Page 1
XJ SUSPENSION 2 - 1
SUSPENSION
TABLE OF CONTENTS
page page
ALIGNMENT .............................. 1
FRONT SUSPENSION ....................... 7
ALIGNMENT
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
WHEEL ALIGNMENT .......................1
DIAGNOSIS AND TESTING
SUSPENSION AND STEERING SYSTEM........3
DESCRIPTION AND OPERATION
WHEEL ALIGNMENT
DESCRIPTION
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 (Fig. 1).
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. Refer to
Group 0, Lubrication And Maintenance for the recommended maintenance schedule.
REAR SUSPENSION ....................... 16
SERVICE PROCEDURES
PRE-ALIGNMENT .........................4
WHEEL ALIGNMENT .......................4
SPECIFICATIONS
ALIGNMENT .............................6
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.
• 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.
Tilting the top of the wheel outward provides positive
camber. Incorrect camber will cause wear on the
inside or outside edge of the tire. The angle is not
adjustable, damaged component(s) must be replaced
to correct the camber angle.
• WHEEL TOE POSITION is the difference
between the leading inside edges and trailing inside
edges 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.
• 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.
Page 2
2 - 2 SUSPENSION XJ
DESCRIPTION AND OPERATION (Continued)
• THRUST ANGLE is the angle of the rear axle
relative to the centerline of the vehicle. Incorrect
thrust angle can cause off-center steering and excessive tire wear. This angle is not adjustable, damaged
component(s) must be replaced to correct the thrust
angle.
1 – WHEEL CENTERLINE
2 – NEGATIVE CAMBER ANGLE
3 – PIVOT CENTERLINE
4 – SCRUB RADIUS
Fig. 1 Wheel Alignment Measurements
5 – TRUE VERTICAL
6 – KING PIN
7 – VERTICAL
8 – POSITIVE CASTER
Page 3
XJ SUSPENSION 2 - 3
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.
VEHICLE INSTABILITY 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
EXCESSIVE STEERING
EFFORT
1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
2. Loose or worn steering or
suspension components.
3. Loose or worn steering gear. 3. Adjust or replace steering gear.
2. Loose or worn steering or
suspension components.
3. Tires worn or out of balance. 3. Replace or balance tires.
4. Alignment. 4. Align vehicle to specifications.
5. Leaking steering dampener. 5. Replace steering dampener.
2. Loose or worn steering or
suspension components.
3. Tire pressure. 3. Adjust tire pressure.
4. Alignment. 4. Align vehicle to specifications.
1. Loose or worn steering gear. 1. Adjust or replace steering gear.
2. Power steering fluid low. 2. Add fluid and repair leak.
3. Column coupler binding. 3. Replace coupler.
4. Tire pressure. 4. Adjust tire pressure.
5. Alignment. 5. Align vehicle to specifications.
2. Tighten or replace components as
necessary.
2. Tighten or replace components as
necessary.
2. Tighten or replace components as
necessary.
2. Tighten or replace components as
necessary.
VEHICLE PULLS TO ONE
SIDE DURING BRAKING
VEHICLE LEADS OR
DRIFTS FROM STRAIGHT
AHEAD DIRECTION ON
UNCROWNED ROAD
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 spec. 7. Align vehicle.
6. Repair as necessary.
Page 4
2 - 4 SUSPENSION XJ
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
KNOCKING, RATTLING
OR SQUEAKING
IMPROPER TRACKING 1. Loose, worn or bent track bar. 1. Inspect, tighten or replace component as
SERVICE PROCEDURES
PRE-ALIGNMENT
Before starting wheel alignment, the following
inspection and necessary corrections must be completed. Refer to Suspension and Steering System
Diagnosis Chart for additional information.
(1) Inspect tires for size and tread wear.
(2) Set tire air pressure.
(3) Inspect front wheel bearings for wear.
(4) Inspect front wheels for excessive radial or lateral runout and balance.
(5) Inspect ball studs, linkage pivot points and
steering gear for looseness, roughness or binding.
(6) Inspect suspension components for wear and
noise.
1. Worn shock bushings. 1. Replace shock.
2. Loose, worn or bent steering/
suspension components.
3. Shock valve. 3. Replace shock.
2. Loose, worn or bent steering/
suspension components.
NOTE: Changing caster angle will also change the
front propeller shaft angle. The propeller shaft
angle has priority over caster. Refer to Group 3 Differential & Driveline for additional information.
2. Inspect, tighten or replace components
as necessary.
necessary.
2. Inspect, tighten or replace components
as necessary.
WHEEL ALIGNMENT
Before each alignment reading, the vehicle should
be jounced (rear first, then front). Grasp each
bumper at the center and jounce the vehicle up and
down several times. Always release the bumper in
the down position. Set the front end alignment to
specifications with the vehicle at its NORMAL RIDE
HEIGHT.
CAMBER
The wheel camber angle is preset. This angle is not
adjustable and cannot be altered.
CASTER
Before checking the caster of the front axle for correct angle, be sure the axle is not bent or twisted.
Road test the vehicle, make left and right turns. If
the steering wheel returns to the center position
unassisted, the caster angle is correct. If steering
wheel does not return toward the center position
unassisted, an incorrect caster angle is probable.
Caster can be adjusted by installing the appropriate size shims (Fig. 2).
Fig. 2 Caster Adjustment
1 – SHIM
2 – SUSPENSION ARM
TOE POSITION (LHD)
NOTE: The wheel toe position adjustment is the
final adjustment. The engine must remain running
during the entire toe position adjustment.
(1) Start the engine and turn wheels both ways
before straightening the wheels. Secure the steering
wheel with the front wheels in the straight-ahead
position.
(2) Loosen the adjustment sleeve clamp bolts (Fig.
3).
(3) Adjust the right wheel toe position with the
drag link. Turn the sleeve until the right wheel is at
correct TOE-IN specifications. Position the clamp
Page 5
XJ SUSPENSION 2 - 5
SERVICE PROCEDURES (Continued)
bolts as shown (Fig. 4) and tighten to 49 N·m (36 ft.
lbs.).
NOTE: Make sure the toe setting does not change
during clamp tightening.
(4) Adjust the left wheel toe position with the tie
rod. Turn the sleeve until the left wheel is at specifications. Position the clamp bolts as shown (Fig. 4)
and tighten to 27 N·m (20 ft. lbs.).
NOTE: Make sure the toe setting does not change
during clamp tightening.
(5) Verify the right toe setting and turn off engine.
(6) Road test the vehicle on a flat level road to verify the steering wheel is centered.
NOTE: Once the toe setting is correct, the steering
wheel can be re-centered by adjusting only the drag
link.
TOE POSITION (RHD)
NOTE: The wheel toe position adjustment is the
final adjustment. The engine must remain running
during the entire toe position adjustment.
(1) Start the engine and turn wheels both ways
before straightening the wheels. Secure the steering
Fig. 4 Drag Link and Tie Rod Clamp (LHD)
1 – TIE ROD CLAMP
2 – DRAG LINK CLAMPS
wheel with the front wheels in the straight-ahead
position.
(2) Loosen the adjustment sleeve clamp bolts (Fig.
5).
(3) Adjust the left wheel toe position with the drag
link. Turn the sleeve until the left wheel is at the
correct TOE-IN specifications. Position the clamp
bolts to their original position and tighten to 49 N·m
(36 ft. lbs.).
1 – PITMAN ARM
2 – ADJUSTMENT SLEEVE
3 – DRAG LINK
Fig. 3 Steering Linkage (LHD)
4 – TIE ROD
5 – STEERING DAMPENER
Page 6
2 - 6 SUSPENSION XJ
SERVICE PROCEDURES (Continued)
Fig. 5 Steering Linkage (RHD)
1 – PITMAN ARM
2 – DRAG LINK
3 – STEERING DAMPNER
NOTE: Make sure the toe setting does not change
during clamp tightening.
(4) Adjust the right wheel toe position with the tie
rod. Turn the sleeve until the right wheel is at correct TOE-IN specifications. Position the clamp bolts
to their original position and tighten to 27 N·m (20
ft. lbs.).
NOTE: Make sure the toe setting does not change
during clamp tightening.
SPECIFICATIONS
ALIGNMENT
NOTE: All alignment specifications are in degrees.
4 – TIE ROD
5 – ADJUSTMENT SLEEVE
(5) Verify the right toe setting and turn off engine.
(6) Road test the vehicle on a flat level road to ver-
ify the steering wheel is centered.
NOTE: Once the toe setting is correct, the steering
wheel can be re-centered by adjusting only the drag
link.
ANGLE PREFERRED RANGE MAX RT/LT DIFFERENCE
CASTER + 7.0° + 5.25° to + 8.5° 1.25°
CAMBER
(fixed angle)
− 0.25° − 0.75° to + 0.5° 1.0°
TOTAL TOE-IN + 0.25° 0° to + 0.45° .05°
THRUST ANGLE 0° 6 0.15°
Page 7
XJ SUSPENSION 2 - 7
FRONT SUSPENSION
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
SUSPENSION COMPONENTS................7
SHOCK ABSORBERS ......................7
JOUNCE BUMPER.........................7
COIL SPRINGS AND ISOLATORS .............8
LOWER SUSPENSION ARMS AND BUSHINGS . . . 8
UPPER SUSPENSION ARMS AND BUSHINGS . . . 8
STABILIZER BAR..........................9
TRACK BAR..............................9
HUB/BEARING............................9
DIAGNOSIS AND TESTING
SHOCK DIAGNOSIS .......................9
REMOVAL AND INSTALLATION
SHOCK ABSORBER........................9
DESCRIPTION AND OPERATION
SUSPENSION COMPONENTS
The front suspension is a link/coil design (Fig. 1).
This suspension is use on Left Hand Drive (LHD)
and Right Hand Drive (RHD) vehicles. The suspension is comprised of:
• Drive axle (4WD), tube axle (2WD)
• Dual-action shock absorbers
• Coil springs
• Upper and lower suspension arms
• Stabilizer bar
• Track bar
• Jounce bumpers
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.
COIL SPRING/JOUNCE BUMPER .............9
STEERING KNUCKLE .....................10
LOWER SUSPENSION ARM ................10
UPPER SUSPENSION ARM .................11
FRONT AXLE BUSHING ....................11
STABILIZER BAR.........................12
TRACK BAR.............................12
HUB BEARING...........................12
WHEEL MOUNTING STUDS.................13
SPECIFICATIONS
TORQUE CHART .........................14
SPECIAL TOOLS
FRONT SUSPENSION .....................15
NOTE: Periodic lubrication of the front suspension/
steering system components may be required. Rubber bushings must never be lubricated. Refer to
Group 0, Lubrication And Maintenance for the recommended maintenance schedule.
SHOCK ABSORBERS
DESCRIPTION
The top of the shock absorbers are bolted to a
frame bracket. The bottom of the shocks are bolted to
the axle brackets.
OPERATION
The shock absorbers dampen jounce and rebound
motion of the vehicle over various road conditions
and limit suspension rebound travel.
JOUNCE BUMPER
CAUTION: Suspension components with rubber/
urethane bushings (except stabilizer bar) should be
tightened with the vehicle at normal ride height. It is
important to have the springs supporting the weight
of the vehicle when the fasteners are torqued. If
springs are not at their normal ride position, vehicle
ride comfort could be affected and premature bushing wear may occur.
DESCRIPTION
The jounce bumpers are mounted under the frame
rail inside of the coil spring.
OPERATION
The jounce bumpers are used to limit suspension
travel in compression.
Page 8
2 - 8 SUSPENSION XJ
DESCRIPTION AND OPERATION (Continued)
Fig. 1 Suspension Components (LHD)
1 – LINKS
2 – SHOCK ABSORBER
3 – UPPER SUSPENSION ARM
4 – STABILIZER BAR
5 – COIL SPRING
COIL SPRINGS AND ISOLATORS
DESCRIPTION
The coil springs mount up in the wheelhouse which
is part of the unitized body bracket. A rubber doughnut isolator is located between the top of the spring
and the bracket. The bottom of the spring seats on a
axle pad and retained with a clip.
OPERATION
The coil springs control ride quality and maintain
proper ride height. The isolators provide road noise
isolation.
LOWER SUSPENSION ARMS AND BUSHINGS
DESCRIPTION
The lower suspension arms are steel and use bushings at one end of the arm. The arms mount to the
frame rail bracket and the axle brackets.
6 – JOUNCE BUMPER
7 – LOWER SUSPENSION ARM
8 – TRACK BAR
9 – AXLE
OPERATION
The arm and bushings provide location and react
to loads from the axle. The bushings provide isolation
from the axle. The lower suspension arms can be
used to adjust caster and pinion angle, through the
use of shims at the frame rail bracket.
UPPER SUSPENSION ARMS AND BUSHINGS
DESCRIPTION
The upper suspension arms are steel and use rubber bushings at each end of the arm. The arms
mount to the frame rail bracket and the axle brackets.
OPERATION
The arm and bushings provide location and react
to loads from the axle. The bushings provide isolation
from the axle.
Page 9
XJ SUSPENSION 2 - 9
DESCRIPTION AND OPERATION (Continued)
STABILIZER BAR
DESCRIPTION
The spring steel bar extends across the underside
of the chassis frame rails. Links are connected from
the bar to the axle brackets. The stabilizer bar and
links are isolated by rubber bushings.
OPERATION
The stabilizer bar is used to control vehicle body
roll during turns. The bar helps to control the vehicle
body in relationship to the suspension.
TRACK BAR
DESCRIPTION
The bar is attached to a frame rail bracket with a
ball stud and an axle bracket with a bushing. The
bar is forged and has non replaceable isolator bushing and ball stud.
OPERATION
The track bar is used to control front axle lateral
movement and provides cross car location of the axle
assembly.
HUB/BEARING
ing components. Repair as necessary if any of these
conditions exist.
A squeaking noise from the shock absorber may be
caused by the hydraulic valving and may be intermittent. This condition is not repairable and the shock
absorber must be replaced.
The shock absorbers are not refillable or adjustable. If a malfunction occurs, the shock absorber
must be replaced. To test a shock absorber, hold it in
an upright position and force the piston in and out of
the cylinder four or five times. The action throughout
each stroke should be smooth and even.
The shock absorber bushings do not require any
type of lubrication. Do not attempt to stop bushing
noise by lubricating them. Grease and mineral oilbase lubricants will deteriorate the bushing.
REMOVAL AND INSTALLATION
SHOCK ABSORBER
REMOVAL
(1) Remove the nut, retainer and grommet from
the upper stud in the engine compartment (Fig. 2).
(2) Remove the lower nuts and bolts from the axle
bracket.
(3) Remove the shock absorber.
DESCRIPTION
The bearing used on the front hub of this vehicle is
the combined hub and bearing unit type assembly.
This unit assembly combines the front wheel mounting hub (flange) and the front wheel bearing into a
one piece unit. The wheel mounting studs are the
only replaceable component of the hub/bearing
assembly.
OPERATION
The hub/bearing assembly is mounted to the steering knuckle and is retained by three mounting bolts
accessible from the back of the steering knuckle. The
hub/bearing unit is not serviceable and must be
replaced as an assembly if the bearing or the hub is
determined to be defective.
DIAGNOSIS AND TESTING
SHOCK DIAGNOSIS
A knocking or rattling noise from a shock absorber
may be caused by movement between mounting
bushings and metal brackets or attaching components. These noises can usually be stopped by tightening the attaching nuts. If the noise persists,
inspect for damaged and worn bushings, and attach-
INSTALLATION
(1) Position the lower retainer and grommet on the
shock stud. Insert the shock absorber through the
shock tower hole.
(2) Install the lower bolts and nuts. Tighten nuts
to 23 N·m (17 ft. lbs.).
(3) Install the upper grommet and retainer on the
stud. Install the nut and tighten to 22 N·m (16 ft.
lbs.).
COIL SPRING/JOUNCE BUMPER
REMOVAL
(1) Raise and support the vehicle. Position a
hydraulic jack under the axle to support it.
(2) Remove the wheel and tire assemblies.
(3) Mark and disconnect the front propeller shaft
from the axle.
(4) Remove lower suspension arms mounting nuts
and bolts from the axle (Fig. 2).
(5) Remove the stabilizer bar link and shock
absorber from the axle.
(6) Remove the track bar from the body rail
bracket.
(7) Remove the drag link from the pitman arm.
Page 10
2 - 10 SUSPENSION XJ
REMOVAL AND INSTALLATION (Continued)
Fig. 2 Coil Spring & Shock Absorber
1 – SPRING
2 – SCREW
3 – SPRING RETAINER
4 – NUT
5 – RETAINER
6 – GROMMET
7 – ISOLATOR
8 – BUMPER
(8) Lower the axle until the spring is free from the
upper mount. Remove the coil spring clip and remove
the spring.
(9) Pull jounce bumper out of mount.
INSTALLATION
(1) Install jounce bumper into mount.
(2) Position the coil spring on the axle pad. Install
the spring clip and bolt. Tighten bolt to 21 N·m (16
ft. lbs.).
(3) Raise the axle into position until the spring
seats in the upper mount.
(4) Install the stabilizer bar links and shock
absorbers to the axle bracket.
(5) Install the track bar to the body rail bracket.
(6) Install the lower suspension arms to the axle.
Install mounting bolts and nuts finger tight.
(7) Install the front propeller shaft to the axle.
(8) Install the wheel and tire assemblies.
(9) Remove the supports and lower the vehicle.
(10) Tighten lower suspension arms nuts to 115
N·m (85 ft. lbs.).
9 – SPRING
10 – NUT
11 – SCREW
12 – SHOCK ABSORBER
13 – RETAINER
14 – GROMMET
15 – FRAME
16 – CONTROL ARM
STEERING KNUCKLE
For service procedures on the steering knuckle and
ball joints refer to Group 3 Differentials And Driveline.
LOWER SUSPENSION ARM
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the lower suspension arm nut and bolt
from the axle bracket.
(3) Remove the nut and bolt from the rear bracket
and remove the lower suspension arm (Fig. 3).
INSTALLATION
(1) Position the lower suspension arm at the axle
bracket and rear bracket.
(2) Install the bolts and finger tighten the nuts.
(3) Remove support and lower the vehicle.
(4) Tighten the front and rear nuts to 115 N·m (85
ft. lbs.).
Page 11
XJ SUSPENSION 2 - 11
REMOVAL AND INSTALLATION (Continued)
(2) Position Spacer 7932-3 over the axle bushing
on a 4x2 vehicle and right side on a 4x4 vehicle.
(3) Place Receiver 7932-1 over flanged end of the
bushing. (Fig. 4).
(4) Place small end of Remover/Install 7932-2
against other side of the bushing.
(5) Install bolt 7604 through remover, bushing and
receiver.
(6) Install Long Nut 7603 and tighten nut too pull
bushing out of the axle bracket.
Fig. 3 Upper and Lower Suspension Arms
1 – BOLT
2 – UPPER ARM
3 – NUT
4 – BOLT
5 – NUT
6 – FRAME RAIL
7 – LOWER ARM
8 – NUT
9 – BOLT
10 – NUT
UPPER SUSPENSION ARM
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the upper suspension arm nut and bolt
at the axle bracket.
(3) Remove the nut and bolt at the frame rail and
remove the upper suspension arm (Fig. 3).
INSTALLATION
(1) Position the upper suspension arm at the axle
and frame rail.
(2) Install the bolts and finger tighten the nuts.
(3) Remove the supports and lower the vehicle.
(4) Tighten the nut at the axle to 75 N·m (55 ft.
lbs.). Tighten the nut at the frame bracket to 90 N·m
(66 ft. lbs.).
FRONT AXLE BUSHING
Fig. 4 Bushing Removal
1 – RECEIVER
2 – AXLE BRACKET
3 – BOLT
4 – REMOVER/INSTALLER
5 – LONG NUT
(7) Remove nut, bolt, receiver, remover and bush-
ing.
NOTE: On 4x2 vehicle and right side of 4x4 vehicle,
leave Spacer 7932-3 in position for bushing installation.
INSTALLATION
(1) Place Receiver 7932-1 on the other side of the
axle bracket.
(2) Position new bushing up to the axle bracket.,
and large end of Remover/Install 7932-2 against the
bushing (Fig. 5).
(3) Install bolt 7604 through receiver, bushing and
installer.
(4) Install Long Nut 7603 and tighten nut to draw
the bushing into the axle bracket.
(5) Remove tools and install the upper suspension
arm.
REMOVAL
(1) Remove the upper suspension arm from axle.
Page 12
2 - 12 SUSPENSION XJ
REMOVAL AND INSTALLATION (Continued)
Fig. 5 Bushing Installation
1 – REMOVER/INSTALLER
2 – AXLE BRACKET
3 – BOLT
4 – RECEIVER
5 – LONG NUT
STABILIZER BAR
REMOVAL
(1) Raise and support the vehicle.
(2) Remove nuts, retainers and grommets from the
links at the stabilizer bar (Fig. 6).
(3) Remove the links mounting nuts and bolts
from the axle brackets.
(4) Remove the stabilizer bar clamps from the
body rails. Remove the stabilizer bar.
INSTALLATION
(1) Inspect stabilizer bar bushings. Replace bush-
ings if cracked, cut, distorted, or worn.
(2) Position the stabilizer bar on the body rail and
install the bushings and clamps. Ensure the bar is
centered with equal spacing on both sides. Tighten
the bolts to 75 N·m (40 ft. lbs.).
(3) Install the links and grommets onto the stabilizer bar and axle brackets.
(4) Tighten the link nuts at the axle bracket to 95
N·m (70 ft. lbs.).
(5) Tighten the link nuts at the stabilizer bar to 36
N·m (27 ft. lbs.).
(6) Remove the supports and lower the vehicle.
TRACK BAR
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the cotter pin and nut from the ball
stud end at the body rail bracket.
(3) Use a universal puller tool to separate the ball
stud from the frame rail bracket.
Fig. 6 Stabilizer Bar (LHD)
1 – RETAINER
2 – GROMMET
3 – BUSHING
4 – CLAMP
5 – STABILIZER BAR
6 – LINK
(4) Remove the bolt and flag nut from the axle
shaft tube bracket (Fig. 7).
(5) Remove the track bar.
INSTALLATION
(1) Install the track bar at axle tube bracket.
Loosely install the retaining bolt and flag nut.
(2) It may be necessary to pry the axle assembly
over to install the track bar at the body rail. Install
track bar at the body rail bracket. Install the retaining nut on the stud.
(3) Remove the supports and lower the vehicle.
(4) Tighten the retaining bolt at the axle shaft
tube bracket to 54 N·m (40 ft. lbs.).
(5) Tighten the ball stud nut to 81 N·m (60 ft.
lbs.). Install a new cotter pin.
HUB BEARING
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the wheel and tire assembly.
(3) Remove the brake caliper, rotor and ABS wheel
speed sensor, refer to Group 5 Brakes.
(4) Remove the cotter pin, nut retainer and axle
hub nut (Fig. 8).
Page 13
XJ SUSPENSION 2 - 13
REMOVAL AND INSTALLATION (Continued)
(2) Install the hub bearing to knuckle bolts and
tighten to 102 N·m (75 ft. lbs.).
(3) Install the hub washer and nut. Tighten the
hub nut to 237 N·m (175 ft. lbs.). Install the nut
retainer and a new cotter pin.
(4) Install the brake rotor, caliper and ABS wheel
speed sensor, refer to Group 5 Brakes.
(5) Install the wheel and tire assembly.
(6) Remove support and lower the vehicle.
WHEEL MOUNTING STUDS
CAUTION: Do not use a hammer to remove wheel
studs.
REMOVAL
(1) Raise and support vehicle.
(2) Remove wheel and tire assembly.
(3) Remove brake caliper, caliper adapter and
rotor, refer to Group 5 Brakes for procedure.
(4) Remove stud from hub with Remover C-4150A
Fig. 7 Track Bar (LHD)
1 – NUT
2 – SUPPORT BRACKET
3 – LEFT FRAME RAIL
4 – STUD
5 – SCREW
6 – COTTER PIN
7 – NUT
8 – FRAME BRACKET
9 – NUT PLATE
10 – TRACK BAR
11 – BALL STUD END
12 – NUT
(5) Remove the hub bearing mounting bolts from
the back of the steering knuckle. Remove hub bearing from the steering knuckle and off the axle shaft.
(Fig. 9).
INSTALLATION
(1) Install new stud into hub flange.
(2) Install three washers onto stud, then install
lug nut with the flat side of the nut against the
washers.
(3) Tighten lug nut until the stud is pulled into
the hub flange. Verify that the stud is properly
seated into the flange.
(4) Remove lug nut and washers.
(5) Install the brake rotor, caliper adapter, and caliper, refer to Group 5 Brakes for procedure.
(6) Install wheel and tire assembly, use new lug
nut on stud or studs that were replaced.
(7) Remove support and lower vehicle.
INSTALLATION
(1) Install the hub bearing and brake dust shield
to the knuckle.
Page 14
2 - 14 SUSPENSION XJ
REMOVAL AND INSTALLATION (Continued)
1 – BRAKE SHIELD
2 – WASHER
3 – RETAINER
4 – COTTER PIN
5 – NUT
Fig. 9 Wheel Stud Removal
1 – REMOVER
2 – WHEEL STUD
Fig. 8 Hub Bearing & Knuckle
6 – HUB AND BEARING ASSEMBLY
7 – STEERING KNUCKLE
8 – BOLT
9 – TONE WHEEL (ABS)
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Shock Absorber
Upper Nut ............... 22N·m(16ft.lbs.)
Lower Nut ............... 23N·m(17ft.lbs.)
Suspension Arm Upper
Front Nut ............... 74N·m(55ft.lbs.)
Rear Nut ................ 89N·m(66ft.lbs.)
Suspension Arm Lower
Front Nut ............... 115N·m(85ft.lbs.)
Rear Nut ............... 115N·m(85ft.lbs.)
Stabilizer Bar
Clamp Bolt ............... 54N·m(40ft.lbs.)
Link Upper Nut ........... 36N·m(27ft.lbs.)
Link Lower Nut ........... 95N·m(70ft.lbs.)
Track Bar
Ball Stud Nut ............ 81N·m(60ft.lbs.)
Axle Bracket Bolt .......... 54N·m(40ft.lbs.)
Page 15
XJ SUSPENSION 2 - 15
SPECIFICATIONS (Continued)
DESCRIPTION TORQUE
Track Bar Bracket
Bolts .................. 125N·m(92ft.lbs.)
Nut ................... 100N·m(74ft.lbs.)
Support Bolts ............. 42N·m(31ft.lbs.)
Hub/Bearing
Bolts .................. 102N·m(75ft.lbs.)
Axle Nut .............. 237N·m(175 ft. lbs.)
SPECIAL TOOLS
FRONT SUSPENSION
Remover/Installer Suspension Bushing 7932
Nut, Long 7603
Bolt, Special 7604
Remover C-4150A
Page 16
2 - 16 SUSPENSION XJ
REAR SUSPENSION
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
SUSPENSION COMPONENT ................16
SHOCK ABSORBERS .....................16
JOUNCE BUMPERS.......................16
STABILIZER BAR.........................16
COIL SPRINGS AND ISOLATORS ............16
DIAGNOSIS AND TESTING
SPRING AND SHOCK .....................17
DESCRIPTION AND OPERATION
SUSPENSION COMPONENT
The rear suspension is comprised of:
• Shock Absorbers
• Jounce Bumpers
• Stabilizer Bar (optional)
• Leaf Springs
• Drive Axle
CAUTION: A vehicle should always be loaded so
the vehicle weight center-line is located immediately forward of the rear axle. Correct vehicle loading provides proper front tire-to-road contact. This
results in maximum vehicle handling stability and
safety. Incorrect vehicle weight distribution can
cause excessive tire tread wear, spring fatigue or
failure, and erratic steering.
CAUTION: Suspension components with rubber/
urethane bushings (except stabilizer bar) should be
tightened with the vehicle at normal ride height. It is
important to have the springs supporting the weight
of the vehicle when the fasteners are torqued. If
springs are not at their normal ride position, vehicle
ride comfort could be affected and premature bushing wear may occur.
REMOVAL AND INSTALLATION
SHOCK ABSORBER.......................17
STABILIZER BAR.........................17
LEAF SPRING ...........................18
LEAF SPRING AND SHACKLE BUSHING.......18
SPECIFICATIONS
TORQUE CHART .........................19
OPERATION
The shock absorbers dampen jounce and rebound
motion of the vehicle over various road conditions
and limit suspension rebound travel.
JOUNCE BUMPERS
DESCRIPTION
The jounce bumpers are bolted to the bottom of the
frame rail.
OPERATION
The jounce bumpers are used to limit suspension
travel in compression.
STABILIZER BAR
DESCRIPTION
The spring steel bar extends across the axle and
mounts to leaf spring brackets. Links are connected
from the bar to the underside of the frame rail. The
stabilizer bar and links are isolated by rubber bushings.
OPERATION
The stabilizer bar is used to control vehicle body
roll during turns. The bar helps to control the vehicle
body in relationship to the suspension.
SHOCK ABSORBERS
DESCRIPTION
The top of the shock absorbers are bolted to the
body crossmember. The bottom of the shocks are
bolted to the axle brackets.
COIL SPRINGS AND ISOLATORS
DESCRIPTION
The front of the multi-leaf springs mount to frame
rail brackets. The rear of the spring mounts to shackles which mount the frame. The springs and shackles
have bushing at the mounting points.
Page 17
XJ SUSPENSION 2 - 17
DESCRIPTION AND OPERATION (Continued)
OPERATION
The leaf springs control ride quality and maintain
proper ride height. The shackles allow the springs to
change their length as the vehicle moves over various
road conditions. The bushings are used to isolate
axle/road noise.
DIAGNOSIS AND TESTING
SPRING AND SHOCK
A knocking or rattling noise from a shock absorber
may be caused by movement between mounting
bushings and metal brackets or attaching components. These noises can usually be stopped by tightening the attaching nuts. If the noise persists,
inspect for damaged and worn bushings, and attaching components. Repair as necessary if any of these
conditions exist.
A squeaking noise from the shock absorber may be
caused by the hydraulic valving and may be intermit-
SPRING AND SHOCK ABSORBER
tent. This condition is not repairable and the shock
absorber must be replaced.
The shock absorbers are not refillable or adjustable. If a malfunction occurs, the shock absorber
must be replaced. To test a shock absorber, hold it in
an upright position and force the piston in and out of
the cylinder four or five times. The action throughout
each stroke should be smooth and even.
The spring eye and shock absorber bushings do not
require any type of lubrication. Do not attempt to
stop spring bushing noise by lubricating them.
Grease and mineral oil-base lubricants will deteriorate the bushing rubber.
If the vehicle is used for severe, off-road operation,
the springs should be examined periodically. Check
for broken and shifted leafs, loose and missing clips,
and broken center bolts. Refer to Spring and Shock
Absorber Diagnosis chart for additional information.
CONDITION POSSIBLE CAUSES CORRECTION
SPRING SAGS 1. Broken leaf. 1. Replace spring.
2. Spring fatigue. 2. Replace spring.
SPRING NOISE 1. Loose spring clamp bolts. 1. Tighten to specification.
2. Worn bushings. 2. Replace bushings.
3. Worn or missing spring tip inserts. 3. Replace spring tip inserts.
SHOCK NOISE 1. Loose mounting fastener. 1. Tighten to specification.
2. Worn bushings. 2. Replace shock.
3. Leaking shock. 3. Replace shock.
REMOVAL AND INSTALLATION
SHOCK ABSORBER
REMOVAL
(1) Remove the shock absorber upper bolts from
the body bracket (Fig. 1).
(2) Remove lower attaching nut and washer from
the bracket stud. Remove the shock absorber.
STABILIZER BAR
REMOVAL
(1) Raise and support the vehicle.
(2) Disconnect stabilizer bar links from spring
brackets (Fig. 2).
(3) Disconnect the stabilizer bar brackets from the
body rails. Remove the stabilizer bar and links.
INSTALLATION
INSTALLATION
(1) Install the shock absorber lower eye on the
spring bracket stud. Install the shock absorber and
upper bolts on the body bracket.
(2) Tighten the lower nut to 62 N·m (46 ft. lbs.).
(3) Tighten the upper bolts to 23 N·m (17 ft. lbs.).
(1) Position the stabilizer bar links at the spring
brackets. Install the attaching bolts and nuts and
tighten to 74 N·m (55 ft. lbs.).
(2) Attach the stabilizer bar to the body rail brackets with the bolts. Tighten to 54 N·m (40 ft. lbs.).
(3) Remove the supports and lower the vehicle.
Page 18
2 - 18 SUSPENSION XJ
REMOVAL AND INSTALLATION (Continued)
Fig. 1 Rear Suspension Components
1 – SHOCK ABSORBER
2 – SPRING BRACKET
3 – NUT
4 – BUSHING
5 – BUMPER
6 – BRACKET
7 – NUT
LEAF SPRING
REMOVAL
(1) Raise vehicle at body rails.
(2) Remove the wheel and tire assemblies.
(3) Support axle with hydraulic jack to relieve axle
weight.
(4) Disconnect the stabilizer bar link from the
spring bracket stud.
(5) Remove nuts, U-bolts and spring bracket from
axle.
(6) Remove nut and bolt attaching spring front eye
to shackle.
(7) Remove nut and bolt from spring rear eye.
(8) Remove spring from vehicle.
INSTALLATION
(1) Position the spring front eye in the bracket.
Loosely install the attaching bolt and nut. Do not
tighten at this time.
8 – RETAINER
9 – SHOCK ABSORBER
10 – SPRING
11 – U-BOLTS
12 – BUSHING
13 – SHACKLE
(2) Position the rear eye in the shackle bracket.
Loosely install the attaching bolt and nut. Do not
tighten at this time.
(3) Position the axle. Install the spring bracket,
U-bolts and nuts. Tighten the nuts to 70 N·m (52 ft.
lbs.).
(4) Connect the stabilizer bar link to the spring
bracket.
(5) Remove the hydraulic jack.
(6) Lower the vehicle.
(7) Tighten the spring front eye attaching bolts to
156 N·m (115 ft. lbs.).
(8) Tighten the spring rear eye attaching bolts to
108 N·m (80 ft. lbs.).
(9) Tighten the stabilizer bar link to 74 N·m (55 ft.
lbs.).
LEAF SPRING AND SHACKLE BUSHING
For front bushings bend tabs DOWN before
removal. Use an appropriate driver tool and force the
original bushing out of the spring eye.
Page 19
XJ SUSPENSION 2 - 19
REMOVAL AND INSTALLATION (Continued)
Fig. 2 Stabilizer Bar
1 – LINK
2 – BUSHING
3 – GROMMET
4 – FRAME RAIL
5 – CLAMP
6 – SCREW
7 – NUT
8 – SPRING BRACKET
9 – BOLT
10 – SWAY BAR
11 – SCREW
(1) Assemble tools shown (Fig. 3). Tighten nut at
the socket wrench end of the threaded rod until the
bushing is forced out.
(2) Assemble and align the bushing installation
tools.
(3) Align the bushing with the spring eye or
shackle eye and tighten the nut at the socket wrench
end of the threaded rod. Tighten until the bushing is
forced into the spring eye.
NOTE: The bushing must be centered in the spring
eye. The ends of the bushing must be flush or
slightly recessed within the end surfaces of the
spring eye.
(4) For front bushings bend tabs up after installation.
Fig. 3 Spring Eye Bushing Removal
1 – NUT
2 – PIPE
(RECEIVER)
3 – SPRING EYE
4 – NUT
5 – THREADED ROD
6 – FLAT WASHER
7 – SOCKET WRENCH
(DRIVER)
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Shock Absorber
Upper Bolt ............... 23N·m(17ft.lbs.)
Lower Nut ............... 62N·m(46ft.lbs.)
Stabilizer Bar
Clamp Bolt ............... 54N·m(40ft.lbs.)
Link Upper Bolt ........... 12N·m(9ft.lbs.)
Link Lower Nut ........... 74N·m(55ft.lbs.)
Spring
U-Bolt Nut ............... 70N·m(52ft.lbs.)
Front Pivot Bolt ......... 156N·m(115ft.lbs.)
Upper Shackle Bolt ...... 156N·m(115ft.lbs.)
Lower Shackle Bolt ....... 108N·m(80ft.lbs.)
Page 20
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