Chrysler ZH Crossfire (2004) Service Manual

8A
8B

8E

8F
8G
8H

8I
8J
8L

8M

8N
8O

8P

8Q
8R

8W

11
13
14
19
21
22
23
24
25

GROUP TAB LOCATOR

Introduction
Lubrication & Maintenance

0

Suspension

2

Differential & Driveline

3

Brakes

5

Clutch

6

Cooling

7

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

9

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

Service Manual Comment Forms (Rear of Manual)

ZH INTRODUCTION 1

INTRODUCTION

TABLE OF CONTENTS

page page

VEHICLE SAFETY CERT LABEL

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

VEHICLE IDENTIFICATION NUMBER

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

INTERNATIONAL SYMBOLS

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

FASTENER IDENTIFICATION

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

FASTENER USAGE

DESCRIPTION

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

METRIC SYSTEM

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

TORQUE REFERENCES

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

VECI LABEL

DESCRIPTION ..........................9

VEHICLE SAFETY CERT LABEL

DESCRIPTION

A vehicle safety certification label is attached to the rear shut­face of the driver’s door. 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.

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

2 INTRODUCTION ZH

VEHICLE IDENTIFICATION NUMBER

DESCRIPTION

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

CROSSFIRE VIN CODE BREAKDOWN

POSITION INTERPRETATION CODE = DESCRIPTION

1 Country of Origin 1 = Manufactured By DaimlerChrysler Corporation
2 Make C = Chrysler
3 Vehicle Type 3 = Passenger Car
4 Other K = Restraint System Front Air Bags Next Generation

(CGW) With Standard Side Air Bag Supplement (CGS)

5 Car Line N = Crossfire (LHD)

P = Crossfire (RHD)

6 Series 6 = “S” Series

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

E = 5 Speed Automatic (DGU)
7 Body Style 9 = Specialty Coupe
8 Engines L = 3.2L V6 SOHC 18 Valve
9 Check Digit See explanation in this section

10 Model Year 4 = Model Year
11 Plant X = Osnabrueck Germany

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

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.

ZH INTRODUCTION 3

FASTENER IDENTIFICATION (Continued)

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 WINDSCREEN 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

FASTENER IDENTIFICATION

DESCRIPTION

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

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

4 INTRODUCTION ZH

FASTENER IDENTIFICATION (Continued)

ZH INTRODUCTION 5

FASTENER IDENTIFICATION (Continued)

6 INTRODUCTION ZH

FASTENER USAGE

DESCRIPTION
FASTENER USAGE

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

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

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

THREADED HOLE REPAIR

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

METRIC SYSTEM

DESCRIPTION

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

CONVERSION FORMULAS AND EQUIVALENT VALUES

MULTIPLY BY TO GET MULTIPLY BY TO GET

in-lbs x 0.11298 = Newton Meters

(N·m)

ft-lbs x 1.3558 = Newton Meters

(N·m)
Inches Hg (60° F) x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg
psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches
Feet x 0.3048 = Meters (M) M x 3.281 = Feet
Yards x 0.9144 = Meters M x 1.0936 = Yards
mph x 1.6093 = Kilometers/Hr.

(Km/h)
Feet/Sec x 0.3048 = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec
mph x 0.4470 = Meters/Sec (M/S) M/S x 2.237 = mph
Kilometers/Hr. (Km/h) x 0.27778 = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr. (Km/h)

N·m x 8.851 = in-lbs

N·m x 0.7376 = ft-lbs

Km/h x 0.6214 = mph

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

ZH INTRODUCTION 7

METRIC SYSTEM (Continued)

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.).

8 INTRODUCTION ZH

TORQUE REFERENCES

DESCRIPTION

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

ZH INTRODUCTION 9

VECI LABEL

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.

ZH LUBRICATION & MAINTENANCE 0 - 1

LUBRICATION & MAINTENANCE

TABLE OF CONTENTS

page page

LUBRICATION & MAINTENANCE

SPECIFICATIONS - FLUID CAPACITIES .......1

FLUID TYPES

DESCRIPTION

ENGINE OIL AND LUBRICANTS ...........2

DESCRIPTION - HOAT COOLANT ..........4

DESCRIPTION - AUTOMATIC

TRANSMISSION FLUID ..................5

DESCRIPTION - DIFFERENTIAL

LUBRICANT...........................6

INTERNATIONAL SYMBOLS

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

FLUID FILL/CHECK LOCATIONS

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

LUBRICATION & MAINTENANCE

SPECIFICATIONS - FLUID CAPACITIES

FLUID CAPACITY

Automatic Transmission Fluid 8.0 L (8.5 qts.)

Brake System 0.5 L (0.5 qts.)

Cooling System 11.2 L (11.8 qts.)

Engine Oil W/ Filter 5.5 L (6.1 qts.)

Fuel 60.0 L (15.8 gal.)

Manual Transmission Fluid 1.5 L (1.6 qts.)

Power Steering 1.0 L (1.1 qts.)

Rear Axle 1.3 L (1.4 qts.)

TOWING

STANDARD PROCEDURE - TOWING .........6

JUMP STARTING

STANDARD PROCEDURE

JUMP STARTING ......................8

HOISTING

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

MAINTENANCE SCHEDULES

DESCRIPTION - FLEXIBLE SERVICE SYSTEM

(FSS) ...............................11

LUBRICATION POINTS

DESCRIPTION .........................14

EMERGENCY TOW HOOKS

DESCRIPTION .........................14

PARTS AND LUBRICANT RECOMMENDATIONS

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

AUTOMATIC TRANSMISSION FLUID

Use ShellT 3403 automatic transmission fluid or equavalent.

ENGINE COOLANT

The green and the orange engine coolant MUST NOT BE MIXED.

0 - 2 LUBRICATION & MAINTENANCE ZH

FUEL

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

FLUID CHECK/FILL POINTS AND LUBRICATION LOCATIONS

The fluid check/fill points and lubrication locations are located in each applicable Sections.

FLUID TYPES

DESCRIPTION
ENGINE OIL AND LUBRICANTS

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

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

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

• Society of Automotive Engineers (SAE)

• American Petroleum Institute (API)

• National Lubricating Grease Institute (NLGI)

API SERVICE GRADE CERTIFIED

Use an engine oil that is API Certified. MOPART provides engine oils, that meet or exceed this requirement.

SAE VISCOSITY

An SAE viscosity grade is used to specify the viscosity of
engine oil. Use only engine oils with multiple viscosities such
as 5W-30 or 10W-30. These are specified with a dual SAE vis­cosity grade which indicates the cold-to-hot temperature vis­cosity range. Select an engine oil that is best suited to your
particular temperature range and variation.

ENERGY CONSERVING OIL

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

ZH LUBRICATION & MAINTENANCE 0 - 3

CONTAINER IDENTIFICATION

Standard engine oil identification notations have been adopted
to aid in the proper selection of engine oil. The identifying
notations are located on the front label of engine oil plastic
bottles and the top of engine oil cans.

This symbol means that the oil has been certified by the Amer­ican Petroleum Institute (API). DiamlerChrysler only recom­mend API Certified engine oils. Use MoparT engine oil or
equivalent.

GEAR 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 on the label. At
the bottom of the NLGI symbol is the usage and quality iden­tification letters. Wheel bearing lubricant is identified by the let­ter “G”. Chassis lubricant is identified by the letter “L”. The
letter following the usage letter indicates the quality of the
lubricant. The following symbols indicate the highest quality.

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.

0 - 4 LUBRICATION & MAINTENANCE ZH

DESCRIPTION - HOAT COOLANT

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

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

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

The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection.
MoparT Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene-glycol base coolant
with 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.

CAUTION: MoparT Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any
other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT), may result in
engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protec­tion.

COOLANT PERFORMANCE

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

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

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

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

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

ZH LUBRICATION & MAINTENANCE 0 - 5

COOLANT SELECTION AND ADDITIVES

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

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

DESCRIPTION - AUTOMATIC TRANSMISSION FLUID

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

Note: For fluid level checking procedures, Refer to Page 21-294 .

TRANSMISSION FLUID

ShellT 3403 Automatic Transmission Fluid (ATF) 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. 3403 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.

0 - 6 LUBRICATION & MAINTENANCE ZH

DESCRIPTION - DIFFERENTIAL LUBRICANT

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

INTERNATIONAL SYMBOLS

DESCRIPTION

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

FLUID FILL/CHECK LOCATIONS

DESCRIPTION

The fluid fill/check point locations are located in each applicable service manual section.

TOWING

STANDARD PROCEDURE - TOWING

WARNINGS AND PRECAUTIONS

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

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

ZH LUBRICATION & MAINTENANCE 0 - 7

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

TOWING RECOMMENDATIONS

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

GROUND CLEARANCE

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

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

0 - 8 LUBRICATION & MAINTENANCE ZH

JUMP STARTING

STANDARD PROCEDURE
JUMP STARTING

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

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

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

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

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

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

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

TO JUMP START A DISABLED VEHICLE:

WARNING: SHIELD EYES AND FACE FROM BATTERIES AT ALL TIMES

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

1. Raise hood on disabled vehicle and visually inspect engine compartment for:

• Battery cable clamp condition, clean if necessary.

• Frozen battery.

• Yellow or bright color test indicator, if equipped.

• Low battery fluid level.

• Generator drive belt condition and tension.

• Fuel fumes or leakage, correct if necessary.

ZH LUBRICATION & MAINTENANCE 0 - 9

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

3. On disabled vehicle, place gear selector in park or neutral
and set park brake. Turn off all accessories.

4. Connect positive jumper cable to positive (+) terminal of the
disabled battery.

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

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

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

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

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

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

DISCONNECT CABLE CLAMPS AS FOLLOWS:

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

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

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

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

0 - 10 LUBRICATION & MAINTENANCE ZH

HOISTING

STANDARD PROCEDURE - HOISTING

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

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

The vehicle can be lifted with:

• A twin-post, chassis hoist.

• A ramp-type, drive-on hoist.

FLOOR JACK

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

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

• An axle shaft.

• A body side sill.

• A steering linkage component.

• A drive shaft.

• The engine or transmission oil pan.

• A front suspension arm.

ZH LUBRICATION & MAINTENANCE 0 - 11

MAINTENANCE SCHEDULES

DESCRIPTION - FLEXIBLE SERVICE SYSTEM (FSS)

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

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

• The four wheel speed sensors from the CAB.

• Coolant temperature from the PCM.

• Engine speed from the PCM.

• Load torque from the PCM.

TRIP ODOMETER, FSS INDICATOR

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

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

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

MAIN ODOMETER

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

0 - 12 LUBRICATION & MAINTENANCE ZH

This symbol represents Service A.

The second symbol represents Service B.

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

ZH LUBRICATION & MAINTENANCE 0 - 13

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

The counter can also be reset by any individual after the indi­cated service has been performed. To do so:

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

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

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

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

After approximately ten seconds, a tone sounds and the display shows 6,000 miles (10,000 km) for approximately
ten seconds.

5. Release the knob/button to the left of the display.

If the FSS counter was inadvertently reset, the counter must be reset.
The message is displayed for approximately ten seconds when turning the key to the ON/RUN position, or while

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

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

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

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

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

0 - 14 LUBRICATION & MAINTENANCE ZH

LUBRICATION POINTS

DESCRIPTION

Lubrication point locations are located in each applicable Section.

EMERGENCY TOW HOOKS

DESCRIPTION

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

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

ZH SUSPENSION 2 - 1

SUSPENSION

TABLE OF CONTENTS

page page

SUSPENSION

DIAGNOSIS AND TESTING - SUSPENSION

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

SPECIAL TOOLS

SUSPENSION .........................2

WHEEL ALIGNMENT ......................4

FRONT SUSPENSION .....................14

REAR SUSPENSION ......................48

SUSPENSION

DIAGNOSIS AND TESTING - SUSPENSION AND STEERING SYSTEM

CONDITION POSSIBLE CAUSES CORRECTION

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

2. Loose or worn steering or
suspension components.

EXCESSIVE PLAY IN
STEERING

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

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

2. Loose or worn steering or
suspension components.

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

2. Tighten or replace components as
necessary.

2. Tighten or replace components as
necessary.

2. Loose or worn steering or
suspension components.

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

4. Alignment. 4. Align vehicle to specifications.

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

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

2. Loose or worn steering or
suspension components.

3. Tire pressure. 3. Adjust tire pressure.

4. Alignment. 4. Align vehicle to specifications.

EXCESSIVE STEERING
EFFORT

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

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

3. Column coupler binding. 3. Replace coupler.

4. Tire pressure. 4. Adjust tire pressure.

5. Alignment. 5. Align vehicle to specifications.

2. Tighten or replace components as
necessary.

2. Tighten or replace components as
necessary.

2 - 2 SUSPENSION ZH

CONDITION POSSIBLE CAUSES CORRECTION

VEHICLE PULLS TO ONE
SIDE DURING BRAKING

VEHICLE LEADS OR
DRIFTS FROM STRAIGHT
AHEAD DIRECTION ON
UNCROWNED ROAD

KNOCKING, RATTLING
OR SQUEAKING

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

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

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

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

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

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

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

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

5. Wheel Alignment. 5. Align vehicle.

6. Loose or worn steering or
suspension components.

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

1. Worn shock bushings. 1. Replace shock.

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

3. Worn shock valve. 3. Replace shock.

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

6. Repair as necessary.

2. Inspect, tighten or replace components
as necessary.

necessary.

2. Inspect, tighten or replace components
as necessary.

SPECIAL TOOLS
SUSPENSION

C-3894–A Tie Rod Puller

9150 Rear Spring Compressor

ZH SUSPENSION 2 - 3

9150 Rear Spring Compressor

9152 Spring Compressor Plates

9168 Ball Joint Puller

9199 Bearing Tool

2 - 4 WHEEL ALIGNMENT ZH

WHEEL ALIGNMENT

TABLE OF CONTENTS

page page

WHEEL ALIGNMENT

DESCRIPTION ..........................4

OPERATION ............................5

STANDARD PROCEDURE

STANDARD PROCEDURE - WHEEL

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

STANDARD PROCEDURE - CHASSIS

ALIGNMENT INSPECTION ................7

INSPECTING AND ADJUSTING VEHICLE

LEVEL AT FRONT AND REAR AXLES .......8

INSPECTING AND ADJUSTING VEHICLE

LEVEL AT FRONT AND REAR AXLES

WITH AN ELECTRONIC INCLINOMETER.....8

CHECKING AND ADJUSTING FRONT AXLE

CAMBER AND CASTER..................8

STANDARD PROCEDURE - CHECKING AND

ADJUSTING FRONT TOE-IN .............10

STANDARD PROCEDURE - CHECKING

TOE-OUT ON TURNS...................11

STANDARD PROCEDURE - CHECKING

REAR AXLE CAMBER ..................11

STANDARD PROCEDURE - CHECKING AND

ADJUSTING REAR AXLE TOE ............12

SPECIFICATIONS

SPECIFICATIONS - WHEEL ALIGNMENT ....13

SPECIFICATIONS - SUSPENSION .........13

WHEEL ALIGNMENT

DESCRIPTION

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

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

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

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

ZH WHEEL ALIGNMENT 2 - 5

OPERATION

CASTER

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

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

CAMBER

Is the inward or outward tilt of the wheel relative to the center
of the vehicle. Tilting the top of the wheel inward provides neg­ative camber (NEG.). Tilting the top of the wheel outward pro­vides positive camber (POS.). Incorrect camber will cause
wear on the inside or outside edge of the tire.

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

2 - 6 WHEEL ALIGNMENT ZH

WHEEL TOE POSITION

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

• Negative Toe (Toe Out) B > A.

• Positive Toe (Toe In) B < A.

TOE-OUT ON TURNS

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

STEERING AXIS INCLINATION ANGLE

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

STANDARD PROCEDURE
STANDARD PROCEDURE - WHEEL ALIGNMENT INSPECTION

1. Inspect the overall condition of the vehicle.

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

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

3. Inspect the tire condition.

ZH WHEEL ALIGNMENT 2 - 7

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

4. Inspect the wheel condition

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

5. Inspect the tire pressure.

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

6. Inspect the underside of the vehicle.

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

7. Inspect the wheel bearing play.

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

8. Inspecting the condition of the steering mechanism.

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

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

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

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

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

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

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

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

STANDARD PROCEDURE - CHASSIS ALIGNMENT INSPECTION

1. Observe the general information on chassis alignment inspection. Refer to Page 2-6.

2. Drive the vehicle onto an electronic measuring system.

3. Unlock the turntables and the sliding platforms.

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

5. Attach the wheel sensors.

6. Perform the initial measurement process.

7. Inspect the vehicle level at the front and the rear axles and adjust if necessary. Refer to Page 2-6.

8. Inspect the vehicle level at the front and the rear axles with an electronic inclinometerand adjust if necessary.
Refer to Page 2-6.

9. Inspect and adjust the rear axle toe. Refer to Page 2-6.

10. Inspect and adjust the front axle camber and caster. Refer to Page 2-6.

11. Inspect the rear axle camber. Refer to Page 2-6.

12. Inspect and adjust the front axle toe. Refer to Page 2-6.

13. Perform the final measurement of the vehicle.

14. Detach the sensors.

15. Remove the brake pedal winch.

16. Carefully drive the vehicle off the measuring system.

17. Lock the turntables.

2 - 8 WHEEL ALIGNMENT ZH

INSPECTING AND ADJUSTING VEHICLE LEVEL AT FRONT AND REAR AXLES

1. Observe the general information on chassis alignment inspection. Refer to Page 2-6.

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

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

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

level, viewed from the center of the vehicle. Refer to Page 2-6.

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

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

2. Position contact arm on the rear axle shaft and read off the plumb value of the vehicle level, viewed from
the center of the vehicle. Refer to Page 2-6.

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

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

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

1. Observe the general information on chassis alignment inspection. Refer to Page 2-6.

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

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

Note: Remove any metal shavings on the measuring plate.

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

3. Inspect the vehicle level at the front axle via control arm inclination. Refer to Page 2-6.

4. Inspect the vehicle level at the rear axle via the rear axle shaft inclination. Refer to Page 2-6.

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

• Adjust the vehicle level by changing the springs or the spring rubber mounts. Refer to Page 2-6.

CHECKING AND ADJUSTING FRONT AXLE CAMBER AND CASTER

CHECKING

1. Observe the general information on chassis alignment check. Refer to Page 2-6.

2. Check the vehicle level at the front and rear axles. Refer to Page 2-6.

3. Check the vehicle level at the front and rear axles with an electronic clinometer and adjust if necessary. Refer to
Page 2-6.

4. Check the camber and assign to tabular value. Refer to Page 2-13.

Note: Measure with the wheels turned to 20°.

5. Check the caster and assign to tabular value. Refer to Page 2-13.

ADJUSTING

1. Raise and support the vehicle.

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

ZH WHEEL ALIGNMENT 2 - 9

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

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

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

Note: Inspect for prior installation of the alignment bolt.

3. For camber, compress the front spring (1). Refer to Page
2-42.

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

5. Release the front spring (1).

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

Note: Inspect for prior installation of the alignment bolt.

7. For caster, compress the front spring (2). Refer to Page
2-42.

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

9. Release the front spring (2).

10. Lower the vehicle and settle the suspension by pulling and

pushing firmly several times.

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

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

• Vehicle level at the front axle. Refer to Page 2-6.

• With an electronic inclinometer. Refer to Page 2-6.

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

2 - 10 WHEEL ALIGNMENT ZH

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

13. Adjust the rear axle toe. Refer to Page 2-6.

14. Adjust the front axle toe. Refer to Page 2-6.

STANDARD PROCEDURE - CHECKING AND ADJUSTING FRONT TOE-IN

1. Set the steering wheel in the center position.

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

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

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

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

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

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

• Negative Toe (Toe Out) B > A.

• Positive Toe (Toe In) B < A.

ZH WHEEL ALIGNMENT 2 - 11

STANDARD PROCEDURE - CHECKING TOE-OUT ON TURNS

1. Check and adjust the toe-in at the front axle. Refer to Page 2-6.

2. Check the toe-out on turns. To check steering geometry measure toe-out on turns. This is the difference in the
wheel angle between the wheel on the outside of a curve and the wheel on the inside of a curve when the wheel
on the inside of the curve is turned 20°. Greater deviations may be caused as follows whereby it is assumed that
camber and caster are adjusted correctly: Refer to Page 2-6.

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

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

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

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

STANDARD PROCEDURE - CHECKING REAR AXLE CAMBER

1. Check the vehicle level at the front and rear axles and adjust if necessary. Refer to Page 2-6.

2. Check the vehicle level at the front and rear axles with an electronic inclinometer and adjust if necessary. Refer
to Page 2-6.

2 - 12 WHEEL ALIGNMENT ZH

3. Check the rear axle camber. (POS+) = Positive Camber,
(NEG-) = Negative Camber. The camber on the rear axle is
not adjustable. If a substantial deviations in the rear axle
camber are found, the cause may be one of the following:
Refer to Page 2-13.

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

• Camber strut bent.

• Accident damage to the frame floor. Level differences

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

STANDARD PROCEDURE - CHECKING AND ADJUSTING REAR AXLE TOE

1. Check the vehicle level at the front and rear axles and adjust if necessary. Refer to Page 2-6.

2. Check the vehicle level at the front and rear axles with an electronic inclinometer and adjust if necessary. Refer
to Page 2-6.

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

ZH WHEEL ALIGNMENT 2 - 13

SPECIFICATIONS

SPECIFICATIONS - WHEEL ALIGNMENT

DESCRIPTION SPECIFICATION

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

Vehicle level - rear axle 0.4° (±0.8)

Ball point position 30,5±2 mm

Front axle toe-in 0° 20’±10’

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

steered through 20°

Total rear axle toe 0 ° 33’±7’

ALIGNMENT SPECIFICATIONS

Front Axle Toe 2.5°

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

Front Caster 5° 12’ (5.20°)

Rear Camber -1° 08’ (-1.13°)

Permissible difference in front axle camber between

right and left side of vehicle

-1° 25’±30’

20’

SPECIFICATIONS - SUSPENSION

TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Steering idler arm to bearing

bushing

Repair Nut 120 88.5 1060

Lock Nut 50 37 443

Cam bolt, rear axle tie rod 70 52 620

30 22 266

2 - 14 FRONT SUSPENSION ZH

FRONT SUSPENSION

TABLE OF CONTENTS

page page

FRONT SUSPENSION

SPECIFICATIONS

TORQUE CHART - FRONT SUSPENSION . . . 14

KNUCKLE

DESCRIPTION .........................15

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

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

HUB / BEARING

DESCRIPTION .........................23

DIAGNOSIS AND TESTING

ADJUSTING WHEEL BEARING ...........24

REMOVAL .............................25

INSTALLATION .........................27

LOWER BALL JOINT

REMOVAL .............................29

INSTALLATION .........................32

FRONT SUSPENSION

SPECIFICATIONS
TORQUE CHART - FRONT SUSPENSION

LOWER CONTROL ARM

REMOVAL .............................34

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

UPPER CONTROL ARM

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

INSTALLATION .........................39

SHOCK

REMOVAL .............................40

INSTALLATION .........................41

SPRING

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

INSTALLATION .........................44

STABILIZER BAR

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

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

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Front Shock Absorber

Upper Nut

Front Shock Absorber

Lower Nut

Front Sway Bar To Lower

Control Arm Nut

Front Sway Bar Bushing

Nuts

M10 40 30 354

M8 20 15 177

Front Sway Bar To Frame

Nut

Upper Control Arm Joint

To Steering Knuckle

Clamping Nut 11 8 97

Lower Ball Joint To

Steering Knuckle

18 13 159

55 41 487

20 15 177

60 44 531

45 33 398

140 103 1240

ZH FRONT SUSPENSION 2 - 15

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Lower Ball Joint To lower

Control Arm

Upper Control Arm To

Body Nut

Lower Control Arm To

Frame Nut

105 77 929

65 50 575

120 88 1060

KNUCKLE

DESCRIPTION

1 - UPPER CONTROL ARM
2 - TIE ROD END
3 - WHEEL SPEED SENSOR
4 - UPPER BALL JOINT NUT
5 - DUST SHIELD BOLT
6 - ROTOR LOCK BOLT
7 - ROTOR
8 - DUST CAP

9 - HUB NUT
10 - BEARING
11 - HUB
12 - DUST SHIELD
13 - TIE ROD END NUT
14 - LOWER BALL JOINT NUT
15 - CALIPER BOLT
16 - LOWER BALL JOINT

The knuckle is a single casting with legs machined for the upper and lower ball joints. The knuckle also has
machined mounting locations for the front brake calipers and hub bearing.

2 - 16 FRONT SUSPENSION ZH

REMOVAL

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

1. Raise and support the vehicle.

2. Remove the front wheel and tire assembly.

3. Remove the front disc brake caliper (1). Refer to Page
5-25.

4. Remove the front disc brake rotor (1). Refer to Page 5-38.

5. Remove the front wheel hub (3). Refer to Page 2-25.

ZH FRONT SUSPENSION 2 - 17

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

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

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

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

Note: The use of a allen wrench may be required to hold
the stud while turning the nut.

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

2 - 18 FRONT SUSPENSION ZH

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

Note: The use of a allen wrench may be required to hold
the stud while turning the nut.

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

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

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

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

Note: The use of a allen wrench may be required to hold
the stud while turning the nut.

11. Remove the steering knuckle from the upper control arm

by removing the nut (1) from the upper ball joint stud.

12. Using Special Tool 9168 Ball Joint Puller slowly tighten the

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

ZH FRONT SUSPENSION 2 - 19

CHECKING

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

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

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

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

5. Measure the steering knuckle, if necessary.

2 - 20 FRONT SUSPENSION ZH

INSTALLATION

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

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

ZH FRONT SUSPENSION 2 - 21

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

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

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

2 - 22 FRONT SUSPENSION ZH

6. Install the front wheel hub (3). Refer to Page 2-27.

7. Install the front disc brake rotor (1). Refer to Page 5-40.

8. Install the front disc brake caliper (1). Refer to Page 5-32.

9. Install the front wheel and tire assembly. Refer to Page
22-42.

10. Lower the vehicle and check vehicle alignment. Refer to

Page 2-13.

ZH FRONT SUSPENSION 2 - 23

HUB / BEARING

DESCRIPTION

1 - HUB
2 - BEARING
3 - HUB NUT

4 - DUST CAP
5 - ROTOR
6 - CALIPER

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

2 - 24 FRONT SUSPENSION ZH

DIAGNOSIS AND TESTING
ADJUSTING WHEEL BEARING

1 - WHEEL BOLT
2 - DUST CAP
3 - ROTOR

4 - HUB NUT
5 - ROTOR LOCK BOLT

1. Remove the wheel and tire assembly.

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

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

4. Remove the dust cap (2).

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

6. Attach a dial indicator.

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

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

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

9. Remove the dial indicator.

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

11. Remove the wheel bolt from the rotor.

12. Install the front wheel and tire assembly. Refer to Page 22-42.

ZH FRONT SUSPENSION 2 - 25

REMOVAL

1. Raise and support vehicle.

2. Remove the front wheel and tire assembly.

3. Remove and inspect the front disc brake caliper (1). Refer
to Page 5-25. Inspect for any damage or wear.

4. Remove and inspect the front disc brake rotor (1). Refer to
Page 5-38. Inspect for any damage or wear.

2 - 26 FRONT SUSPENSION ZH

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

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

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

INSPECTING HUB AND BEARINGS

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

ZH FRONT SUSPENSION 2 - 27

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

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

2. Inspect the spindle for any discoloration or wear on the
bearing seats or the contact surface of the radial seal ring.
Replace if necessary. Refer to Page 2-16.

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

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

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

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

• The roller cage and the face ends of the tapered roll-

ers are not worn or damaged.

• The bearing races sit tight in the wheel hub.

INSTALLATION

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

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

2 - 28 FRONT SUSPENSION ZH

3. Install the front disc brake rotor (1). Refer to Page 5-40.

4. Install the front disc brake caliper (6). Refer to Page 5-32.

5. Adjust the wheel bearing end play. Refer to Page 2-24.

6. Install the dust cap (4).

ZH FRONT SUSPENSION 2 - 29

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

7. Install the wheel and tire assembly. Refer to Page 22-42.

LOWER BALL JOINT

REMOVAL

1. Raise and support the vehicle.

2. Remove the front wheel and tire assembly.

3. Remove the front disc brake caliper (1). Refer to Page
5-25.

4. Remove the front disc brake rotor (1). Refer to Page 5-38.

2 - 30 FRONT SUSPENSION ZH

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

6. Remove the front shock absorber bolt (1). Refer to Page
2-40.

7. Remove the front spring (1). Refer to Page 2-42.

ZH FRONT SUSPENSION 2 - 31

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

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

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

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

upper ball joint stud from the lower control arm.

2 - 32 FRONT SUSPENSION ZH

INSTALLATION

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

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

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

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

ZH FRONT SUSPENSION 2 - 33

5. Install the front disc brake rotor (1). Refer to Page 5-40.

6. Install the front disc brake caliper (1). Refer to Page 5-32.

7. Install the compressed front spring (1). Refer to Page 2-44.

2 - 34 FRONT SUSPENSION ZH

8. Install the front shock absorber bolt and nut (1). Refer to
Page 2-41.

9. Install the front wheel and tire assembly. Refer to Page
22-42.

LOWER CONTROL ARM

REMOVAL

1. Remove the front wheel and tire assembly.

2. Remove the front spring. Refer to Page 2-42.

ZH FRONT SUSPENSION 2 - 35

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

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

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

6. Remove the nut (1) attaching the lower control arm to the
lower ball joint.

2 - 36 FRONT SUSPENSION ZH

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

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

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

9. Remove the lower control arm from the vehicle.

ZH FRONT SUSPENSION 2 - 37

INSTALLATION

1. Install the lower control arm to the vehicle.

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

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

2 - 38 FRONT SUSPENSION ZH

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

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

6. Install the front spring (1). Refer to Page 2-44.

7. Lower the vehicle and check vehicle alignment. Refer to
Page 2-6.

8. Install the front wheel and tire assembly. Refer to Page
22-42.

ZH FRONT SUSPENSION 2 - 39

UPPER CONTROL ARM

REMOVAL

Note: If working on the right side remove the air cleaner
housing to access the upper control arm bolt and nut.

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

1. Remove the front wheel and tire assembly.

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

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

CAUTION: Do not subject the brake hose and any electri­cal cables to any tension.

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

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

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

INSTALLATION

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

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

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

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

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

4. Lower the vehicle and check vehicle alignment. Refer to
Page 2-6.

5. Install the wheel and tire assembly. Refer to Page 22-42.

2 - 40 FRONT SUSPENSION ZH

SHOCK

REMOVAL

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

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

2. Remove the washer and rubber mounts.

3. Raise and support the vehicle.

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

5. Remove any mounting parts from the shock absorber.

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

ZH FRONT SUSPENSION 2 - 41

INSTALLATION

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

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

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

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

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

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

7. Lower the vehicle and check vehicle alignment. Refer to
Page 2-6.

2 - 42 FRONT SUSPENSION ZH

SPRING

REMOVAL

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

2. Remove the washer and rubber mount.

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

ZH FRONT SUSPENSION 2 - 43

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

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

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

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

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

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

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

2 - 44 FRONT SUSPENSION ZH

INSTALLATION

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

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

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

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

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

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

ZH FRONT SUSPENSION 2 - 45

6. Install the lower shock mounting hardware (1).

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

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

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

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

11. Lower the vehicle and check vehicle alignment. Refer to

Page 2-6.

2 - 46 FRONT SUSPENSION ZH

STABILIZER BAR

REMOVAL

1 - STABILIZER BAR BRACKETS
2 - LOWER CONTROL ARM
3 - RUBBER BUSHING

4 - RETAINER BRACKET BOLTSAND NUTS
5 - RUBBER BUSHINGS
6 - STABILIZER BAR

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

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

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

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

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

ZH FRONT SUSPENSION 2 - 47

INSTALLATION

1 - STABILIZER BAR BRACKETS
2 - LOWER CONTROL ARM
3 - RUBBER BUSHING

4 - RETAINER BRACKET BOLTSAND NUTS
5 - RUBBER BUSHINGS
6 - STABILIZER BAR

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

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

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

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

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

4. Tighten both stabilizer bar bolts to frame.

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

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

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

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

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

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

11. Lower the vehicle and check vehicle alignment. Refer to Page 2-6.

2 - 48 REAR SUSPENSION ZH

REAR SUSPENSION

TABLE OF CONTENTS

page page

REAR SUSPENSION

SPECIFICATIONS .......................48

CAMBER STRUT

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

INSTALLATION .........................50

TRAILING LINK

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

INSTALLATION .........................51

LATERAL LINK

REMOVAL .............................51

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

TRACK BAR

REMOVAL .............................52

INSTALLATION .........................53

LOWER CONTROL ARM

REMOVAL .............................53

INSTALLATION .........................55

KNUCKLE

REMOVAL .............................58

REAR SUSPENSION

SPECIFICATIONS

INSTALLATION .........................63

HUB / BEARING

REMOVAL .............................67

INSTALLATION .........................70

STABILIZER BAR

REMOVAL .............................72

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

SHOCK

REMOVAL .............................80

INSTALLATION .........................81

SPRING

REMOVAL .............................83

INSTALLATION .........................85

REAR AXLE CARRIER

REMOVAL .............................87

INSTALLATION .........................93

Torque Specifications

Description N·M Ft. Lbs. In. Lbs.

Stabilizer Link to Stabilizer

Bar

Stabilizer Bar to Stabilizer

Link Nut

Bolt, Stabilizer Bar Clamp 20 15 177

Upper Shock Nut 18 13 159

Shock Absorber to Lower

Control Arm

Front Rear Axle Carrier

Nut

Rear Axle Carrier Rear

Axle Nut

Rear Axle Center

Assembly At Front to Rear

Axle Carrier

30 22 266

20 15 177

55 41 487

90 66 797

90 66 797

50 37 443

ZH REAR SUSPENSION 2 - 49

Description N·M Ft. Lbs. In. Lbs.

Rear Axle Center

Assembly At Rear to Rear

Axle Carrier

Lower Control Arm to

Rear Axle Carrier

Lower Control Arm to

Wheel Carrier

Camber Strut to Rear Axle

Carrier

Camber Strut to Wheel

Carrier

Trailing Link to Rear Axle

Carrier

Trailing Link to Wheel

Carrier

Lateral Link to Rear Axle

Carrier

Lateral Link to Wheel

Carrier

Track Bar to Rear Axle

Carrier

Track Bar to Wheel

Carrier

110 81 974

70 52 620

120 88 1060

70 52 620

70 52 620

70 52 620

70 52 620

70 52 620

30 22 266

70 52 620

70 52 620

CAMBER STRUT

REMOVAL

1. Raise and support the vehicle.

2. Remove the wheel and tire assembly.

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

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

Note: Lightly tap the camber strut with a plastic headed
hammer to loosen or guide the rubber mounts out of their
mounting flanges.

5. Remove the camber strut.

2 - 50 REAR SUSPENSION ZH

INSTALLATION

1. Install the camber strut onto the vehicle.

CAUTION: Do not tighten to torque value at this point. The
vehicle must be in ready-to-drive position.

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

CAUTION: Do not tighten to torque value at this point. The
vehicle must be in its ready-to-drive position.

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

4. Install the wheel and tire assembly.

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

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

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

8. Check vehicle alignment. Refer to Page 2-6.

TRAILING LINK

REMOVAL

1. Raise and support the vehicle.

2. Remove the wheel and tire assembly.

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

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

Note: Lightly tap the trailing link with a plastic headed
hammer to loosen or guide the rubber mounts out of their
mounting flanges.

5. Remove the trailing link.

ZH REAR SUSPENSION 2 - 51

INSTALLATION

1. Install the trailing link onto the vehicle.

CAUTION: Do not tighten to torque value at this point. The
vehicle must be in its ready-to-drive position.

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

CAUTION: Do not tighten to torque value at this point. The
vehicle must be in its ready-to-drive position.

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

4. Install the wheel and tire assembly.

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

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

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

8. Check vehicle alignment. Refer to Page 2-6.

LATERAL LINK

REMOVAL

1. Raise and support the vehicle.

2. Remove the wheel and tire assembly.

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

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

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

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

Note: Lightly tap the lateral link with a plastic headed
hammer to loosen or guide the rubber mounts out of their
mounting flanges.

6. Remove the lateral link (1).

2 - 52 REAR SUSPENSION ZH

INSTALLATION

1. Install the lateral link onto the vehicle.

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

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

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

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

CAUTION: Tighten the nuts and bolts in the “ready-to­drive” position.

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

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

TRACK BAR

REMOVAL

1. Raise and support the vehicle.

2. Remove the wheel and tire assembly.

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

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

Note: Lightly tap the track bar with a plastic headed ham­mer to loosen or guide the rubber mounts out of their
mounting flanges.

5. Remove the track bar.

ZH REAR SUSPENSION 2 - 53

INSTALLATION

1. Install the track bar onto the vehicle.

CAUTION: Do not tighten to torque value at this point. The
vehicle must be in its “ready-to-drive” position.

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

CAUTION: Do not tighten to torque value at this point. The
vehicle must be in its “ready-to-drive” position.

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

4. Install the wheel and tire assembly.

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

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

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

8. Check vehicle alignment. Refer to Page 2-6.

LOWER CONTROL ARM

REMOVAL

1. Remove the rear tire and wheel assembly.

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

2 - 54 REAR SUSPENSION ZH

3. Remove the rear spring (1). Refer to Page 2-83.

4. Remove the rear shock absorber (1). Refer to Page 2-80.

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

ZH REAR SUSPENSION 2 - 55

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

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

INSTALLATION

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

2 - 56 REAR SUSPENSION ZH

2. Install the rear shock absorber (1). Refer to Page 2-81.

3. Install the rear spring (1). Refer to Page 2-85.

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

ZH REAR SUSPENSION 2 - 57

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

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

7. Install the wheel and tire assembly.

8. Check vehicle alignment. Refer to Page 2-6.

2 - 58 REAR SUSPENSION ZH

KNUCKLE

REMOVAL

1 - TRAILING LINK
2 - CAMBER STRUT
3 - DUST SHIELD
4 - HUB
5 - AXLE NUT

6 - PARKING BRAKE CABLE
7 - TRACK BAR
8 - LOWER CONTROL ARM
9 - LATERAL LINK

1. Raise and support vehicle.

2. Remove the wheel and tire assembly.

3. Remove the rear disc brake caliper (1). Refer to Page
5-25.

ZH REAR SUSPENSION 2 - 59

4. Remove the disc brake rotor. Refer to Page 5-38.

5. Remove the parking brake shoe assembly. Refer to Page
5-70.

6. Remove the parking brake cable (2). Refer to Page 5-61.

2 - 60 REAR SUSPENSION ZH

7. Remove the rear Wheel Speed Sensor (2) (WSS). Refer to
Page 5-197.

8. Remove the rear axle halfshaft from the rear hub assembly.
Refer to Page 3-4.

9. Remove the rear disc brake dust shield by removing the
hex bolts (1) from the rear hub assembly.

ZH REAR SUSPENSION 2 - 61

10. Remove the camber strut, nuts and bolts (1-2). Refer to

Page 2-49.

11. Remove the trailing link, nuts and bolts (1-2). Refer to

Page 2-50.

12. Remove the lateral link, nuts and bolts (1-2). Refer to

Page 2-51.

2 - 62 REAR SUSPENSION ZH

13. Remove the track bar. Refer to Page 2-52.

14. Remove the lower control arm. Refer to Page 2-53.

15. Remove the knuckle from the vehicle.

16. Inspect the bearing assembly (5) for any wear or damage,

replace if necessary. Refer to Page 2-67.

ZH REAR SUSPENSION 2 - 63

INSTALLATION

1 - TRAILING LINK
2 - CAMBER STRUT
3 - DUST SHIELD
4 - HUB
5 - AXLE NUT

6 - PARKING BRAKE CABLE
7 - TRACK BAR
8 - LOWER CONTROL ARM
9 - LATERAL LINK

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

1. Install the knuckle to the vehicle.

2. Install the trailing link, nuts and bolts (1-2). Refer to Page
2-50.

2 - 64 REAR SUSPENSION ZH

3. Install the trailing link nuts and bolts (1-2). Refer to Page
2-51.

4. Install the lateral link nuts and bolts (1-2). Refer to Page
2-52.

5. Install the track bar nuts and bolts (1-2). Refer to Page
2-53.

6. Install the lower control arm. Refer to Page 2-55.

ZH REAR SUSPENSION 2 - 65

7. Install the rear disc brake dust shield by installing the bolts
(1) to the rear hub assembly.

8. Install the rear axle halfshaft to the rear hub assembly.
Refer to Page 3-5.

9. Install the rear Wheel Speed Sensor (2) (WSS). Refer to
Page 5-198.

2 - 66 REAR SUSPENSION ZH

10. Install the parking brake cable (2). Refer to Page 5-64.

11. Install the parking brake shoe assembly (1-5). Refer to

Page 5-73.

12. Install the disc brake rotor (1). Refer to Page 5-40.

ZH REAR SUSPENSION 2 - 67

13. Install the rear disc brake caliper and bolts (1). Refer to

Page 5-32.

14. Install the wheel and tire assembly. Refer to Page 22-42.

15. Check vehicle alignment. Refer to Page 2-6.

HUB / BEARING

REMOVAL

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

2 - 68 REAR SUSPENSION ZH

2. Remove rear disc brake rotor (1). Refer to Page 5-38.

3. Remove the parking brake shoes (1-5). Refer to Page
5-70.

4. Remove the rear axle halfshaft. Refer to Page 3-4.

ZH REAR SUSPENSION 2 - 69

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

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

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

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

8. Clamp the rear axle halfshaft flange in vise.

9. Fit the thrust piece with the large diameter on the rear axle
halfshaft flange.

10. Place the complete puller over the inner bearing race.

11. Clamp it firmly at the upper grooves of the clamping pliers

over the tapered sleeve of the puller.

12. Pull the inner bearing race off the rear axle halfshaft

flange using the puller.

13. Check the lateral and radial runout of the rear axle half-

shaft flange. Replace rear axle halfshaft flange if test val­ues are exceeded.

• Permissible lateral runout 0.001 18 in. (0.03 mm).

• Permissible radial runout 0.001 18 in. (0.03 mm).

2 - 70 REAR SUSPENSION ZH

INSTALLATION

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

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

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

Note: Make sure that the pressure plate lies flush against
the bearings inner race during insertion.

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

ZH REAR SUSPENSION 2 - 71

4. Install the parking brake shoes (1-5). Refer to Page 5-73.

5. Install the disc brake rotor (1). Refer to Page 5-40.

6. Install the rear disc brake caliper bolts (1). Refer to Page
5-32.

2 - 72 REAR SUSPENSION ZH

7. Install the rear axle halfshaft. Refer to Page 3-5.

8. Install wheel and tire assembly. Refer to Page 22-42.

STABILIZER BAR

REMOVAL

1. Raise and support the vehicle.

2. Remove both wheel and tire assemblies.

3. Remove the right and left wheel speed sensors (2). Refer
to Page 5-197.

ZH REAR SUSPENSION 2 - 73

4. Remove the rear brake hoses (1) from the rear brake cali­pers. Refer to Page 5-12.

5. Remove the rear springs (1). Refer to Page 2-83.

6. Remove the rear shocks (1). Refer to Page 2-80.

2 - 74 REAR SUSPENSION ZH

7. Remove the rear parking brake cables (2) from the parking
brake equalizer (1). Refer to Page 5-61.

8. Remove the propeller shaft from the rear axle differential
carrier. Refer to Page 3-26.

9. Remove the rear stabilizer bar links (2) from the stabilizer
bar (1).

ZH REAR SUSPENSION 2 - 75

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

lifting device (2).

11. Remove the two bolts (1) attaching the rear axle carrier to

the front portion of the frame.

12. Remove the two bolts (2) attaching the rear axle carrier to

the rear portion of the frame.

13. Lower the rear differential housing down approximately 4 -

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