suspension DODGE RAM 2002 Service User Guide

KNUCKLE
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the wheel and tire assembly.
(3) Remove the brake caliper and rotor, (Refer to 5
- BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - REMOVAL).
(4) Remove the cotter pin and nut from the tie-rod
end. Remove the tie rod end from the knuckle with
Puller C-3894-A.
(5) Remove the cotter pins and nuts from the
upper and lower ball joints. Separate upper ball joint
from knuckle with remover MD-990635. Separate
lower ball joint with remover C-4150A and remove
knuckle.
INSTALLATION
(1) Position the knuckle on the ball joints and
install the ball joint nuts.
(2) Tighten the upper ball joint nut to 81 N´m (60
ft. lbs.) and install cotter pin.
(3) Tighten the lower ball joint nut to:
²149 N´m (110 ft. lbs.) Install the cotter pin.
(4) Install the tie rod end on the steering knuckle
and tighten the nut to 108 N´m (80 ft. lbs.). Install
cotter pin.
(5) Install the brake rotor and caliper, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - INSTALLATION).
(6) Install wheel and tire assembly (Refer to 22 -
TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(7) Remove support and lower vehicle.
LOWER BALL JOINT
DIAGNOSIS AND TESTING - LOWER BALL
JOINT
(1) Raise the front of the vehicle. Place safety floor
stands under both lower suspension arms as far out-
board as possible. Lower the vehicle to allow the
stands to support some or all of the vehicle weight.
NOTE: The upper suspension arms must not be in
maximum rebound position.
(2) Remove the tire and wheel assembly.
(3) Mount a dial indicator solidly under the lower
suspension arm.
(4) Position indicator plunger against the bottom
of the steering knuckle lower ball joint boss.NOTE: The dial Indicator plunger must be perpen-
dicular to the machined surface of the steering
knuckle lower ball joint boss.
(5) Position a pry bar over the top of the upper
suspension arm and under the pivot bar of the upper
suspension arm. Pry down on the upper suspension
arm and then zero the dial indicator.
(6) Reposition the pry bar under the upper suspen-
sion arm and on top of the frame rail. Pry up on the
upper suspension arm and record the dial indicator
reading.
(7) If the travel exceeds 0.8 mm (0.030 in.) replace
the suspension arm.
LOWER CONTROL ARM
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly.
(3) Remove the brake caliper assembly and rotor,
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
ROTORS - REMOVAL).
(4) Remove the cotter pin and nut from the tie rod.
Remove the tie rod end from the steering knuckle
with Puller C-3894-A.
(5) Remove the stabilizer bar link from lower sus-
pension arm.
(6) Support the lower suspension arm outboard
end with jack. Place a jack under the arm in the
front of the shock mount.
(7) Remove the cotter pin and nut from the lower
ball joint. Separate the ball joint with Remover
C-4150A.
(8) Remove the lower shock bolt from the suspen-
sion arm.
(9) Lower the jack and suspension arm until
spring tension is relieved. Remove spring and rubber
isolator (Fig. 6).
(10) Remove bolts mounting suspension arm to
crossmember and remove arm.
INSTALLATION
(1) Position the suspension arm on the crossmem-
ber and install the bolts and nuts snug.
(2) Install the rubber isolator on top of the spring.
Position the spring into upper spring seat.
(3) Raise the lower suspension arm with a jack
and position the spring into the lower suspension
arm mount.
(4) Install the lower shock bolt and tighten to 142
N´m (105 ft. lbs.).
(5) Install the steering knuckle on the lower ball
joint. Install the lower ball joint nut and tighten to:
2 - 10 FRONT - 2WDBR/BE

²136 N´m (110 ft. lbs.) Install the lower ball joint
cotter pin.
(6) Install the stabilizer bar link on the lower sus-
pension arm. Install the grommet, retainer and nut
and tighten to 37 N´m (27 ft. lbs.).
(7) Install the tie rod end on the steering knuckle
and tighten nut to 108 N´m (80 ft. lbs.). Install cotter
pin.
(8) Install the brake rotor and caliper assembly,
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
ROTORS - INSTALLATION).
(9) Install the tire and wheel assembly, (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(10) Remove the support and lower the vehicle.
(11) Tighten the suspension arm crossmember
nuts to 169 N´m (125 ft. lbs.).
SHOCK
DIAGNOSIS AND TESTING - SHOCK
A knocking or rattling noise from a shock absorber
may be caused by movement between mounting
bushings and metal brackets or attaching compo-
nents. These noises can usually be stopped by tight-
ening the attaching nuts. If the noise persists,
inspect for damaged and worn bushings, and attach-
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 intermit-
tent. This condition is not repairable and the shock
absorber must be replaced.
The shock absorbers are not refillable or adjust-
able. 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 oil-
base lubricants will deteriorate the bushing.
REMOVAL
(1) Raise and support vehicle.
(2) Remove shock upper nut and remove retainer
and grommet.
(3) Remove lower mounting bolt from suspension
arm and remove shock (Fig. 5).
INSTALLATION
(1) Extend shock fully, install retainer and grom-
met on top of shock absorber. Check grommets and
retainer for wear.(2) Guide shock up through upper suspension arm
bracket. Install top grommet, retainer and nut.
Tighten nut to 54 N´m (40 ft. lbs.).
(3) Align bottom end of shock into lower suspen-
sion arm and install mounting bolt. Tighten bolt to
142 N´m (105 ft. lbs.).
(4) Remove support and lower vehicle.
SPRING
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly.
(3) Remove the brake caliper assembly and rotor,
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
ROTORS - REMOVAL).
(4) Remove the cotter pin and nut from the tie rod.
Remove the tie rod end from the steering knuckle
with Puller C-3894-A.
(5) Remove the stabilizer bar link from the lower
suspension arm.
(6) Support the lower suspension arm outboard
end with a jack. Place a jack under the arm in front
of the shock mount.
(7) Remove the cotter pin and nut from the lower
ball joint. Separate the ball joint with Remover
C-4150A.
(8) Remove the lower shock bolt from the suspen-
sion arm.
(9) Lower the jack and suspension arm until
spring tension is relieved. Remove spring and rubber
isolator (Fig. 6).
Fig. 5 Shock
1 - SHOCK
2 - JOUNCE BUMPER
BR/BEFRONT - 2WD 2 - 11
LOWER CONTROL ARM (Continued)

INSTALLATION
(1) Install the rubber isolator on top of the spring.
Position the spring into the upper spring seat.
(2) Raise the lower suspension arm with a jack
and position the spring into the lower suspension
arm mount.
(3) Install the lower shock bolt and tighten to 142
N´m (105 ft. lbs.).
(4) Install the steering knuckle on the lower ball
joint. Install the lower ball joint nut and tighten to:
²136 N´m (110 ft. lbs.) Install the lower ball joint
cotter pin.
(5) Install the stabilizer bar link on the lower sus-
pension arm. Install the grommet, retainer and nut
and tighten to 37 N´m (27 ft. lbs.).
(6) Install the tie rod end on the steering knuckle
and tighten nut to 108 N´m (80 ft. lbs.). Install cotter
pin.
(7) Install the brake rotor and caliper assembly,
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
ROTORS - INSTALLATION).
(8) Install the tire and wheel assembly, (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(9) Remove the support and lower the vehicle.
STABILIZER BAR
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the link nuts, retainers and grommets
from lower suspension arm and stabilizer bar (Fig.
7).
(3) Remove the stabilizer bar clamps from the
frame rails. Remove the stabilizer bar.
INSTALLATION
(1) Position the stabilizer bar on the frame rail
and install the clamps and bolts. Ensure the bar is
centered with equal spacing on both sides. Tighten
the bolts to 54 N´m (40 ft. lbs.).
(2) Install links on stabilizer bar and lower sus-
pension arm. Install grommets, retainers and nuts.
Tighten nuts to 37 N´m (27 ft. lbs.).
(3) Remove the supports and lower the vehicle.
UPPER BALL JOINT
DIAGNOSIS AND TESTING - UPPER BALL
JOINT
(1) Position a floor jack under the lower suspen-
sion arm. Raise the wheel and allow the tire to
lightly contact the floor (vehicle weight relieved from
the tire).
(2) Mount a dial indicator solidly on the upper sus-
pension arm.
(3) Position the indicator plunger against the
upper ball stud boss of the steering knuckle.
(4) Grasp the top of the tire and apply force in and
out. Look for movement at the ball joint between the
upper suspension arm and steering knuckle.
(5) If lateral movement is greater than 0.8 mm
(0.030 in.), replace the suspension arm.
Fig. 6 Coil Spring
1 - COIL SPRING
2 - RUBBER ISOLATER
Fig. 7 STABILIZER BAR
1 - STABILIZER BAR
2 - GROMMET
3 - GROMMET
4 - LINK
2 - 12 FRONT - 2WDBR/BE
SPRING (Continued)

UPPER CONTROL ARM
REMOVAL
(1) Raise and support vehicle.
(2) Remove tire and wheel assembly.
(3) Support lower suspension arm at outboard end
with jack stand.
(4) Remove upper ball joint cotter pin and nut.
(5) Separate ball joint from knuckle with remover
MB-990635.
(6) Remove pivot bar bolts from upper suspension
arm bracket and remove arm from vehicle (Fig. 8).
INSTALLATION
(1) Position the upper suspension arm on the
bracket and install the pivot bar bolts. Tighten to
169 N´m (125 ft. lbs.).
(2) Install the ball joint in the knuckle. Install the
nut and tighten to 81 N´m (60 ft. lbs.) and replace-
ment the cotter pin.
(3) Remove the jack from the lower suspension
arm.
(4) Install the tire and wheel assembly, (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(5) Remove the support and lower the vehicle.(6) Align the front suspension, (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
Fig. 8 Upper Suspension Arm
1 - PIVOT BAR
2 - UPPER SUSPENSION ARM
3 - SUSPENSION ARM FRAME MOUNT
4 - ADJUSTMENT SLOTS
BR/BEFRONT - 2WD 2 - 13

FRONT - 4WD
TABLE OF CONTENTS
page page
FRONT - 4WD
DESCRIPTION
DESCRIPTION........................14
DESCRIPTION........................15
SPECIFICATIONS
TORQUE CHART......................15
SPECIAL TOOLS
LINK/COIL SUSPENSION...............16
HUB / BEARING
REMOVAL.............................16
INSTALLATION.........................17
KNUCKLE
REMOVAL.............................19
INSTALLATION.........................19
UPPER CONTROL ARM
REMOVAL.............................19
INSTALLATION.........................19
UPPER BALL JOINT
REMOVAL - DANA 44 & 60................19
INSTALLATION
INSTALLATION - DANA 44 AXLE..........20
INSTALLATION - DANA 60 AXLE..........20
LOWER CONTROL ARM
REMOVAL.............................20INSTALLATION.........................20
LOWER BALL JOINT
REMOVAL
REMOVAL - DANA 44 AXLE..............21
REMOVAL - DANA 60 AXLE..............21
INSTALLATION
INSTALLATION - DANA 44 AXLE..........21
INSTALLATION - DANA 60 AXLE..........22
SHOCK
DIAGNOSIS AND TESTING - SHOCK........22
REMOVAL.............................22
INSTALLATION.........................22
SPRING
REMOVAL.............................23
INSTALLATION.........................23
STABILIZER BAR
REMOVAL.............................23
INSTALLATION.........................23
TRACK BAR
DIAGNOSIS AND TESTING - TRACK BAR....24
REMOVAL.............................24
INSTALLATION.........................24
FRONT - 4WD
DESCRIPTION
DESCRIPTION
The link/coil suspension allows each wheel to adapt
to different road surfaces. The suspension is com-
prised of (Fig. 1) :
²Shock absorbers
²Coil springs
²Upper and lower suspension arms
²Stabilizer bar
²Track bar
²Steering Knuckles
²Jounce Bumper
Fig. 1 Link/Coil Suspension
1 - STABILIZER BAR
2 - SHOCK ABSORBER
3 - COIL SPRING
4 - UPPER SUSPENSION ARM
5 - LOWER SUSPENSION ARM
6 - TRACK BAR
2 - 14 FRONT - 4WDBR/BE

CAUTION: Components attached with a nut and cot-
ter 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.
CAUTION: Suspension components with rubber
bushings (except stabilizer bar) should be tightened
with the vehicle at normal height. It is important to
have the springs supporting the weight of the vehi-
cle when the fasteners are torqued. If springs arenot at their normal ride position, vehicle ride com-
fort could be affected and premature bushing wear
may occur.
DESCRIPTION
The upper and lower suspension arms use bush-
ings to isolate road noise. The suspension arms are
bolted to the frame and axle through the rubber
bushings. The lower suspension arm uses cam bolts
at the axle to allow for caster and pinion angle
adjustment.
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Shock Absorber
Upper Nut47 35 Ð
Shock Absorber
Lower Bolt135 100 Ð
Shock Absorber
Bracket75 55 Ð
Suspension Arm Lower
Axle Nut190 140 Ð
Suspension Arm Lower
Frame Nut190 140 Ð
Suspension Arm Upper
Axle Nut163 120 Ð
Suspension Arm Upper
Frame Nut163 120 Ð
Stabilizer Bar
Clamp Bolt54 40 Ð
Stabilizer Bar
Link Upper Nut37 27 Ð
Stabilizer Bar
Link Lower Nut47 35 Ð
Track Bar
Ball Stud Nut95 70 Ð
Track Bar
Axle Bracket Bolt176 130 Ð
Hub/Bearing
Nut245 180 Ð
Hub/Bearing
Bolts166 122 Ð
BR/BEFRONT - 4WD 2 - 15
FRONT - 4WD (Continued)

SPECIAL TOOLS
LINK/COIL SUSPENSION
HUB / BEARING
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the wheel and tire assembly.
(3) Remove the hub extension mounting nuts and
remove the extension from the rotor if equipped (Fig.
2).(4) Remove the brake caliper, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - REMOVAL).
(5) Remove the cotter pin and the hub nut from
the axle shaft (Fig. 3).
(6) Disconnect the ABS wheel speed sensor wire
from under the hood. Remove the sensor wire from
the frame and steering knuckle if equipped.
(7) Back off the hub/bearing mounting bolts 1/4
inch each (Fig. 4). Then tap the bolts with a hammer
to loosen the hub/bearing from the steering knuckle.
(8) Remove the hub/bearing mounting bolts and
remove the hub/bearing.
Puller C-3894±A
Remover, Wheel Stud C-4150A
Fig. 2 Hub Extension
1 - HUB EXTENSION
2 - HUB
Fig. 3 Hub Nut Cotter Pin
1 - HUB NUT
2 - COTTER PIN
Fig. 4 Hub/Bearing Mounting Bolts
1 - SOCKET AND EXTENSION
2 - ROTOR AND HUB
3 - STEERING KNUCKLE
2 - 16 FRONT - 4WDBR/BE
FRONT - 4WD (Continued)

KNUCKLE
REMOVAL
(1) Remove hub bearing and axle shaft.
(2) Remove tie-rod or drag link end from the steer-
ing knuckle arm.
(3) Remove the ABS sensor wire and bracket from
knuckle. Refer to Brakes, for proper procedures.
(4) Remove the cotter pin from the upper ball stud
nut. Remove the upper and lower ball stud nuts.
(5) Strike the steering knuckle with a brass ham-
mer to loosen.
(6) Remove knuckle from axle tube yokes.
INSTALLATION
(1) Position the steering knuckle on the ball studs.
(2) Install and tighten lower ball stud nut to 47
N´m (35 ft. lbs.) torque. Do not install cotter pin at
this time.
(3) Install and tighten upper ball stud nut to 94
N´m (70 ft. lbs.) torque. Advance nut to next slot to
line up hole and install new cotter pin.
(4) Retorque lower ball stud nut to 190±217 N´m
(140±160 ft. lbs.) torque. Advance nut to next slot to
line up hole and install new cotter pin.
(5) Install the hub bearing and axle shaft.
(6) Install tie-rod or drag link end onto the steer-
ing knuckle arm.
(7) Install the ABS sensor wire and bracket to the
knuckle. Refer to Brakes, for proper procedure.
UPPER CONTROL ARM
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the upper suspension arm nut and bolt
at the axle bracket (Fig. 12).
(3) Remove the nut and bolt at the frame rail and
remove the upper suspension arm.
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 nut at the axle bracket to 163 N´m
(120 ft. lbs.). Tighten nut at frame bracket to 163
N´m (120 ft. lbs.).
UPPER BALL JOINT
REMOVAL - DANA 44 & 60
(1) Position tools as shown to remove upper ball
stud (Fig. 13).
Fig. 12 Upper and Lower Suspension Arm
1 - STABILIZER BAR
2 - SHOCK ABSORBER
3 - COIL SPRING
4 - UPPER SUSPENSION ARM
5 - LOWER SUSPENSION ARM
6 - TRACK BAR
Fig. 13 UPPER BALL JOINT REMOVAL
1 - SPECIAL TOOL C4212-F
2 - SPECIAL TOOL 6761
3 - KNUCKLE
4 - SPECIAL TOOL 8445-3
BR/BEFRONT - 4WD 2 - 19

INSTALLATION
INSTALLATION - DANA 44 AXLE
(1) Position tools as shown to install upper ball
stud (Fig. 14).
INSTALLATION - DANA 60 AXLE
(1) Position tools as shown to install upper ball
stud (Fig. 15).
LOWER CONTROL ARM
REMOVAL
(1) Raise and support the vehicle.
(2) Paint or scribe alignment marks on the cam
adjusters and suspension arm for installation refer-
ence (Fig. 16).
(3) Remove the lower suspension arm nut, cam
and cam bolt from the axle.
(4) Remove the nut and bolt from the frame rail
bracket and remove the lower suspension arm (Fig.
12).
INSTALLATION
(1) Position the lower suspension arm at the axle
bracket and frame rail bracket.
(2) Install the rear bolt and finger tighten the nut.
(3) Install the cam bolt, cam and nut in the axle
and align the reference marks.
(4) Remove support and lower the vehicle.
(5) Tighten cam nut at the axle bracket to 190
N´m (140 ft. lbs.). Tighten rear nut at the frame
bracket to 190 N´m (140 ft. lbs.).
Fig. 14 UPPER BALL JOINT INSTALLATION
1 - SPECIAL TOOL C-4212-F
2 - SPECIAL TOOL 6758
3 - BALL JOINT
4 - SPECIAL TOOL 6289-C
5 - KNUCKLE
Fig. 15 UPPER BALL JOINT INSTALLATION
1 - SPECIAL TOOL C4212-F
2 - SPECIAL TOOL 8445-2
3 - BALL JOINT
4 - KNUCKLE
Fig. 16 Cam Adjuster
1 - ADJUSTMENT CAM
2 - AXLE BRACKET
3 - BRACKET REINFORCEMENT
4 - LOWER SUSPENSION ARM
2 - 20 FRONT - 4WDBR/BE
UPPER BALL JOINT (Continued)

SPRING
REMOVAL
(1) Raise and support the vehicle. Position a
hydraulic jack under the axle to support it.
(2) Paint or scribe alignment marks on lower sus-
pension arm cam adjusters and axle bracket for
installation reference.
(3) Remove the upper suspension arm and loosen
lower suspension arm bolts.
(4) Mark and disconnect the front propeller shaft
from the axle 4x4 models.
(5) Disconnect the track bar from the frame rail
bracket.
(6) Disconnect the drag link from pitman arm.
(7) Disconnect the stabilizer bar link and shock
absorber from the axle.
(8) Lower the axle until the spring is free from the
upper mount. Remove the coil spring.
INSTALLATION
(1) Position the coil spring on the axle pad.
(2) Raise the axle into position until the spring
seats in the upper mount.
(3) Connect the stabilizer bar links and shock
absorbers to the axle bracket. Connect the track bar
to the frame rail bracket.
(4) Install the upper suspension arm.
(5) Install the front propeller shaft to the axle 4x4
model.(6) Install drag link to pitman arm and tighten
nut to specifications. Install new cotter pin.
(7) Remove the supports and lower the vehicle.
(8) Tighten the following suspension components
to specifications:
²Link to stabilizer bar nut.
²Lower shock bolt.
²Track bar bolt at axle shaft tube bracket.
²Upper suspension arm nut at axle bracket.
²Upper suspension nut at frame bracket.
²Align lower suspension arm reference marks and
tighten cam nut.
²Lower suspension nut at frame bracket.
STABILIZER BAR
REMOVAL
(1) Raise and support the vehicle.
(2) Hold the stabilizer link shafts with a wrench
and remove the link nuts at the stabilizer bar.
(3) Remove the retainers and grommets from the
stabilizer bar links.
(4) Remove the stabilizer bar link nuts from the
axle brackets.
(5) Remove the links from the axle brackets with
Puller C-3894-A (Fig. 24).
(6) Remove the stabilizer bar clamps from the
frame rails and remove the stabilizer bar.
INSTALLATION
(1) Position the stabilizer bar on the frame rail
and install the clamps and bolts. Ensure the bar is
centered with equal spacing on both sides.
(2) Tighten the clamp bolts to 54 N´m (40 ft. lbs.).
(3) Install links to the axle bracket and tighten
nut to 47 N´m (35 ft. lbs.).
Fig. 23 Shock Absorber Axle Mount
1 - SHOCK
2 - SPRING
3 - FLAG NUT
4 - SHOCK BOLT
Fig. 24 Stabilizer Link
1 - PULLER
2 - LINK
BR/BEFRONT - 4WD 2 - 23
SHOCK (Continued)