204 JAGUAR X308 1998 2.G User Guide

3. Lower front of vehicl
e.

4. W
A
RNING: ENSURE THAT THE DOWEL OF TOOL 204-114
IS CORRECTLY POSITIONED ACROSS THE SUSPENSION TURRET
SLOT.
Locate special tool in suspension turret slot.
Pas s
special tool 204-114 thro
ugh slot in suspension turret
and rotate stem to locate dowel.

5. WARNING: WHE N
TIGHTENING
TOOL NUT, USE LOWER
DOWEL AS A GUIDE TO ENSURE THAT THE TOOL STEM DOES
NOT ROTATE AND DISTURB POSITION OF DOWEL IN
SUSPENSION TURRET.
Tighten nut of special tool 204-114 to full extent, to achieve
suspension mid-laden position.
6. Ra
ise front of vehicle and support
on stands. refer to Section
100-02.
7. Remove appropriate road wheel. Refer to Section 100-02.

8. Remove an d discard tiestraps se
curing wheel speed sensor
harness to upper wishbone.
9. Move steering to appropriate full lock for access to suspension.

10 . R
emove nut securing upper wish
bone ball joint to vertical
link.
11. CAUTION: Do not use special tool 211-098 in the

f
ollowing procedure as this will
damage the ball joint gaiter.
Release wishbone ball joint from vertical link.
1. Install special tool 204-192 on upper wishbone ball joint.
2. Tighten bolt of special tool to release ball joint
taper from vertical link.
12. Remove special tool from ball joint.

13
.
Lift upper wishbone to withdraw ball joint from vertical link.

14
.
To prevent damage to lower ball joint, secure vertical link to
road spring using strong wire.

15
.
Remove upper wishbone fulcrum nut and bolt and withdraw
wishbone from vehicle.
16. Secure upper wishbone in a vise.
17. Using a hacksaw, partially cut through two diametrically
opposite segments of ball joint flange.

I
nstallation


23
.
Install special tool 204-200 on ball joint and operate press to
release joint from wishbone.
24. Remove special tool from ball joint.
25. Remove ball joint and wishbone from press.
26. Ensuring that their relative positions are clearly marked,
place ball joint, rubber gaiter and retaining clip in a clean
plastic bag and return for warranty purposes.
27. Thoroughly clean wishbone paying particular attention to ball
joint and pivot bolt locations.

1. Inst
all ball joint in wishbone.
Pos

ition support of special tool 204-199 on press bed and
place wishbone on tool.
U
sing ball joint plastic cover to align, position mandrel of
special tool 204-199 on ball joint
Ali
gn assembly with press ram and operate press to fully
seat ball joint in wishbone.
2. Remove tool mandrel 204-199 from ball joint.
3. Remove wishbone and support tool 204-199 from press.
4. Position wishbone on suspensi on beam, install fulcrum shaft
thread rearward, install nu t and tighten to 60-80Nm.

10
.
Install road wheel. Re fer to Section 100-02
11. Raise vehicle, remove stands and fully lower vehicle.

12
.
Fully slacken nut on special tool 204-114.

13
.
Release dowel of special tool from suspension turret slot.
14. Raise vehicle for access an d remove special tool from
suspension.
15. Fully lower vehicle.
16. Carry out steering geometry an d wheel alignment checks and
if necessary adjust. Refer to 57.65.01.

Front Suspension - Rear Lower Arm
Remo
val and Installation
Remov
a
l
CAUTI
O
N: Replacement of
nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the
vehicle. These devices restrict the number of times a nut or bolt can be used. Refer to Section 100-00 for further
information.
S p
ecial Tool(s)

R
o
ad spring compressor
204-111 (JD115)

Taper separator
2
11-098 (JD 100)

Ball
Jo
int Taper Separator
204-192 (JD 219)

Bal l
joint splitter
204-293
1. Ra
ise front of vehicle and support on stands. Refer to Section
100-02.
2. Remove appropriate road wheel. Refer to Section 100-02.

3. CAUTIO
N: Do not suspend caliper from brake hose as
this will damage the hose.
Remove brake calipers from carriers. 1. Remove caliper spring clip.
2. Remove guide pin dust caps.
3. Slacken and withdraw guide pins.
4. Remove caliper from carrier and tie to suspension mounting bracket.
4. Ra
ise vehicle further to provid
e access for Special Tool 204-

1
11 and support on stands. Refer to Section 100-02.

5. Ins
tall Special Tool 204-111 in road spring.
Sl

acken tool adjuster to suit spring length.
Install adaptor

and thrust collar.
Posit

ion stem of tool in center of spring passing dowel
through slot in su spension turret.

6. R
otate stem of Special Tool to
position dowel across slot.

7. W
ARNING: WHEN TURNING TOOL ADJUSTER, ENSURE
THAT TOOL STEM DOES NOT ROTATE AND DISTURB POSITION
OF DOWEL IN SUSPENSION TURRET.
Rotate adjuster of Special Tool to tension spring.

8. R
emove spring pan to lower
wishbone securing bolts.
9. Rotate adjuster of Special Tool to release tension from spring.

10. NOTE
: It is not necessary to re
move Special Tool from spring
at this stage.
Remove spring assembly and Special Tool 204-111 from
suspension turret.
11. Lower vehicle to working heig ht and support on stands.

12 . Remove an
d discard tiestraps
securing wheel speed sensor
harness to upper wishbone.

13 . R
emove wheel speed sensor se
curing screw and withdraw
sensor from vertical link.

14 . R
emove nut securing tie rod oute
r ball joint to steering arm.
15. Release tie rod ball joint from vertical link.

1
. Install special tool 211-098 on tie rod ball joint.
2. Tighten tool bolt to rele ase taper pin from vertical
link.

16
.
Remove nut securing upper wish bone ball joint to vertical
link.

17
.
CAUTION: Do not use special tool 211-098 in the
following procedure as this will damage the ball joint gaiter.
Release upper wishbone ball joint from vertical link/hub
assembly.
1. Install special tool 204-192 on ball joint.
2. Tighten tool bolt to rele ase ball joint taper pin from
vertical link.

18
.
Slacken but do not remove nut securing lower wishbone ball
joint to vertical link.
19. CAUTION: Do not use special tool 211-098 in the
following procedure as this will damage the ball joint gaiter.
Release lower wishbone ball joint from vertical link/hub
assembly.

1.
Install special tool 204-293 on ball joint.
2. Tighten tool bolt to rele ase ball joint taper pin from
vertical link.
20. Remove special tool 204-293 from ball joint.

21 . R
emove vertical link/hub assembly.
Support
ing ver
tical link/ hu
b assembly, remove lower
wishbone ball joint nut.
R e
move vertical link /hub assembly.

22 . R
emove stabilizer bar link to
wishbone securing nut and bolt.

23 . R
emove wishbone front arm to
rear arm securing bolt .
24. Slacken but do not remove shock absorber lower nut and
bolt.

12
.
Install nut securing upper ball jo int to vertical link and tighten
to 60-80Nm.

13
.
Position tie rod ball joint taper pin on steering arm and install
and tighten nut to 71-85Nm.
14. Raise vehicle and support on st ands to provide access for
Special Tool 204-111 and road spring.

15
.
Install spring pan, rubber lowe r seat, spring and rubber upper
seat on Special Tool 204-111.
16. Install road spring in suspension turret.
Install
spring pan/spring as
sembly and Special Tool 204-
111 in suspension turret.