack
stands are supporting the total weight of the vehicle.
(9) Tighten front lower control arm pivot bolt to a
torque of 183 N·m (135 ft. lbs.).
(10) Install the wheel and tire assembly. 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. 30 Jack Stands Supporting Vehicle Weight
1 - LOWER CONTROL ARMS
2 - BALL JOINT
3 - JACK STANDS
4 - BALL JOINT
(11) Raise vehicle, remove jack stands and lower
vehicle to the ground.
(12) Perform front wheel alignment as necessary.
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT STANDARD PROCEDURE)
STABILIZER BAR
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.
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.
Page 58
RS FRONT SUSPENSION 2-17
STABILIZER BAR (Continued)
REMOVAL
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCEDURE)
(2) Remove the bolts fastening the power steering
cooler to the front suspension cradle crossmember
reinforcement (Fig. 31).
Fig. 31 Power Steering Cooler
1 - CRADLE CROSSMEMBER REINFORCEMENT
2 - POWER STEERING COOLER
(3) Remove the lower control arm rear bushing
retainer bolts located on each side of each lower control arm rear bushing.
NOTE: The bolts fastening the cradle crossmember
reinforcement are of two different thread sizes. Note
the location of the various sizes.
(4) Remove the bolts attaching the cradle crossmember reinforcement to the front suspension cradle
crossmember (Fig. 32). Remove the 2 bolts fastening
the reinforcement and rear of cradle crossmember to
the body of the vehicle. Remove the reinforcement.
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. 33).
(5) Remove the stabilizer bar links from each end
of the stabilizer bar (Fig. 33). 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.
Fig. 32 Cradle Crossmember Reinforcement
Attachment
1 - STEERING GEAR
2 - RIGHT LOWER CONTROL ARM
3 - LEFT LOWER CONTROL ARM
4 - CRADLE CROSSMEMBER REINFORCEMENT
5 - REAR CRADLE CROSSMEMBER ISOLATOR BUSHING
6 - STABILIZER BAR
7 - CRADLE CROSSMEMBER
(6) Remove the stabilizer bar bushing (cushion)
retainers from the front suspension cradle crossmember (Fig. 34).
(7) Remove the stabilizer bar and bushings (cushions) as an assembly from the front suspension cradle crossmember.
INSPECTION
Inspect for broken or distorted stabilizer bar bushings (cushions), bushing retainers, and worn or damaged stabilizer bar links.
INSTALLATION
NOTE: Two different diameter stabilizer bars are
available for this vehicle. Therefore, two different
size bushings/cushions are also used. Use the correct bushing/cushion on the correct stabilizer bar.
Page 59
2 - 18 FRONT SUSPENSION RS
STABILIZER BAR (Continued)
cle with the square corner toward the ground,
when the stabilizer bar is installed on the vehicle (Fig. 35).
Fig. 33 Stabilizer Bar Link To Stabilizer Bar
Attachment
1 - RATCHET
2 - WRENCH
3 - STRUT
4 - STABILIZER BAR LINK
5 - NUT
6 - STABILIZER BAR
Fig. 35 Correctly Installed Stabilizer Bar To Cradle
Bushing
1 - SWAY BAR ISOLATOR BUSHING
2 - SLIT IN SWAY BAR BUSHING
3-SWAYBAR
(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. 36). Do not
tighten Stabilizer bar bushing retainers bolts at
this time.
Fig. 34 Front Stabilizer Bar Retainers
1 - STEERING GEAR
2 - STABILIZER BAR
3 - RAISED BEAD
4 - FRONT CRADLE CROSSMEMBER
5 - RETAINERS
(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 vehi-
Fig. 36 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
Page 60
RS FRONT SUSPENSION 2-19
STABILIZER BAR (Continued)
(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.
37).
Fig. 37 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
(4) Install the stabilizer bar link mounting stud
through the hole in each end of the stabilizer bar
(Fig. 33).
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. 33).
(9) Install the two bolts and bushings attaching
the reinforcement and rear of cradle crossmember to
body of vehicle (Fig. 32). Tighten bolts to a torque of
163 N·m (120 ft. lbs.).
(10) Install the power steering cooler (Fig. 31).
Tighten bolts to a torque of 11 N·m (100 in. lbs.).
(11) Lower the vehicle.
STRUT
DESCRIPTION - STRUT ASSEMBLY
A Macpherson type strut assembly is used in place
of a conventional front suspension’s upper control
arm and upper ball joint. The bottom of the strut
mounts directly to the steering knuckle using two
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 components listed
in the figure (Fig. 38).
Each component is serviced by removing the strut
assembly from the vehicle and disassembling it.
The coil springs are side-oriented. Springs on the
left side of the vehicle have a left-hand wind top-tobottom while springs on the right side have a righthand wind top-to-bottom. This helps provide better
vehicle stability during jounce and rebound maneuvers of the front suspension. Left and right springs
must not be interchanged. 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 are replaced with springs meeting the correct load rating and spring rate for the
vehicle and its specific options.
(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. 33). Tighten
each nut to a torque of 88 N·m (65 ft. lbs.).
(6) Tighten the stabilizer bar bushing retainer to
cradle attaching bolts (Fig. 34) to 68 N·m (50 ft. lbs.)
torque.
(7) Install the reinforcement on the front suspension cradle crossmember and install the bolts attaching the reinforcement to the cradle crossmember
(Fig. 32). Tighten the M-14 size bolts to a torque of
153 N·m (113 ft. lbs.). Tighten the M-12 size bolts to
a torque of 106 N·m (78 ft. lbs.).
(8) Install the lower control arm rear bushing
retainer bolts through reinforcement on each side of
each lower control arm rear bushing. Tighten these
M-10 size bolts to a torque of 61 N·m (45 ft. lbs.).
OPERATION - STRUT ASSEMBLY
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.
Page 61
2 - 20 FRONT SUSPENSION RS
STRUT (Continued)
Fig. 38 STRUT ASSEMBLY
1 - NUT 6 - COIL SPRING
2 - UPPER MOUNT 7 - DUST SHIELD
3 - PIVOT BEARING 8 - JOUNCE BUMPER
4 - UPPER SPRING SEAT 9 - LOWER SPRING ISOLATOR
5 - UPPER SPRING ISOLATOR 10 - STRUT (DAMPER)
DIAGNOSIS AND TESTING - STRUT ASSEMBLY
(1) Inspect for damaged or broken coil springs
(Fig. 38).
(2) Inspect for torn or damaged strut assembly
dust boots (Fig. 38).
(3) Inspect the coil spring isolator on the lower
spring seat for any signs of damage or deterioration.
(4) Lift dust boot (Fig. 39) 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 strut rod and strut shaft seal is not
unusual and does not affect performance of the strut
assembly (Fig. 39). Also inspect jounce bumpers for
signs of damage or deterioration.
Fig. 39 Strut Assembly Leakage Inspection (Typical)
REMOVAL - STRUT ASSEMBLY
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 - DUST BOOT
2 - STRUT SHAFT
3 - STRUT FLUID RESERVOIR
4 - INSPECT THIS AREA FOR EVIDENCE OF EXCESSIVE FLUID
LEAKAGE
(1) Raise the vehicle. See Hoisting in Lubrication
and Maintenance.
Page 62
RS FRONT SUSPENSION 2-21
STRUT (Continued)
(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. 40).
Fig. 41 Stabilizer Bar Link To Strut Attachment
1 - NUT
2 - STRUT
3 - STABILIZER BAR LINK
Fig. 40 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. 41).
(5) Remove the stabilizer bar link from the bracket
on the strut assembly (Fig. 41). To do so, place an
open-end wrench on the flat machined into the link’s
mounting stud, then remove the nut while holding
the wrench in place. Push the stud out of the
bracket.
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. 42).
(7) Remove the 3 nuts attaching the strut assembly upper mount to the strut tower (Fig. 43) and
remove the strut assembly from the vehicle.
(8) To disassemble the strut assembly, (Refer to 2 SUSPENSION/FRONT/STRUT - DISASSEMBLY).
Fig. 42 Strut Damper Attachment To Steering
Knuckle
1 - STRUT CLEVIS BRACKET
2 - ATTACHING BOLTS
3 - TIE ROD END
4 - ROTOR
5 - STEERING KNUCKLE
DISASSEMBLY - STRUT ASSEMBLY
The strut assembly must be removed from the
vehicle for it to be disassembled and assembled.
For the disassembly and assembly of the strut
assembly, use of Strut Spring Compressor, Pentastar
Service Equipment (PSE) tool W-7200, or the equivalent, is recommended to compress the coil spring.
Follow the manufacturer’s instructions closely.
Page 63
2 - 22 FRONT SUSPENSION RS
STRUT (Continued)
Fig. 43 Strut Assembly To Strut Tower Attaching
Nuts (Typical)
1 - WINDSHIELD WIPER MODULE
2 - STRUT TOWER
3 - STRUT MOUNT ATTACHING BOLTS
4 - UPPER STRUT MOUNT
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.
Fig. 44 Mount Rotated And Hooks Positioned
1 - UPPER MOUNT TURNED TOWARD COMPRESSOR
2 - COMPRESSOR UPPER HOOKS
3 - UPPER SPRING SEAT
(1) Position the strut assembly in the strut coil
spring compressor following the manufacturers
instructions. Position the lower hooks on the coil
spring first. The strut clevis bracket should be positioned straight outward from the compressor.
(2) Turn the upper mount of the strut assembly
toward the inside of the compressor as shown to
allow positioning of the compressor upper hooks (Fig.
44). Position the upper hooks on top of the coil spring
upper seat approximately 1 inch from outside diameter of seat (Fig. 47). Do not allow hooks to be
placed closer to edge. 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.
(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. 45). 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.
(5) Remove the upper mount from the strut shaft.
(6) If the 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.
Fig. 45 Retaining Nut Removal/Installation (Typical)
1 - UPPER MOUNT
2 - SPECIAL TOOL 6864
NOTE: If the coil spring or upper spring seat needs
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 with upper spring isolator.
(9) Remove the coil spring from the spring compressor.
Page 64
RS FRONT SUSPENSION 2-23
STRUT (Continued)
(10) Remove the dust shield and jounce bumper 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.
(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. 38).
(13) Inspect the strut assembly components (Fig.
38) for the following and replace as necessary:
• 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 stress cracks and wear.
• Check the upper spring isolator for severe dete-
rioration.
• 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 - STRUT ASSEMBLY
For the disassembly and assembly of the strut
assembly, use of Strut Spring Compressor, Pentastar
Service Equipment (PSE) tool W-7200, or the equivalent, is recommended to compress the coil spring.
Follow the manufacturer’s instructions closely.
Fig. 46 Spring Positioned In Compressor (Right
Spring Shown)
1 - COMPRESSOR LOWER HOOKS
2 - COIL SPRING END
(2) Install the upper seat and upper isolator on top
of the coil spring. Position the notch in the perimeter
of the upper seat toward the front of the compressor
(same 6 o’clock position as in step 1).
(3) Position the upper hooks on top of the coil
spring upper seat so the upper hooks span approximately 1 inch past outside diameter of upper seat
(Fig. 47). This will allow proper clearance for upper
mount installation without pinching the hooks in-between the two pieces. Do not allow hooks to be
placed closer to edge.
NOTE: Coil Springs on this vehicle are side-oriented. Springs on the left side of the vehicle have a
left-hand wind top-to-bottom while springs on the
right side have a right-hand wind top-to-bottom.
Left and right springs must not be interchanged.
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 lower
hooks following the manufacturers instructions.
Proper 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 compressor, are at the 6 o’clock position. Place the lower coil
spring end at the 12 o’clock position for left springs
and at the 6 o’clock position for right springs. (Fig.
46).
Fig. 47 Hook Placement On Upper Seat
1 - HOOKS POSITIONED 1 INCH FROM EDGE
2 - PIVOT BEARING AND UPPER SEAT
(4) Compress the coil spring far enough to allow
strut installation.
(5) If the pivot bearing has been removed from the
upper seat, install the pivot bearing on the top of the
Page 65
2 - 24 FRONT SUSPENSION RS
STRUT (Continued)
upper spring seat (Fig. 48). 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. 49 Coil Spring Positioning
1 - END OF LEFT COIL SPRING AT STRUT LOWER SEAT
2 - END OF RIGHT COIL SPRING AT STRUT LOWER SEAT
3 - LOWER SEATS OF STRUTS
4 - RIGHT STRUT CLEVIS BRACKET
5 - LEFT STRUT CLEVIS BRACKET
Fig. 48 Pivot Bearing Installation
1 - PIVOT BEARING
2 - UPPER SEAT
(6) Install the spring isolator on the lower spring
seat of the strut (Fig. 38).
(7) Install the jounce bumper on the strut shaft
(Fig. 38). The jounce bumper is to be installed with
the small end pointing downward.
(8) Install the dust shield 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. The jounce bumper will be
at the top of the inner dust boot. Return the dust
shield to its fully extended length.
(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). If necessary, reposition the strut or coil spring in the compressor so
the strut clevis bracket lines up with the lower coil
spring end as indicated in the figure (Fig. 49). Install
the clamp to hold the strut and coil spring together.
(10) Install the strut mount over the strut shaft
and onto the top of the pivot bearing and upper seat
as shown (Fig. 44). 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. 45). 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 100 N·m (75 ft.
lbs.).
NOTE: Before releasing the tension the compressor
has on the spring, using the following figure as reference (Fig. 50), make sure the upper spring seat,
coil spring and strut clevis bracket are all lined up
properly (within 5° of one another).
Fig. 50 Components Lined Up
1 - IMAGINARY VERTICAL LINE
2 - CLEVIS BRACKET
3 - END OF COIL SPRING (RIGHT SIDE ONLY)
4 - NOTCH IN UPPER SPRING SEAT
Page 66
RS FRONT SUSPENSION 2-25
STRUT (Continued)
(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 are 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. (Refer to
2 - SUSPENSION/FRONT/STRUT - INSTALLATION)
INSTALLATION - STRUT ASSEMBLY
CAUTION: Front strut coil springs are side-oriented.
When installing a strut assembly, make sure the
strut being installed has the correct coil spring for
that side of the vehicle. Springs on the left side of
the vehicle have a left-hand wind top-to-bottom
while springs on the right side have a right-hand
wind top-to-bottom (Fig. 49). Do not interchange the
two sides.
(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.
43). 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.
NOTE: The strut clevis-to-steering knuckle bolts are
installed differently on each side of the vehicle. Left
hand side bolts are to be installed from vehicle rear
to front. Right side bolts are to be installed from
vehicle front to rear.
(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. 42). 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. Tighten the
strut clevis-to-steering knuckle attaching bolts to a
torque of 81 N·m (60 ft. lbs.) plus an additional 1/4
(90°) turn after specified torque is met.
(3) Install the stabilizer bar link mounting stud
through the bracket on the strut assembly (Fig. 41).
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. 41).
(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. 41). 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. 40). 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.).
Page 67
2 - 26 REAR SUSPENSION RS
REAR SUSPENSION
TABLE OF CONTENTS
page page
REAR SUSPENSION
DESCRIPTION - REAR SUSPENSION .......26
SPECIFICATIONS
REAR SUSPENSION FASTENER TORQUE . . 28
SPECIAL TOOLS
REAR SUSPENSION ...................28
BUSHING - LEAF SPRING FRONT
REMOVAL .............................29
INSTALLATION .........................30
HUB / BEARING
DESCRIPTION .........................30
OPERATION ...........................30
DIAGNOSIS AND TESTING - HUB AND
BEARING ............................31
REMOVAL .............................31
INSTALLATION .........................33
JOUNCE BUMPER
DESCRIPTION .........................35
OPERATION ...........................35
REMOVAL
REMOVAL - AWD, HEAVY DUTY, CARGO . . . 36
REMOVAL - FRONT-WHEEL-DRIVE .......36
INSTALLATION
INSTALLATION - AWD, HEAVY DUTY,
CARGO .............................36
INSTALLATION - FRONT-WHEEL-DRIVE ....36
SHOCK ABSORBER
DESCRIPTION .........................36
OPERATION ...........................36
REMOVAL - SHOCK ABSORBER ...........36
DISASSEMBLY - SHOCK ABSORBER (UPPER
BUSHING) ...........................37
ASSEMBLY - SHOCK ABSORBER (UPPER
BUSHING) ...........................37
INSTALLATION - SHOCK ABSORBER ........38
SPRING - AWD
REMOVAL .............................38
INSTALLATION .........................39
SPRING - CARGO
REMOVAL .............................40
INSTALLATION .........................40
SPRING - FWD
REMOVAL .............................40
INSTALLATION .........................42
SPRING MOUNTS - FRONT
REMOVAL .............................42
INSTALLATION .........................43
SPRING MOUNTS - REAR
REMOVAL .............................43
INSTALLATION .........................43
SPRING SHACKLE
REMOVAL .............................44
INSTALLATION .........................44
STABILIZER BAR
DESCRIPTION .........................44
OPERATION ...........................44
REMOVAL
REMOVAL - AWD ......................44
REMOVAL - FWD .....................45
REMOVAL - FWD - FOLD-IN-FLOOR
SEATING ............................45
INSTALLATION
INSTALLATION - AWD ..................45
INSTALLATION - FWD ..................45
INSTALLATION - FWD - FOLD-IN-FLOOR
SEATING ............................45
TRACK BAR
DESCRIPTION .........................45
OPERATION ...........................46
REMOVAL .............................46
INSTALLATION .........................46
REAR SUSPENSION
DESCRIPTION - REAR SUSPENSION
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 four different rear suspension designs
available:
• Front-Wheel-Drive
• Front-Wheel-Drive with Fold-in-Floor Seating
• All-Wheel-Drive
• Front-Wheel-Drive Commercial
The Front-Wheel-Drive (FWD) rear suspension
uses an axle that is mounted to mono-leaf springs
using isolator bushings at the axle mounting brackets. The stabilizer bar mounts behind the axle.
Page 68
RS REAR SUSPENSION 2-27
REAR SUSPENSION (Continued)
Fig. 1 Front-Wheel-Drive Rear Suspension
1 - SHACKLE 7 - LEAF SPRING (MONO-LEAF)
2 - REAR MOUNT (HANGER) 8 - ISOLATOR
3 - TRACK BAR 9 - FWD REAR AXLE
4 - SPRING PLATE 10 - STABILIZER BAR LINKS
5 - ISOLATOR 11 - STABILIZER BAR
6 - FRONT MOUNT (HANGER)
pension except for the fact that the stabilizer bar
mounts in from of the axle.
The All-Wheel-Drive (AWD) rear suspension uses a
unique axle that is mounted to multi-leaf springs,
and does not use isolator bushings between the rear
axle and the leaf springs.
The Front-Wheel-Drive Cargo rear suspension uses
multi-leaf springs and a different rear axle than
either the standard FWD or AWD. It also does not
utilize a stabilizer bar. It is very similarly to the
AWD suspension.
The rear suspension consists of these major components:
• Leaf springs (One each side)
• Jounce bumpers (One each side)
• Shock absorbers (One each side)
Fig. 2 All-Wheel-Drive Rear Suspension
1 - SHACKLE
2 - REAR MOUNT (HANGER)
3 - LEAF SPRING (MULTI-LEAF)
4 - AWD REAR AXLE
• Hub and bearings (One each side)
• Track bar
• Stabilizer bar
The Front-Wheel-Drive with Fold-in-Floor Seating
rear suspension is very much like the FWD rear sus-
Page 69
2 - 28 REAR SUSPENSION RS
REAR SUSPENSION (Continued)
SPECIFICATIONS
REAR SUSPENSION FASTENER TORQUE
DESCRIPTION N·m
Hub And Bearing Mounting
Bolts
Hub And Bearing Axle Hub
Nut
Jounce Bumper Mounting
Bolt
Leaf Spring Front Mount-ToBody Bolts
Leaf Spring Front Pivot Bolt 156 115 —
Leaf Spring Plate-To-Axle
Bolts
Leaf Spring Rear Mount-To-
Body Bolts
Leaf Spring Shackle Plate
Nuts
Shock Absorber Mounting
Bolts
Stabilizer Bar Bushing
Retainer Bolts
Stabilizer Bar Link Nuts 61 45 —
Stabilizer Bar Link Frame
Bracket Mounting Bolts
Track Bar Bracket-To-Body
Mount Bolts
Track Bar Pivot Bolts 95 70 —
Wheel Mounting (Lug) Nut 135 100 —
129 95 —
244 180 —
33 24 290
61 45 —
95 70 —
61 45 —
61 45 —
88 65 —
61 45 —
61 45 —
61 45 —
Ft.
Lbs.
SPECIAL TOOLS
REAR SUSPENSION
In.
Lbs.
Remover, Hub/Bearing 8458
Remover/Installer, Bushing 8459
Remover/Installer, Bushing 8526
Press, Ball Joint C-4212F
Page 70
RS REAR SUSPENSION 2-29
BUSHING - LEAF SPRING FRONT
REMOVAL
(1) Raise vehicle on frame-contact hoist as follows:
(a) Position the hoist arm supporting the corner
of the vehicle to be serviced against a block of wood
placed on the body sill as shown (Fig. 3).
(b) Position the remaining hoist arms at each
corner of the vehicle in the normal fashion. (Refer
to LUBRICATION & MAINTENANCE/HOISTING
- STANDARD PROCEDURE)
(c) Raise the vehicle to a comfortable working
level.
be necessary to place a wooden block between the
spring and vehicle to hold forward end of the spring
in place.
(6) Remove leaf spring forward pivot bolt, then
remove mounting bracket.
(7) Straighten the retainer tabs on the bushing
(Fig. 4).
Fig. 4 Straightened Retaining Tabs
1 - SPRING EYE
2 - RETAINING TABS
Fig. 3 Lifting Point And Spring Mount
1 - BODY SILL AREA
2 - MOUNTING BOLTS
3 - SPRING MOUNTING BRACKET
4 - LEAF SPRING
5 - HOIST LIFT ARM
6 - WOODEN BLOCK
(2) Position an under-hoist utility jack or transmis-
sion jack under rear axle toward the side needing
bushing replacement. Jack pad should just contact
axle.
(3) Remove shock absorber lower mounting bolt.
NOTE: If shock absorber bolt deflects upward during removal, raise axle by adjusting support jack. If
shock absorber bolt deflects downward during
removal, lower axle by adjusting support jack (or by
pulling on axle).
(4) Remove four bolts securing leaf spring front
mounting bracket to the body (Fig. 3).
(5) Using jack, slowly lower rear axle, permitting
the forward end of rear spring to hang down. Lower
it enough to allow access to spring pivot bolt. It may
(8) Place Remover/Installer, Special Tool 8459 on
leaf spring and bushing as shown (Fig. 5) and tighten
Set Screw securing Remover Plate to tool threaded
shaft.
Fig. 5 Tool 8459 Mounted For Bushing Removal
1 - BUSHING
2 - BEARING
3 - WASHER
4 - NUT
5 - BODY (8459-1)
6 - PIN
7 - REMOVER PLATE (8459-2)
8 - SET SCREW
Page 71
2 - 30 REAR SUSPENSION RS
BUSHING - LEAF SPRING FRONT (Continued)
(9) Tighten nut (Fig. 5), removing bushing from
spring eye.
(10) Remove the tool from spring, then remove
bushing from tool.
INSTALLATION
(1) Install by hand NEW bushing in left side of
leaf spring eye.
(2) Place Remover/Installer, Special Tool 8459 on
leaf spring and bushing as shown (Fig. 6) and tighten
Set Screw securing Installer Plate (8459–3) to tool
threaded shaft.
(7) Install the nut on the pivot bolt and lightly
tighten. Do not fully tighten bolt at this time.
(8) Raise the under-hoist utility jack or transmission jack, guiding the forward mounting bracket into
place against the body. It may help to use a drift
punch placed through the hole centered between the
mounting bolt holes in the bracket and the pilot hole
in the body of the vehicle as a guide. When the four
mounting bolt holes line up with their threads in the
body, Install the mounting bolts (Fig. 3). Tighten the
four mounting bolts to 61 N·m (45 ft. lbs.) torque.
(9) Raise or lower the jack until shock absorber
lower eye aligns with threads in axle housing. Install
shock absorber lower mounting bolt. Do not fully
tighten bolt at this time.
(10) Lower the vehicle and remove hoist arms and
block of wood from under vehicle.
(11) Tighten the spring front pivot bolt to 156 N·m
(115 ft. lbs.) torque.
(12) Tighten the lower shock absorber mounting
bolt to 88 N·m (65 ft. lbs.) torque.
HUB / BEARING
Fig. 6 Tool 8459 Mounted For Bushing Installation
1 - NUT
2 - WASHER
3 - BEARING
4 - LEAF SPRING EYE
5 - BUSHING
6 - INSTALLER PLATE (8459-3)
7 - PIN
8 - BODY (8459-1)
(3) Tighten nut (Fig. 6), installing bushing in
spring eye. Tighten nut until there is approximately
a 1 mm gap between the bushing flange and the
spring eye. Do not bottom the flange against the
spring eye.
(4) Remove Remover/Installer from the bushing
and leaf spring.
(5) Bend the retainer tabs on bushing outward
against spring eye.
(6) Position spring mounting bracket over spring
eye and install pivot bolt through center of bushing
from the outboard side.
NOTE: The pivot bolt must be installed from the
outboard side to allow proper bracket to body
mounting.
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 (Unit III). 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 stub axle acceptance.
Front-Wheel-Drive vehicles with antilock brakes
have an internally mounted wheel speed sensor and
tone wheel. This hub and bearing can be identified
by the rounded cap and molded in connector on the
rear of the assembly (Fig. 7). The sensor and tone
wheel cannot be serviced separately from the hub
and bearing.
OPERATION
The hub and bearing has internal bearings that
allow the hub to rotate with the tire and wheel
assembly (and driveshaft on All-Wheel-Drive vehicles). The five wheel mounting studs mount the tire
and wheel assembly, and disc brake rotor or brake
drum to the vehicle.
On All-Wheel-Drive vehicles, the splined mating of
the driveshaft stub axle and hub allows the driveshaft to rotate with the hub and wheel.
Front-Wheel-Drive vehicles equipped with antilock
brakes have a wheel speed sensor and tone wheel
mounted to the rear of the hub and bearing. The tone
Page 72
RS REAR SUSPENSION 2-31
HUB / BEARING (Continued)
(b) Push up on metal retaining clip (Fig. 8) until
it bottoms. This will release wheel speed sensor
head from hub and bearing.
(c) While holding metal clip up, pull back on
wheel speed sensor head removing it from hub and
bearing.
Fig. 7 Hub And Bearing - FWD With ABS
wheel rotates with the hub which is sensed by the
wheel speed sensor.
DIAGNOSIS AND TESTING - HUB AND BEARING
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.
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 sometimes noticeable at lower speeds and at other times
is more noticeable at speeds above 105 km/h (65
mph).
REMOVAL
FRONT-WHEEL-DRIVE VEHICLES
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCEDURE)
(2) Remove wheel and tire. (Refer to 22 - TIRES/
WHEELS - REMOVAL)
(3) Remove brake drum or disc brake caliper and
rotor from hub and bearing. (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/DRUM - REMOVAL)(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
ROTOR - REMOVAL)
(4) If equipped with antilock brakes, perform the
following:
(a) Remove secondary (yellow) retaining clip at
rear of wheel speed sensor head (Fig. 8).
Fig. 8 Sensor Connector At Hub And Bearing
1 - SECONDARY SENSOR RETAINING CLIP
2 - METAL SENSOR RETAINING CLIP
3 - HUB AND BEARING
(5) Remove the 4 bolts attaching the hub and bear-
ing to the rear axle.
CAUTION: Corrosion may occur between the hub
and bearing, and the axle. If this occurs the hub
and bearing will be difficult to remove from the
axle. If the hub and bearing will not come out of the
axle by pulling on it by hand, do not pound on the
hub and bearing to remove it from the axle. Damage
will occur. Use the following procedure.
(6) If the hub and bearing cannot be removed from
the axle by hand, use Remover, Special Tool 8458
(Fig. 9) and the following procedure to press the hub
and bearing out of the axle.
(a) Remove the two outboard spring plate bolts.
(b) Thread Threaded Guide Pins into hub and
bearing mounting bolt holes.
(c) Using the spring plate bolts, install the
Screw Mount, Special Tool 8458–2, as shown (Fig.
9). Mount the Screw Mount to the spring plate
with the tool number facing the hub and bearing
and the beveled edge on the bottom facing the
spring, otherwise the Forcing Screw will rub the
spring plate when installed.
(d) Place Push Plate, Special Tool 8458–1, on
ends of Threaded Guide Pins
(e) Place a dab of grease in dimple of Push
Plate.
Page 73
2 - 32 REAR SUSPENSION RS
HUB / BEARING (Continued)
(9) Release the parking brake.
(10) Remove the disc brake caliper to adapter
guide pin bolts (Fig. 15).
(11) Remove rear caliper from adapter using the
following procedure. First rotate front of caliper up
from the adapter. Then pull the rear of the caliper
and the outboard brake shoe anti-rattle clip out from
under the rear abutment on the adapter (Fig. 14).
(12) Support caliper to prevent the weight of the
caliper from damaging the flexible brake hose (Fig.
10).
Fig. 9 Removal Using Special Tool 8458
1 - THREADED GUIDE PINS 8458-4
2 - HUB AND BEARING
3 - LEAF SPRING PLATE
4 - FORCING SCREW 8458-3
5 - SCREW MOUNT 8458-2
6 - PUSH PLATE 8458-1
(f) Install Forcing Screw, Special Tool 8458–3,
through Screw Mount from rear.
(g) Tighten the Forcing Screw up against dimple
in Push Plate and press hub and bearing out of
axle by continuing to tighten screw.
(h) Remove the tool.
(i) Reinstall the two outboard spring plate bolts.
Tighten the bolts to 102 N·m (75 ft. lbs.) torque.
(7) Remove the hub/bearing from the rear axle and
brake support plate.
ALL-WHEEL-DRIVE VEHICLES
(1) Set the parking brake. The parking brake is
set to keep the hub and bearing, and axle shaft
from rotating when loosening the hub nut.
(2) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCEDURE)
(3) Remove the wheel/tire assembly. (Refer to 22 -
TIRES/WHEELS - REMOVAL)
(4) Remove the cotter pin and nut retainer (Fig.
18) from the stub shaft of the outer C/V joint.
(5) Remove the spring washer (Fig. 17) from the
stub shaft of the outer C/V joint.
(6) Remove the hub nut and washer (Fig. 16) from
the stub shaft of the outer C/V joint.
(7) Remove the 6 bolts mounting the driveshaft
inner joint to the output shaft of the rear drive line
module.
(8) Remove the rear wheel speed sensor (Fig. 19)
from the rear hub/bearing.
Fig. 10 Correctly Supported Caliper
1 - WIRE
2 - CALIPER
3 - ADAPTER
4 - ROTOR
5 - INNER FENDER
(13) Remove the rotor from the hub/bearing.
Remove driveshaft from rear drive line module
(14)
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.
(15) Remove the hub/bearing to axle mounting
bolts (Fig. 13).
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.
Page 74
RS REAR SUSPENSION 2-33
HUB / BEARING (Continued)
(16) Remove the hub/bearing from the axle. (Fig.
12).
(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. 11). 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.
(a) If metal sensor retaining clip is not in the
neutral installed position on hub and bearing cap,
install from the bottom, if necessary, and push clip
upward until it snaps into position.
(b) Install wheel speed sensor head into rear of
hub and bearing aligning index tab with the notch
in the top of the mounting hole. Push the sensor in
until it snaps into place on the metal retaining
clip.
(c) Install secondary (yellow) retaining clip over
wheel speed sensor head and engage the tabs on
each side (Fig. 8).
(5) Install brake drum or disc brake rotor and
brake caliper. (Refer to 5 - BRAKES/HYDRAULIC/
MECHANICAL/DRUM - INSTALLATION)(Refer to 5
- BRAKES/HYDRAULIC/MECHANICAL/ROTOR INSTALLATION)
(6) Install wheel and tire (Refer to 22 - TIRES/
WHEELS - INSTALLATION). Tighten the wheel
nuts in the proper sequence to a torque of 135 N·m
(100 ft. lbs.).
(7) Adjust the rear brakes as necessary. (Refer to 5
- BRAKES/HYDRAULIC/MECHANICAL/BRAKE
PADS/SHOES - ADJUSTMENTS)
(8) Lower vehicle.
(9) Road test vehicle to ensure proper operation of
brakes.
Fig. 11 Hub/Bearing Removal From Caliper Adapter
1 - SPECIAL TOOL 8214-1
2 - PARK BRAKE CABLE
3 - DISC BRAKE CALIPER ADAPTER
4 - HUB/BEARING
INSTALLATION
FRONT-WHEEL-DRIVE VEHICLES
(1) Install the 4 hub and 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 and bearing with the 4
mounting bolts and start mounting bolts into hub
and bearing. Tighten the 4 bolts in a crisscross pattern until the hub and bearing and brake support
plate is fully and squarely seated onto flange of rear
axle. Tighten the 4 mounting bolts to a torque of 129
N·m (95 ft. lbs.)
NOTE: If equipped with antilock brakes, make sure
wheel speed sensor stays clean and dry as it is
installed into the hub and bearing cap.
(4) If the vehicle is equipped with antilock brakes,
perform the following:
ALL-WHEEL-DRIVE VEHICLES
(1) Install hub/bearing on end of axle. (Fig. 12).
Fig. 12 Hub/Bearing Removal And Installation
1 - PARK BRAKE BRAKE SHOE
2 - HUB/BEARING
3 - PARK BRAKE BRAKE SHOE
(2) Install the hub/bearing mounting bolts. In a
progressive crisscross pattern, tighten the 4 hub/
bearing mounting bolts (Fig. 13) until the disc brake
caliper adapter and hub/bearing are squarely seated
Page 75
2 - 34 REAR SUSPENSION RS
HUB / BEARING (Continued)
against the axle. Then tighten the hub/bearing
mounting bolts to a torque of 129 N·m (95 ft. lbs.).
Fig. 14 Removing/Installing Caliper (Left Side
Shown)
1 - LIFT THIS END OF CALIPER AWAY FROM ADAPTER FIRST
Fig. 13 Hub/Bearing Mounting Bolts
1 - HUB/BEARING
2 - AXLE
3 - MOUNTING BOLTS
4 - CALIPER ADAPTER
2 - DISC BRAKE CALIPER
3 - ADAPTER ABUTMENT
4 - OUTBOARD BRAKE SHOE HOLD DOWN CLIP
5 - OUTBOARD BRAKE SHOE
6 - ROTOR
7 - ADAPTER
(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.
(5) Carefully lower disc brake caliper and brake
shoes over rotor and onto caliper adapter by reversing the removal procedure (Fig. 14).
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. 15). Tighten the guide pin bolts to a torque of
35 N·m (26 ft. lbs.).
(7) Clean all foreign material off the threads of the
outer C/V joint stub shaft. Install the washer and
hub nut (Fig. 16) 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 to a torque of 61
N·m (45 ft. lbs.).
(12) Tighten the outer C/V joint hub nut (Fig. 16)
to a torque of 244 N·m (180 ft. lbs.).
Fig. 15 Caliper Guide Pin Bolts
1 - STUD PIN BOLTS
2 - DISC BRAKE CALIPER
3 - DRIVESHAFT
4 - AXLE
5 - DISC BRAKE CALIPER ADAPTER
(13) Install the spring washer (Fig. 17) on the stub
shaft of the outer C/V joint.
(14) Install the nut retainer and cotter pin (Fig.
18) 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. 19). Tighten the wheel speed sensor attaching bolt to a torque of 12 N·m (105 in. lbs).
(16) Install wheel and tire. (Refer to 22 - TIRES/
WHEELS - INSTALLATION)
Page 76
RS REAR SUSPENSION 2-35
HUB / BEARING (Continued)
Fig. 16 Hub Nut And Washer
1 - CALIPER
2 - HUB NUT
3 - WASHER
4 - ROTOR
5 - ADAPTER
Fig. 17 Spring Washer
1 - HUB NUT
2 - STUB SHAFT
3 - ROTOR
4 - SPRING WASHER
Fig. 18 Cotter Pin And Nut Retainer
1 - CALIPER
2 - COTTER PIN
3 - ROTOR
4 - NUT RETAINER
5 - OUTER C/V JOINT
Fig. 19 Wheel Speed Sensor
1 - MOUNTING BOLT
2 - WHEEL SPEED SENSOR
JOUNCE BUMPER
(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) Lower vehicle.
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.
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.
Page 77
2 - 36 REAR SUSPENSION RS
JOUNCE BUMPER (Continued)
REMOVAL
REMOVAL - AWD, HEAVY DUTY, CARGO
(1) Using slip-joint pliers grasp the base of the
jounce bumper. Turn the base counterclockwise (Fig.
20).
(2) Remove the jounce bumper from the frame rail.
Fig. 20 Jounce Bumper
1 - JOUNCE BUMPER
REMOVAL - FRONT-WHEEL-DRIVE
(1) Remove the bolt attaching the jounce bumper
to frame rail (Fig. 21).
(2) Remove the jounce bumper from the frame rail.
(2) Tighten the jounce bumper to 33 N·m (290 in.
lbs.) torque.
INSTALLATION - FRONT-WHEEL-DRIVE
(1) Hook the forward end of the jounce bumper
bracket in the mounting hole of the frame rail, then
install the mounting bolt in the opposite end, securing the bumper to the frame rail. Tighten the jounce
bumper mounting bolt to 33 N·m (290 in. lbs.) torque.
SHOCK ABSORBER
DESCRIPTION
There is one shock absorber on each side of the
rear suspension. The top of each shock absorber is
bolted to the frame rail. The bottom of each shock
absorber is bolted to the rear axle.
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.
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.
Fig. 21 Jounce Bumper - FWD
1-JOUNCE BUMPER
INSTALLATION
INSTALLATION - AWD, HEAVY DUTY, CARGO
(1) Install jounce bumper through bumper support
plate and thread into welded nut in frame rail.
REMOVAL - SHOCK ABSORBER
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCEDURE)
(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.
(3) Remove the shock absorber lower mounting
bolt.
Page 78
RS REAR SUSPENSION 2-37
SHOCK ABSORBER (Continued)
(4) While holding shock absorber, remove the
shock absorber upper mounting bolt and shock
absorber.
DISASSEMBLY - SHOCK ABSORBER (UPPER BUSHING)
NOTE: This procedure applies to load-leveling
shock absorbers only.
(1) Remove the shock absorber from the vehicle.
(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. 22).
Fig. 23 Removing Bushing From Shock Absorber
1 - SCREW DRIVE
2 - SHOCK ABSORBER
3 - NOTCH
(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. 24). Position the Driver this way
to seat the bushing to its correct depth.
Fig. 22 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. 22) 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. 23).
(4) Tighten the screw drive until the Driver contacts the outer circumference of the bushing evenly
(Fig. 23). 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 - SHOCK ABSORBER (UPPER BUSHING)
NOTE: This procedure applies to load-leveling
shock absorbers only.
Fig. 24 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. 25).
(3) Position the bushing between the shock
absorber eye and the Driver (Fig. 25). 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.
Page 79
2 - 38 REAR SUSPENSION RS
SHOCK ABSORBER (Continued)
Fig. 25 Installing Bushing In Shock Absorber
1 - BUSHING
2 - SCREW DRIVE
3 - SHOCK ABSORBER
4 - NOTCH
(6) Install the shock absorber on the vehicle. Refer
to REMOVAL AND INSTALLATION in this section
for the procedure.
INSTALLATION - SHOCK ABSORBER
(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.
(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 88 N·m (65 ft. lbs.).
Fig. 26 LIFTING POINT AND SPRING MOUNT
1 - BODY SILL AREA
2 - MOUNTING BOLTS
3 - SPRING MOUNTING BRACKET
4 - LEAF SPRING
5 - HOIST LIFT ARM
6 - WOODEN BLOCK
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).
(3) Begin removal of the shock absorber lower
mounting bolt (Fig. 27).
SPRING - AWD
REMOVAL
(1) Raise vehicle on frame-contact hoist as follows:
(a) Position the hoist arm supporting the corner
of the vehicle to be serviced against a block of wood
placed on the body sill as shown (Fig. 26).
(b) Position the remaining hoist arms at each
corner of the vehicle in the normal fashion. (Refer
to LUBRICATION & MAINTENANCE/HOISTING
- STANDARD PROCEDURE)
(c) Raise the vehicle to a comfortable working
level.
(2) Position an under-hoist utility jack or transmis-
sion jack under rear axle toward the side needing
spring replacement. Jack pad should just contact
axle.
Fig. 27 Rear Shock Absorber 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.
Page 80
RS REAR SUSPENSION 2-39
SPRING - AWD (Continued)
(5) Loosen and remove the axle plate bolts from
the rear axle (Fig. 28).
Fig. 28 Axle Plate Bolts
1 - LEAF SPRING
2 - AXLE PLATE BOLTS (4)
3 - AXLE PLATE
4 - AXLE
(6) Using the jack stands slowly lower the rear
axle, permitting the rear springs to hang free.
(7) Loosen and remove the 4 bolts at the front
mount of the rear leaf spring (Fig. 26).
(8) Loosen and remove the 2 bolts and the 2 pin
nuts from the spring shackle for the rear leaf spring
(Fig. 29). Then remove the inner half of the spring
shackle from the outer half hanger of the spring
hanger and the spring.
(10) Remove the leaf spring from the vehicle.
(11) Loosen and remove the pivot bolt from the
front mount of the rear leaf spring. (Fig. 30).
Fig. 30 Leaf Spring Front Mount (Typical)
1 - LEAF SPRING
2 - SPRING MOUNT
INSTALLATION
CAUTION: Pivot bolt must face inboard to prevent
structural damage during installation of spring.
(1) Install the front eyelet of the rear leaf spring
into the spring mount. 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 front spring
mount (Fig. 26). 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 shackle. Install the inner half of the
rear hanger. Install the pin nuts and bolts on the
rear shackle, 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 (Fig. 28). Tighten bolts
to 95 N·m (70 ft. lbs.) torque.
(6) Install shock absorber bolts. Do not tighten
at this time.
(7) Lower the vehicle and remove hoist arms and
block of wood from under vehicle.
Fig. 29 All-Wheel-Drive Rear Suspension
1 - SHACKLE
2 - REAR MOUNT (HANGER)
3 - LEAF SPRING (MULTI-LEAF)
4 - AWD REAR AXLE
(9) Remove the rear leaf spring from the outer half
of the spring shackle.
Page 81
2 - 40 REAR SUSPENSION RS
SPRING - AWD (Continued)
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.
(8) Tighten the spring front pivot bolt to 156 N·m
(115 ft. lbs.) torque.
(9) Tighten rear spring shackle pin nuts to 61 N·m
(45 ft. lbs.) torque.
(10) Tighten rear spring shackle inner to outer
half retaining bolts to 61 N·m (45 ft. lbs.) torque.
(11) Tighten the lower shock absorber mounting
bolt to 102 N·m (75 ft. lbs.) torque.
SPRING - CARGO
REMOVAL
(1) Raise vehicle on frame-contact hoist as follows:
(a) Position the hoist arm supporting the corner
of the vehicle to be serviced against a block of wood
placed on the body sill as shown (Fig. 26).
(b) Position the remaining hoist arms at each
corner of the vehicle in the normal fashion. (Refer
to LUBRICATION & MAINTENANCE/HOISTING
- STANDARD PROCEDURE)
(c) Raise the vehicle to a comfortable working
level.
(2) Position an under-hoist utility jack or transmis-
sion jack under rear axle toward the side needing
spring replacement. Jack pad should just contact
axle.
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).
(3) Begin removal of the shock absorber lower
mounting bolt (Fig. 27).
(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. 28).
(6) Using the jack stands slowly lower the rear
axle, permitting the rear springs to hang free.
(7) Loosen and remove the 4 bolts at the front
mount of the rear leaf spring (Fig. 26).
(8) Loosen and remove the nuts from the spring
hanger for the rear leaf spring (Fig. 35).
(9) Remove the hanger plate from the hanger and
remove the spring from the spring hanger (Fig. 35).
(10) Remove the leaf spring from the vehicle.
(11) Loosen and remove the pivot bolt from the
front mount of the rear leaf spring. (Fig. 30).
INSTALLATION
CAUTION: Pivot bolt must face inboard to prevent
structural damage during installation of spring.
(1) Install the front eyelet of the rear leaf spring
into the spring mount. 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 front spring
mount (Fig. 26). Tighten the 4 mounting bolts to a
torque of 61 N·m (45 ft. lbs.).
(3) Install rear of spring onto rear spring shackle.
Install shackle plate and nuts (Fig. 35). 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 (Fig. 28). Tighten bolts
to 95 N·m (70 ft. lbs.) torque.
(6) Install shock absorber bolts. Do not tighten
at this time.
(7) Lower the vehicle and remove hoist arms and
block of wood from under vehicle.
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.
(8) Tighten the spring front pivot bolt to 156 N·m
(115 ft. lbs.) torque.
(9) Tighten rear spring shackle pin nuts to 61 N·m
(45 ft. lbs.) torque.
(10) Tighten the lower shock absorber mounting
bolt to 102 N·m (75 ft. lbs.) torque.
SPRING - FWD
REMOVAL
(1) Raise vehicle on frame-contact hoist as follows:
(a) Position the hoist arm supporting the corner
of the vehicle to be serviced against a block of wood
placed on the body sill as shown (Fig. 31).
Page 82
RS REAR SUSPENSION 2-41
SPRING - FWD (Continued)
(b) Position the remaining hoist arms at each
corner of the vehicle in the normal fashion. (Refer
to LUBRICATION & MAINTENANCE/HOISTING
- STANDARD PROCEDURE)
(c) Raise the vehicle to a comfortable working
level.
Fig. 32 Rear Shock Mounting Bolt
1 - SHOCK BOLT
Fig. 31 Lifting Point And Spring Mount
1 - BODY SILL AREA
2 - MOUNTING BOLTS
3 - SPRING MOUNTING BRACKET
4 - LEAF SPRING
5 - HOIST LIFT ARM
6 - WOODEN BLOCK
(2) Position an under-hoist utility jack or transmis-
sion jack under rear axle toward the side needing
spring replacement. Jack pad should just contact
axle.
(3) Remove the shock absorber lower mounting
bolt (Fig. 32).
NOTE: If shock absorber bolt deflects upward during removal, raise axle by adjusting support jack. If
shock absorber bolt deflects downward during
removal, lower axle by adjusting support jack (or by
pulling on axle).
(4) 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 spring plate bolts from
the rear axle (Fig. 33).
(6) Remove the spring plate from the rear axle and
the leaf spring (Fig. 34).
(7) Using the jack stands slowly lower the rear
axle, permitting the rear springs to hang free.
(8) Loosen and remove the 4 bolts securing the
front mount of the leaf spring to the vehicle (Fig. 31).
Fig. 33 Spring Plate Bolts
1 - SPRING PLATE
Fig. 34 Spring Plate
1 - SPRING PLATE
Page 83
2 - 42 REAR SUSPENSION RS
SPRING - FWD (Continued)
(9) Loosen and remove the nuts from the spring
shackle (Fig. 35).
Fig. 36 Leaf Spring Locator Post
1 - LEAF SPRING ISOLATOR
Fig. 35 Rear Spring Hanger/Shackle
1 - SHACKLE PLATE
2 - SPRING HANGER
(10) Remove the shackle plate from the hanger
and remove the spring from the spring hanger (Fig.
35).
(11) Remove the leaf spring from the vehicle.
(12) Loosen and remove the pivot bolt from the
front mount of the rear leaf spring. Remove mount.
2 - LEAF SPRING
3 - LOCATOR POST
(11) Lower the vehicle and remove hoist arms and
block of wood from under vehicle.
(12) Tighten the spring front pivot bolt to 156 N·m
(115 ft. lbs.) torque.
(13) Tighten rear spring shackle pin nuts to 61
N·m (45 ft. lbs.) torque.
(14) Tighten the lower shock absorber mounting
bolt to 102 N·m (75 ft. lbs.) torque.
INSTALLATION
(1) Assemble front spring mount to front of spring
eye and install pivot bolt and nut. Do not tighten
at this time.
CAUTION: Pivot bolt must face inboard to prevent
structural damage during installation of spring.
(2) Raise front of spring and install four mounting
bolts (Fig. 31). Tighten bolts to 61 N·m (45 ft. lbs.)
torque.
(3) Install rear of spring onto rear spring shackle
(Fig. 35). Install shackle plate and nuts. Do not
tighten at this time.
(4) Verify lower leaf spring isolator is in position.
(5) Raise axle into correct position on leaf spring
with axle centered under spring locator post (Fig.
36).
(6) Verify that the leaf spring isolator is correctly
positioned in the spring plate.
(7) Install spring plate in position on the spring
(Fig. 33).
(8) Install spring plate bolts (Fig. 33). Tighten
bolts to 95 N·m (70 ft. lbs.) torque.
(9) Install lower shock absorber bolt. Do not
tighten at this time.
(10) Remove jack under axle.
SPRING MOUNTS - FRONT
REMOVAL
(1) Raise vehicle on frame-contact hoist as follows:
(a) Position the hoist arm supporting the corner
of the vehicle to be serviced against a block of wood
placed on the body sill as shown (Fig. 37).
(b) Position the remaining hoist arms at each
corner of the vehicle in the normal fashion. (Refer
to LUBRICATION & MAINTENANCE/HOISTING
- STANDARD PROCEDURE)
(c) Raise the vehicle to a comfortable working
level.
(2) Position an under-hoist utility jack or transmis-
sion jack under rear axle toward the side needing
bushing replacement. Jack pad should just contact
axle.
(3) Remove shock absorber lower mounting bolt.
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).
Page 84
RS REAR SUSPENSION 2-43
SPRING MOUNTS - FRONT (Continued)
(4) Raise or lower the jack until shock absorber
lower eye aligns with threads in axle housing. Install
shock absorber lower mounting bolt. Do not fully
tighten bolt at this time.
(5) Lower the vehicle and remove hoist arms and
block of wood from under vehicle.
(6) Tighten the spring front pivot bolt to 156 N·m
(115 ft. lbs.) torque.
(7) Tighten the lower shock absorber mounting
bolt to 88 N·m (65 ft. lbs.) torque.
SPRING MOUNTS - REAR
REMOVAL
(1) Remove the pin nuts securing the leaf spring
rear shackle halves (Fig. 38) (Fig. 39).
Fig. 37 LIFTING POINT AND SPRING MOUNT
1 - BODY SILL AREA
2 - MOUNTING BOLTS
3 - SPRING MOUNTING BRACKET
4 - LEAF SPRING
5 - HOIST LIFT ARM
6 - WOODEN BLOCK
(4) Remove four bolts securing leaf spring front
mounting bracket to the body (Fig. 37).
(5) Using jack, slowly lower rear axle, permitting
the forward end of rear spring to hang down. Lower
it enough to allow access to spring pivot bolt. It may
be necessary to place a wooden block between the
spring and vehicle to hold forward end of the spring
in place.
(6) Remove leaf spring forward pivot bolt, then
remove mounting bracket.
INSTALLATION
(1) Position spring mounting bracket over spring
eye and install pivot bolt through center of bushing
from the outboard side.
NOTE: The pivot bolt must be installed from the
outboard side to allow proper bracket to body
mounting.
(2) Install the nut on the pivot bolt and lightly
tighten. Do not fully tighten bolt at this time.
(3) Raise the under-hoist utility jack or transmission jack, guiding the forward mounting bracket into
place against the body. It may help to use a drift
punch placed through the hole centered between the
mounting bolt holes in the bracket and the pilot hole
in the body of the vehicle as a guide. When the four
mounting bolt holes line up with their threads in the
body, Install the mounting bolts (Fig. 37). Tighten the
four mounting bolts to 61 N·m (45 ft. lbs.) torque.
Fig. 38 Leaf Spring Shackle Nuts (FWD)
1 - SHACKLE PLATE
(2) Install a jack under the side of the axle having
the leaf spring mount removed. Using the jack, 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. 40).
(5) Lower the jack and the rear of the leaf spring.
(6) AWD only – Remove the retaining bolts fastening inner to outer halves of the leaf spring shackle
(Fig. 39).
(7) Remove the shackle from the leaf spring bushing and the spring rear mount.
INSTALLATION
(1) With the rear of the spring in the lowered position, install the spring shackle halves through the
leaf spring bushings and rear mount (Fig. 39).
Page 85
2 - 44 REAR SUSPENSION RS
SPRING MOUNTS - REAR (Continued)
(8) Lower the vehicle so that the full weight of the
vehicle is on all four tires (curb height).
CAUTION: AWD only – In order to avoid bending the
spring shackles, the shackle pin nuts must be tightened to the specified torque before the inboard-tooutboard shackle half bolts can be tightened.
(9) Tighten shackle mounting nuts to 61 N·m (45
ft. lbs.) torque.
(10) If equipped with AWD, tighten shackle-toshackle mounting bolts to 61 N·m (45 ft. lbs.) torque.
(11) Tighten shock absorber lower mounting bolt to
88 N·m (65 ft. lbs.) torque.
Fig. 39 All-Wheel-Drive Rear Suspension
1 - SHACKLE
2 - REAR MOUNT (HANGER)
3 - LEAF SPRING (MULTI-LEAF)
4 - AWD REAR AXLE
Fig. 40 Rear Spring Mount (Typical)
1 - LEAF SPRING MOUNT
(2) Install the shackle mounting nuts on the
hanger pins, but DO NOT TIGHTEN AT THIS
TIME.
(3) AWD only – Install, BUT DO NOT TIGHTEN,
retaining bolts fastening inner to outer halves of leaf
spring hanger at this time (Fig. 39).
(4) Using a jack, raise the leaf spring into
mounted position.
(5) Install the rear spring mount-to-body bolts
(Fig. 40). Tighten rear spring mount bolts to 61 N·m
(45 ft. lbs.) torque.
(6) Install the lower mounting bolt fastening the
shock absorber to the axle. DO NOT TIGHTEN THE
BOLT AT THIS TIME.
(7) Remove the jack from under axle.
SPRING SHACKLE
REMOVAL
(Refer to 2 - SUSPENSION/REAR/SPRING
MOUNTS - REMOVAL)
INSTALLATION
(Refer to 2 - SUSPENSION/REAR/SPRING
MOUNTS - INSTALLATION)
STABILIZER BAR
DESCRIPTION
Some front-wheel-drive models use a stabilizer bar.
It is mounted behind the rear axle. All-wheel-drive
models use a stabilizer bar that is mounted in front
of the rear axle.
The stabilizer bar interconnects both sides of the
rear axle and attaches to the rear frame rails using 2
rubber isolated link arms.
Both type stabilizer bars have the same basic components. Attachment to the rear axle tube, and rear
frame rails is through rubber-isolated bushings.
The 2 rubber isolated links 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.
REMOVAL
REMOVAL - AWD
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCEDURE)
Page 86
RS REAR SUSPENSION 2-45
STABILIZER BAR (Continued)
(2) Remove the bolts securing the stabilizer bar to
links on each end of the bar.
(3) While holding the stabilizer bar in place,
remove the bolts that attach the stabilizer bar bushing retainers to the rear axle.
(4) Remove the stabilizer bar from the vehicle.
(5) If the links need to be serviced, remove the
upper link arm to bracket bolt. Then remove link
arm from frame rail attaching bracket.
REMOVAL - FWD
(1) Raise vehicle. See Hoisting in Lubrication and
Maintenance.
(2) Remove the bolts securing the stabilizer bar to
links on each side of bar.
(3) While holding the stabilizer bar in place,
remove the bolts that attach the stabilizer bar bushing retainers to the rear axle.
(4) Remove the stabilizer bar from the vehicle.
REMOVAL - FWD - FOLD-IN-FLOOR SEATING
(1) Raise and support vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD
PROCEDURE)
(2) At each end of the stabilizer bar, remove the
nuts and bolts securing the bar to the links (Fig. 41).
INSTALLATION
INSTALLATION - AWD
(1) Install the stabilizer bar on the rear axle.
(2) Install bushing retainer bolts. Do not tighten at
this time.
(3) Install bolts connecting links to stabilizer bar.
Do not tighten at this time.
(4) Lower the vehicle so that the full weight of the
vehicle is on all four tires. With the vehicle at its
curb height, tighten the following bolts to the torques
listed:
• Stabilizer bar bushing retainer-to-axle bracket
bolts — 61 N·m (45 ft. lbs.)
• Stabilizer bar-to-link bolts — 61 N·m (45 ft. lbs.)
INSTALLATION - FWD
(1) Lift the stabilizer bar onto the rear axle and
install the two retainer mounting bolts. DO NOT
TIGHTEN.
(2) Install the bolts attaching the stabilizer bar
links to the stabilizer bar. DO NOT TIGHTEN.
(3) Lower the vehicle so that the full weight of the
vehicle is on all four tires. With the vehicle at its
curb height, tighten the following bolts to the torques
listed:
• Stabilizer bar bushing retainer-to-axle bracket
bolts — 61 N·m (45 ft. lbs.)
• Stabilizer bar-to-link — 61 N·m (45 ft. lbs.)
Fig. 41 Stabilizer Bar With Fold-In-Floor Seating
1 - LINK NUT
2 - LINK BOLTAND NUT
3 - STABILIZER LINK
4 - STABILIZER BAR
5 - REAR AXLE
6 - BOLTS
(3) While holding the stabilizer bar in place,
remove the bolts that attach the stabilizer bar bushing retainers to the rear axle (Fig. 41).
(4) Remove the stabilizer bar from the vehicle.
INSTALLATION - FWD - FOLD-IN-FLOOR SEATING
(1) Lift the stabilizer bar onto the rear axle, hooking the bottom of the bushing retainers on the axle,
then install the two retainer mounting bolts (Fig. 41).
DO NOT TIGHTEN AT THIS TIME.
(2) Install the bolts and nuts attaching the stabilizer bar links to the stabilizer bar (Fig. 41). DO NOT
TIGHTEN AT THIS TIME.
(3) Lower the vehicle so that the full weight of the
vehicle is on all four tires. With the vehicle at its
curb height, tighten the following bolts to the torques
listed:
• Stabilizer bar bushing retainer-to-axle bracket
bolts — 61 N·m (45 ft. lbs.)
• Stabilizer bar-to-link — 61 N·m (45 ft. lbs.)
TRACK BAR
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. 1).
The track bar connects the rear axle to the frame/
body of the vehicle. The track bar is isolated from the
Page 87
2 - 46 REAR SUSPENSION RS
TRACK BAR (Continued)
body of the vehicle by an isolator bushing located in
each end of the track bar.
OPERATION
The track bar prevents excessive side-to-side 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.
REMOVAL
(1) Remove the nut and bolt mounting the track
bar to the rear axle (Fig. 42).
(2) Remove the nut and bolt attaching the track
bar to the track bracket on the body of the vehicle
(Fig. 42). Remove the track bar.
INSTALLATION
(1) Install the track bar first into the body bracket
for the track bar (Fig. 42). Install the track bar
mounting bolt in the direction shown, then install
the nut. Do not tighten at this time.
(2) Install the track bar into its mounting bracket
on the rear axle (Fig. 42). Install the track bar
mounting bolt in the direction shown, then install
the nut. Do not tighten at this time.
(3) Lower the vehicle to the ground until the full
weight of the vehicle is supported by the wheels.
Tighten both track bar mounting bolts to 95 N·m (70
ft. lbs.) torque.
Fig. 42 Track Bar Mounting
1 - MOUNTING BOLT
2 - NUT
3 - NUT
4 - MOUNTING BOLT
5 - TRACK BAR
6 - REAR AXLE
7 - FRAME MOUNTED BRACKET
Page 88
RS WHEEL ALIGNMENT 2-47
WHEEL ALIGNMENT
TABLE OF CONTENTS
page page
WHEEL ALIGNMENT
DESCRIPTION - WHEEL ALIGNMENT .......47
DIAGNOSIS AND TESTING - SUSPENSION
AND STEERING ......................50
STANDARD PROCEDURE
STANDARD PROCEDURE - WHEEL
ALIGNMENT .........................52
WHEEL ALIGNMENT
DESCRIPTION - WHEEL ALIGNMENT
Vehicle wheel alignment is the positioning of all
interrelated front and rear suspension angles. These
angles affect the handling and steering of the vehicle
when it is in motion. Proper wheel alignment is
essential for efficient steering, good directional stability, and proper tire wear.
The method of checking a vehicle’s front and rear
wheel alignment varies depending on the manufacturer and type of equipment used. The manufacturer’s instructions should always be followed to ensure
accuracy of the alignment, except when
DaimlerChrysler Corporation’s wheel alignment specifications differ.
On this vehicle, the suspension angles that can be
adjusted are as follows:
• Front Camber (with camber bolt package and
standard procedure)
• Front Toe
Check the wheel alignment and make all wheel
alignment adjustments with the vehicle standing at
its proper curb height specification. Curb height is
the normal riding height of the vehicle. It is measured from a certain point on the vehicle to the
ground or a designated area while the vehicle is sitting on a flat, level surface. Refer to Curb Height
Measurement in this section for additional information.
Typical wheel alignment angles and measurements
are described in the following paragraphs.
STANDARD PROCEDURE - CURB HEIGHT
MEASUREMENT ......................55
SPECIFICATIONS
WHEEL ALIGNMENT ...................56
• Excessive positive camber will cause tread wear
on the outside of the tire.
CAMBER
Camber is the inward or outward tilt of the top of
the tire and wheel assembly (Fig. 1). Camber is measured in degrees of angle relative to a true vertical
line. Camber is a tire wearing angle.
• Excessive negative camber will cause tread wear
at the inside of the tire.
Fig. 1 Camber
1 - WHEELS TILTED OUT AT TOP
2 - WHEELS TILTED IN AT TOP
Page 89
2 - 48 WHEEL ALIGNMENT RS
WHEEL ALIGNMENT (Continued)
CROSS CAMBER
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
Caster is the forward or rearward tilt of the steering knuckle in reference to the position of the upper
and lower ball joints. Caster is measured in degrees
of angle relative to a true vertical center line. This
line is viewed from the side of the tire and wheel
assembly (Fig. 2).
• Forward tilt (upper ball joint ahead of lower)
results in a negative caster angle.
• Rearward tilt (upper ball joint trailing lower)
results in a positive caster angle.
Although caster does not affect tire wear, a caster
imbalance between the two front wheels may cause
the vehicle to lead to the side with the least positive
caster.
TOE
Toe is the inward or outward angle of the wheels
as viewed from above the vehicle (Fig. 3).
• Toe-in is produced when the front edges of the
wheels on the same axle are closer together than the
rear edges.
• Toe-out is produced when the front edges of the
wheels on the same axle are farther apart than the
rear edges.
Toe-in and toe-out can occur at the front wheels
and the rear wheels.
Toe is measured in degrees or inches. The measurement identifies the amount that the front of the
wheels point inward (toe-in) or outward (toe-out). Toe
is measured at the spindle height. Zero toe means
the front and rear edges of the wheels on the same
axle are equally distant.
Fig. 2 Caster
CROSS CASTER
Cross caster is the difference between left and
right caster.
Fig. 3 Toe
1 - TOE-IN
2 - TOE-OUT
Page 90
RS WHEEL ALIGNMENT 2-49
WHEEL ALIGNMENT (Continued)
TOE-OUT ON TURNS
Toe-out on turns is the relative positioning of the
front wheels while steering through a turn (Fig. 4).
This compensates for each front wheel’s turning
radius. As the vehicle encounters a turn, the outboard wheel must travel in a larger radius circle
than the inboard wheel. The steering system is
designed to make each wheel follow its particular
radius circle. To accomplish this, the front wheels
must progressively toe outward as the steering is
turned from center. This eliminates tire scrubbing
and undue tire wear when steering a vehicle through
a turn.
STEERING AXIS INCLINATION (S. A. I.)
Steering axis inclination is the angle between a
true vertical line starting at the center of the tire at
the road contact point and a line drawn through the
center of the upper ball joint (or strut) and the lower
ball joint (Fig. 5). S.A.I. is built into the vehicle and
is not an adjustable angle. If S.A.I. is not within
specifications, a bent or damaged suspension component may be the cause.
Fig. 4 Toe-Out On Turns
1 - TOE-OUT ON TURNS
DYNAMIC TOE PATTERN
Dynamic toe pattern is the inward and outward toe
movement of the front and rear tires through the
suspension’s jounce and rebound travel. As the vehicle’s suspension moves up and down, the toe pattern
varies. Toe pattern is critical in controlling the directional stability of the vehicle while in motion. Front
and rear dynamic toe pattern is preset by the factory
at the time the vehicle is assembled.
It is not necessary to check or adjust front or rear
dynamic toe pattern when doing a normal wheel
alignment. The only time dynamic toe pattern needs
to be checked or adjusted is if the frame of the vehicle has been damaged.
Fig. 5 S.A.I. and I.A.
1 - S.A.I.
2 - CAMBER
3 - I.A.
INCLUDED ANGLE (I. A.)
Included angle is the sum of the S.A.I. angle plus
or minus the camber angle, depending on whether or
not the wheel has positive or negative camber (Fig.
5). If camber is positive, add the camber angle to the
S.A.I. angle. If camber is negative, subtract the camber angle from the S.A.I. angle. Included angle is not
adjustable, but can be used to diagnose a frame misalignment or bent suspension component (spindle,
strut).
Page 91
2 - 50 WHEEL ALIGNMENT RS
WHEEL ALIGNMENT (Continued)
THRUST ANGLE
Thrust angle is the averaged direction the rear
wheels are pointing in relation to the vehicle’s center
line (Fig. 6). The presence of negative or positive
thrust angle causes the rear tires to track improperly
to the left or right of the front tires (dog tracking).
• Negative thrust angle means the rear tires are
tracking to the left of the front tires.
• Positive thrust angle means the rear tires are
tracking to the right of the front tires.
Improper tracking can cause undue tire wear, a
lead or pull and a crooked steering wheel. Excessive
thrust angle can usually be corrected by adjusting
the rear wheel toe so that each wheel has one-half of
the total toe measurement.
Fig. 6 Thrust Angle
DIAGNOSIS AND TESTING - SUSPENSION AND STEERING
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
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
Page 92
RS WHEEL ALIGNMENT 2-51
WHEEL ALIGNMENT (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
Front End Clunk Or Snap
On Turns
Front End Whine With
Vehicle Going Straight At A
Constant Speed
Front End Growl Or
Grinding With Vehicle
Going Straight At A
Constant Speed
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
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
7. Tighten strut attachment to specified
torque
specified torque
4. Replace transaxle gears or bearings
Front End Whine When
Accelerating Or
Decelerating
Front End Clunk When
Accelerating Or
Decelerating
Road Wander 1. Incorrect tire pressure 1. Inflate tires to recommended pressure
1. Worn or defective transaxle gears or
bearings
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
1. Replace transaxle gears or bearings
2. Replace transaxle gears or bearings
specified torque
6. Replace steering coupler
7. Replace strut bearing
Page 93
2 - 52 WHEEL ALIGNMENT RS
WHEEL ALIGNMENT (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
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
STANDARD PROCEDURE
STANDARD PROCEDURE - WHEEL ALIGNMENT
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 ensure proper
alignment.
(1) Verify that the fuel tank is full of fuel. If the
tank is not full, the reduction in weight will affect
the curb height of the vehicle and the alignment
angles.
(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. All tires must be
the same size and in good condition with approximately the same amount of tread wear. Inflate all
the tires to the recommended air pressure.
(4) Check the front wheel and tire assemblies for
excessive radial runout.
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
(5) Inspect lower ball joints and all steering linkage for looseness, binding, wear or damage. Repair as
necessary.
(6) Check suspension fasteners for proper torque
and retighten as necessary.
(7) Inspect all suspension component rubber bushings for signs of wear or deterioration. Replace any
faulty bushings or components before aligning the
vehicle.
(8) Check the vehicle’s curb height to verify it is
within specifications. Refer to Curb Height Measurement.
4. Correctly adjust power steering pump
drive belt
WHEEL ALIGNMENT SETUP
(1) Position the vehicle on an alignment rack.
(2) Install all required alignment equipment on
the vehicle per the alignment equipment manufacturer’s instructions. On this vehicle, a four-wheel alignment is recommended.
Page 94
RS WHEEL ALIGNMENT 2-53
WHEEL ALIGNMENT (Continued)
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.
(3) Read the vehicle’s current front and rear alignment settings. Compare the vehicle’s current alignment settings to the vehicle specifications for camber,
caster and toe-in. (Refer to 2 - SUSPENSION/
WHEEL ALIGNMENT - SPECIFICATIONS)
(4) 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.
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 support-
ing 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
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.
7)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
Fig. 7 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. 8).
Page 95
2 - 54 WHEEL ALIGNMENT RS
WHEEL ALIGNMENT (Continued)
(4) Using an appropriate grinder and grinding
wheel, slot the bottom hole in both sides of the strut
clevis bracket (Fig. 8).
Fig. 9 Package Bolts Correctly Installed
1 - STEERING KNUCKLE
Fig. 8 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
2 - FLANGED BOLT IN TOP HOLE
3 - CAM BOLT IN BOTTOM HOLE
4 - STRUT CLEVIS BRACKET
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.
NOTE: The strut clevis-to-knuckle bolts are installed
differently on each side of the vehicle. Left-handside bolts are installed from vehicle rear to front
(Fig. 9). Right-hand-side bolts are installed from
vehicle front to rear.
(5) Position the knuckle back into the strut clevis
bracket. Using the direction indicated in the above
note, install a flanged bolt from the service package
into the upper mounting hole. Using the direction
indicated in the above note, install a cam bolt into
the bottom mounting hole (Fig. 9).
(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. 10). 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.
(7) Repeat the procedure to the other side strut
clevis bracket.
(8) Reinstall both front tire and wheel assemblies
and tighten to specifications.
Fig. 10 Dog Bone Washer And Nuts Installed
1 - STEERING KNUCKLE
2 - DOG BONE WASHER
3 - STRUT CLEVIS BRACKET
4 - ATTACHING NUTS
(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.
11). 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 81 N·m
(60 ft. lbs.) plus an additional 1/4 (90°) turn after the
required torque is met.
Page 96
RS WHEEL ALIGNMENT 2-55
WHEEL ALIGNMENT (Continued)
Fig. 11 Camber Adjustment Cam Bolt
1 - STEERING KNUCKLE
2 - CLEVIS BRACKET CAM STOP AREAS
3 - LOWER ECCENTRIC CAMBER ADJUSTMENT BOLT
(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.
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. 12). Grasp inner tie rods at serrations and
rotate inner tie rods of steering gear (Fig. 12) to set
front toe to the preferred toe specification. (Refer to 2
- SUSPENSION/WHEEL ALIGNMENT - SPECIFICATIONS)
(3) Tighten tie rod jam nuts (Fig. 12) 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.
Fig. 12 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
STANDARD PROCEDURE - 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 charts.
Page 97
2 - 56 WHEEL ALIGNMENT RS
WHEEL ALIGNMENT (Continued)
CURB HEIGHT SPECIFICATIONS
VEHICLE FRONT REAR
CARGO VAN
ALL OTHERS
755mm±11mm
29.72 in. ± 0.43 in
755mm±11mm
29.72 in. ± 0.43 in
795mm±11mm
31.30 in. ± 0.43 in.
770mm±11mm
30.31 in. ± 0.43 in.
SPECIFICATIONS
WHEEL ALIGNMENT
NOTE: All specifications are given in degrees.
FRONT WHEEL ALIGNMENT PREFERRED SETTING ACCEPTABLE RANGE
CAMBER +0.10° -0.30° to +0.50°
Cross-Camber (Maximum side-to-side
difference)
CASTER* +2.31° +1.31° to +3.31°
Cross-Caster (Maximum side-to-side difference) 0.0° 1.00°
TOTAL TOE** +0.10° 20.10° 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°
TOTAL TOE* ** 0.0° 20.20° to +0.20°
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 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE)
0.0° 0.50°
Page 98
RS DIFFERENTIAL & DRIVELINE 3-1
DIFFERENTIAL & DRIVELINE
HALF SHAFT - FRONT
TABLE OF CONTENTS
page page
HALF SHAFT - FRONT
DESCRIPTION ..........................1
DIAGNOSIS AND TESTING - HALF SHAFT .....1
REMOVAL .............................2
INSTALLATION ..........................4
SPECIFICATIONS - HALF SHAFT - FRONT ....6
HALF SHAFT - FRONT
DESCRIPTION
All vehicles use an unequal length half shaft sys-
tem (Fig. 1).
The left half shaft uses a tuned rubber damper
weight. When replacing the left half shaft, be sure
the replacement half shaft has the same damper
weight as the original.
All half shaft assemblies use the same type of
inner and outer joints. The inner joint of both half
shaft assemblies is a tripod joint, and the outer joint
of both half shaft assemblies is a Rzeppa joint. Both
tripod joints and Rzeppa joints are true constant
velocity (CV) joint assemblies. The inner tripod joint
allows for the changes in half shaft length through
the jounce and rebound travel of the front suspension.
On vehicles equipped with ABS brakes, the outer
CV joint is equipped with a tone wheel used to determine vehicle speed for ABS brake operation.
The inner tripod joint of both half shafts 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 CV joint has a stub shaft that is
splined into the wheel hub and retained by a steel
hub nut.
CV BOOT - INNER
REMOVAL .............................6
INSTALLATION ..........................7
CV BOOT - OUTER
REMOVAL .............................10
INSTALLATION .........................11
DIAGNOSIS AND TESTING - HALF SHAFT
VEHICLE INSPECTION
(1) Check for grease in the vicinity of the inboard
tripod joint and outboard CV joint; this is a sign of
inner or outer joint seal boot or seal boot clamp damage.
NOISE AND/OR VIBRATION IN TURNS
A clicking noise and/or a vibration in turns could
be caused by one of the following conditions:
• Damaged outer CV 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.
• Noise may also be caused by another component
of the vehicle coming in contact with the half shafts.
CLUNKING NOISE DURING ACCELERATION
This noise may be a result of one of the following
conditions:
• A torn seal boot on the inner or outer joint of the
half shaft assembly.
• A loose or missing clamp on the inner or outer
joint of the half shaft assembly.
• A damaged or worn half shaft CV joint.
SHUDDER OR VIBRATION DURING ACCELERATION
This problem could be a result of:
• A worn or damaged half shaft inner tripod joint.
Page 99
3 - 2 HALF SHAFT - FRONT RS
HALF SHAFT - FRONT (Continued)
Fig. 1 Unequal Length Half Shaft System
1 - STUB AXLE 8 - OUTER C/V JOINT
2 - OUTER C/V JOINT 9 - RIGHT HALFSHAFT
3 - OUTER C/V JOINT BOOT 10 - INNER TRIPOD JOINT BOOT
4 - TUNED RUBBER DAMPER WEIGHT 11 - INNER TRIPOD JOINT
5 - INTERCONNECTING SHAFT 12 - INNER TRIPOD JOINT
6 - OUTER C/V JOINT BOOT 13 - INNER TRIPOD JOINT BOOT
7 - STUB AXLE 14 - INTERCONNECTING SHAFT LEFT HALFSHAFT
• A sticking tripod joint spider assembly (inner tri-
pod joint only).
• Improper wheel alignment. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE)
VIBRATION AT HIGHWAY SPEEDS
This problem could be a result of:
• Foreign material (mud, etc.) packed on the backside of the wheel(s).
• Out of balance tires or wheels. (Refer to 22 TIRES/WHEELS - STANDARD PROCEDURE)
• Improper tire and/or wheel runout. (Refer to 22 TIRES/WHEELS - DIAGNOSIS AND TESTING)
REMOVAL
(1) Raise vehicle.
(2) Remove the cotter pin, nut lock (Fig. 2) and
wave washer (Fig. 3) from the end of the half shaft.
(3) Remove the wheel and tire assembly from the
vehicle. (Refer to 22 - TIRES/WHEELS - REMOVAL)
CAUTION: The halfshaft outer CV Joint, when
installed, acts as a bolt and secures the hub/bearing assembly. If the vehicle is to be supported or
moved while the halfshaft is removed, it is neces-
1 - HUB/BEARING
2 - NUT LOCK
3 - COTTER PIN
4 - STUB AXLE
sary to install and properly torque a bolt through
the hub. This will ensure that the hub/bearing
assembly will not loosen.
Fig. 2 Half Shaft Retaining Nut
Page 100
RS HALF SHAFT - FRONT 3-3
HALF SHAFT - FRONT (Continued)
(7) Support disc brake caliper assembly by using a
wire hook and suspending it from the strut assembly
(Fig. 5). Do not allow the brake caliper assembly
to hang by the brake flex hose.
Fig. 3 Wave Washer
1 - HUB/BEARING ASSEMBLY
2 - WAVE WASHER
3 - STUB AXLE
(4) With the vehicle’s brakes applied to keep hub
from turning, loosen and remove the half shaft
nut.
(5) Remove the two front disc brake caliper
adapter to steering knuckle attaching bolts (Fig. 4).
Fig. 4 Front Brake Mounting
1 - BRAKE ROTOR
2 - HUB AND BEARING
3 - STEERING KNUCKLE
4 - ADAPTER MOUNTING BOLTS
5 - BRAKE CALIPER
6 - ADAPTER
7 - CLIP
(6) Remove the disc brake caliper assembly from
the steering knuckle. Caliper assembly is removed by
first rotating top of caliper assembly away from
steering knuckle and then removing bottom of assembly out from under machined abutment on steering
knuckle.
Fig. 5 Properly Supported Disc Brake Caliper -
Typical
1 - STEERING KNUCKLE
2 - BRAKE FLEX HOSE
3 - CALIPER ASSEMBLY
4 - WIRE HANGER
5 - STRUT ASSEMBLY
(8) Remove the brake rotor from the hub and bear-
ing assembly.
(9) Remove the steering knuckle-to-strut attach-
ment bolts (Fig. 6) from the steering knuckle.
Fig. 6 Strut To Steering Knuckle Attaching Bolts
1 - STRUT CLEVIS BRACKET
2 - NUTS AND BOLTS
3 - STEERING KNUCKLE
(10) Pull the steering knuckle from the strut clevis
bracket.
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