engine DODGE TRUCK 1993 Service Owner's Guide

0
- 24
LUBRICATION
AND
MAINTENANCE

•
CAUTION:
Do not
overfill
the
transmission.
(9) Adjust
the
level
of the ATF
accordingly.
It
is
important
to use the
correct fluid
in an

automatic transmission. MOPAR®ATF PLUS
(ATF Type
7176)
should
be
used. Dexron®
II

ATF
can be
used
if the
recommended fluid
is not
available,
(10) Insert
the
dipstick into
the
tube.

DRAIN, FILTER CHANGE, BAND ADJUSTMENT AND REFILL
The chart below lists
the
intervals
at
which
the

transmission should
be
serviced. Also, refer
to the

Fluid Capacities chart
for
fill capacity.
AUTOMATIC TRANSMISSION SERVICE
IN-
TERVALS

Normal

Usage
Light
Duty
Cycle

60 000
km
37,500
miles

Heavy
Duty
Cycle

38
000 km 24,000
miles

Severe
Usage
19 000 km 12,000
miles

J9100-19

It
is
very important
to use the
correct fluid
in

an automatic transmission. MOPAR®ATF PLUS
(ATF Type
7176)
should
be
used.
An
equivalent
Dexron®
II ATF
could
be
used only
if the
recom­
mended fluid
is not
available.
The torque converter does
not
have
a
drain plug.
No attempt should
be
made
to
drain
the
converter.
Refer
to
Group
21
—Transmissions
for
transmission
drain
and
refill procedures.

TRANSFER
CASE
(4WD
VEHICLES)
INSPECTION The NP205
and
NP241 transfer cases fluid level
should
be
checked whenever maintenance
is
neces­
sary under
the
vehicle.

FLUID
LEVEL
The vehicle must
be
level when
the
fluid level
is checked.
The transfer case drain fill hole plugs
are
located
at
the
rear
of the
housing (Figs.
4 and 5).

Determine
the
transfer case fluid level according
to

the following procedure.
(1) Raise
and
support
the
vehicle.
(2) Remove
the
fill hole plug (Figs.
4 and 5)
from
the transfer case.
The
fluid level should
be at the

bottom edge
of the
fill hole.
The
level
can be
slightly
below
the
bottom edge
of the
fill hole
if the
fluid
is
cold.
(3)
If the
level
is not
acceptable, raise
the
fluid
level
to the
bottom edge
of the
fill hole with: • MOPAR®ATF PLUS
or an
equivalent Dexron
II®

ATF
for
NP241 transfer case
• Multi-purpose gear
oil (API GL-5) or
engine
oil

(API
SG,
SG/CD
OR
SG/CE)
for
NP205 transfer

cases.

Add fluid
in
small amounts
to
raise
the
level. (4) Install
the
fill hole plug (Figs.
4 and 5).

Tighten
the
fill hole plug
to 27 N-m (20
ft-lbs) torque.
(5) Remove
the
support
and
lower
the
vehicle.

Fig.
4
HP241 Transfer
Case
Fig.
5
NP205 Transfer
Case

FLUID DRAIN
AND
REFILL The transfer case fluid should
be
changed every
60

000
km
(37,500 miles).
For
vehicles subject
to the

HEAVY DUTY CYCLE Maintenance Schedule,
a 58

000
km
(36,000 miles) interval
is
recommended.
(1) Raise
and
support
the
vehicle.
(2) Remove
the
fill hole plug (Figs.
4 and 5)
from
the transfer case. (3) Place
an
appropriate container under
the
trans­
fer case drain hole plug (Figs.
4 and 5).
(4) Remove
the
drain hole plug. Drain
the
fluid
from
the
transfer case into
the
container.

•

LUBRICATION
AND
MAINTENANCE
0 - 25
CAUTION:
Do not
over-tighten
the
drain
and fill
hole

plugs.
Over-tightening
can strip the
hole
threads

and/or crack
the
aluminum housing.

(5) Install the drain hole plug (Figs. 4 and 5) in
the transfer case. Tighten the drain hole plug to 27 N*m (20 ft-lbs) torque. (6) Fill the transfer case to the bottom edge of the
fill hole (Figs. 4 and 5) with: • MOPAR®ATF PLUS or an equivalent Dexron II®
ATF for NP241 transfer cases
• Multi-purpose gear oil (API GL-5) or engine oil (API SG, SG/CD or SG/CE) for NP205 transfer cases. (7) Install the fill hole plug (Figs. 4 and 5) in the
transfer case. Tighten the plug to 27 N«m (20 ft-lbs) torque.
(8) Remove the support and lower the vehicle.
FLUID SPECIFICATION
• MOPAR®ATF PLUS or an equivalent Dexron II®
ATF for NP241 transfer cases • Multi-purpose gear oil (API GL-5) or engine oil (API SG, SG/CD or SG/CE) for NP205 transfer cases
NP20I
MULTI-PURPOSE GEAR OIL/ENGINE
OIL
SELECTION

MULTI-PURPOSE GEAR OIL-if the anticipated
minimum temperature will: • Be above 32°C (90°F)-use SAE 140, API GL-5;
• Decrease to as low as -23°C (-10°F)-use SAE 90,
API GL-5; and • Be below -23°C (-10°F)-use SAE 80, API GL-5. ENGINE OIL—if the anticipated minimum tem­
perature will be: ® Above 0°C (32°F)-use SAE 50, API SG, SG/CD or
SG/CE;
• Below 0°C (32°F)-use SAE 30, API SG, SG/CD or SG/CE.
SHIFT MECHANISM-NP241 AND NP205 The transfer case shift mechanism should be
cleaned and lubricated as necessary.
Lubricate the pivot, the sliding contact areas and
the shift linkage pivot ends with light-weight engine oil (Figs. 6 and 7).

AXLES
INSPECTION/LUBRICANT LEVEL For normal vehicle operation, periodic axle lubri­
cant level checks are not necessary. The exterior of
the axle housing should be inspected for leakage. Check the lubricant level to confirm the leakage.

LUBRICANT LEVEL
(1) Raise the vehicle with an axle or wheel type
hoist. Support the vehicle.
(2) The rear axle differential housings have a rub­
ber, PRESS-IN type fill plug (Fig. 8). Pry the fill
TRANSMISSION

ASSEMBLY
GEARSHIFT
MECHANISM TRANSFER CASE

SCREWS
(2)
50
FT. LBS.
(68 N*m)
CLAMP
SHIFT
ROD

SCREW

80 IN.
LBS.

(9 N*m)
RP1091
Fig.
6 Shift
Mechanism
Lubrication—NP241 Transfer
Case

Fig.
RY682
7 Shift
Mechanism
Lubrication—NP205 Transfer

Case

plug from the differential housing. The front axle (4WD vehicles)*differential housings have a thread­
ed-type fill plug (Fig. 9). Un-thread the fill plug from
the differential housing.
(3) The lubricant level should be within 12 mm
(1/2 in) of the fill hole for the 8.25 and 9.25 rear ax­

les.
The lubricant level should be between 12mm (1/2
in) and 24mm (1 in.) of the fill hole for the Dana ax­

les.

(4) If necessary, add lubricant to raise the level to
the acceptable position.
(5) Install the fill hole plug in the differential
housing (Figs. 8 and 9).

DRAIN
AND
REFILL
Periodic axle lubricant change for normal vehicle
operation is not necessary. Refer to the chart below-

0
- 28
LUBRICATION
AND
MAINTENANCE

•
CHASSIS AND BODY

page

Body
Component Mechanisms
32
Front
Suspension
Ball
Joints
28

Front
Wheel Bearings
29

Headlamps
32

Lower
and
Upper Suspension
Arm
Bushings
.... 30

Manual
Steering Gear
28

STEERING
LINKAGE

INSPECTION When
a
vehicle
is
raised
for
maintenance under
the vehicle,
all
steering components should
be
checked.
LUBRICATION SCHEDULE The steering linkage
is
lubricated with
a
chassis
lubricant. However,
it is
recommended that
the
link­
age
be
inspected
and
lubricated after each:
•
24 000 km
(15,000 miles) interval
or
every
6

months,
for 2WD
vehicles subject
to the
LIGHT
DUTY CYCLE Maintenance Schedule
•
9 600 km
(6,000 miles) interval
or
every
6
months,
for
2WD
vehicles subject
to the
HEAVY DUTY
CY­
CLE Maintenance Schedule
•
12 000 km
(7,500 miles) interval
or
every
6

months,
for 4WD
vehicles subject
to the
LIGHT DUTY CYCLE Maintenance Schedule
•
9 600 km
(6,000 miles) interval
or
every
6
months,
for
4WD
vehicles subject
to the
HEAVY DUTY
CY­
CLE Maintenance Schedule.
LUBRICATION (1) Inspect
the
steering linkage
for
looseness
and

excessive wear. (2) Replace,
all
ruptured seals
and
damaged steer­
ing linkage components. Damaged seals should
be re­

placed
to
prevent leakage
and
contamination
of the
lubricant.

CAUTION:
Use
care
to
prevent lubricant from
con­

tacting
the
brake rotors.

(3) Lubricate
the
steering linkage:
• Clean
the
Zerk type lubrication fittings
on the tie-

rod
and
center link ball-stud ends
• Lubricate
the
ball studs with MOPAR®Multi-Mile- age Lubricant
• Wipe
the
excess lubricant from
the
exterior sur­
faces
of the
ball joints
page

Power
Brake System
30
Power
Steering System
. . 29

Rear
Wheel Bearings
30

Speedometer Cable
33

Steering Linkage
28

Tires
32

FRONT
SUSPENSION
BALL JOINTS

INSPECTION When
a
vehicle
is
raised
for
lubrication/general
maintenance,
the
ball joints should
be
inspected.
LUBRICATION SCHEDULE The front suspension ball joints
are
lubricated dur­
ing manufacture with
a
long-life chassis lubricant.
However,
it is
recommended that
the
ball joints
be

inspected
and the
studs lubricated:
•
At
each
36 000 km
(22,500 miles) interval
or
every
2 years,
for
vehicles subject
to the
LIGHT DUTY
CY­
CLE Maintenance Schedule
•
At
each
9 600 km
(6,000 miles) interval
or
every
2

years,
for
vehicles subject
to the
HEAVY DUTY
CY­
CLE Maintenance Schedule.
4WD vehicles that
are
frequently driven
off-

road should
be
lubricated
at
every engine
oil
change.
LUBRICATION (1) Inspect
the
front suspension. Examine
the
ball
studs
for
looseness
and
excessive wear. (2) Replace
all
torn ball-stud seals
and
damaged
ball joints. Damaged seals should
be
replaced
to
pre­ vent leakage
and
contamination.

CAUTION:
Use
care
to
prevent lubricant from
con­

tacting
the
brake rotors.

(3) Lubricate
the
ball studs:
• Clean
the
Zerk type lubrication fittings
on the

ball-stud ends
• Lubricate
the
ball studs with MOPAR®Multi-Mile-age Lubricant
• Wipe
the
excess lubricant from
the
exterior sur­
faces
of the
ball joints

MANUAL
STEERING
GEAR

LUBRICATION Manual steering gears
are
permanently lubricated
during manufacture. Periodic lubrication
is not
nec­
essary.

•

LUBRICATION
AND
MAINTENANCE
0 - 29
POWER STEERING SYSTEM

SERVICE SCHEDULE

FLUID
LEWEL

WARNING.
THE
POWER
STEERING
FLUID LEVEL
SHOULD
ALWAYS
BE
CHECKED
WITH THE EN­

GINE
OFF TO
PREVENT
PERSONAL
INJURY.

The power steering fluid should be checked when­
ever the engine is being serviced for other reasons. Clean the outside of the cap before removing. The
fluid should be at the proper level indicated on cap dipstick (Fig. 1).

Fig.
1
Power
Steering Reservoir & Cap—Typical
The reservoir fluid level can be determined with
the fluid either hot or cold. If the fluid level is below
the FULL HOT or FULL COLD marks on the dip­ stick, add power steering fluid. The dipstick is at­
tached to the reservoir cap (Fig. 1).
FLUID SPECIFICATION MOPAR03)Power Steering Fluid is highly recom­
mended.

FRONT
WHEEL BEARINGS
INSPECTION/LUBRICATION SCHEDULE

2WD
VEHICLES
It is recommended that 2WD front wheel bearings
be inspected for proper lubrication whenever the
brake rotors are removed or at least: • At each 39 000 km (24,000 miles) interval for ve­
hicles subject to the LIGHT DUTY CYCLE Mainte­ nance Schedule • At each 36 000 km (22,500 miles) interval for ve­
hicles subject to the HEAVY DUTY CYCLE Mainte­ nance Schedule The bearings should be cleaned and re-packed
with a high temperature, multi-purpose EP lu­
bricant.
4WD
VEHICLES

It is recommended that 4WD front wheel bearings
be inspected for proper lubrication whenever the
brake rotors are removed or at least:
• At each 24 000 km (15,000 miles) interval for ve­
hicles subject to the LIGHT DUTY CYCLE Mainte­ nance Schedule
• At each 19 000 km (12,000 miles) interval for ve­
hicles subject to the HEAVY DUTY CYCLE Mainte­ nance Schedule
For vehicles used for extensive off-road, 4WD
operation, the front wheel bearings should be in­ spected every 1 600 km (1,000 miles).
The bearings should be cleaned and re-packed
with a high temperature, multi-purpose EP lu­
bricant whenever the disc brake rotors are re­ surfaced.
INSPECTION If the lubricant:
• Is not sufficient
• Contaminated with foreign particles
• Appears dry or has been contaminated with water
to produce a milky appearance, the bearings should
be cleaned and re-packed with lubricant.

CAUTION:
Do not add
lubricant
to the
wheel
bear­
ings.
Re-pack completely. Mixing
of
different
types
of lubricants
in
wheel
bearings should
be
avoided.
This could possibly result
in
excessive thinning
and
leakage
of the
lubricant.

LUBRICATION (1) Discard the original seal.
(2) Clean the original lubricant from the bearings
and from the hub cavity (Figs. 2 and 3).
(3) Inspect the bearing rollers for indications of
pitting. Light bearing roller discoloration is consid­ ered normal. A wheel bearing must be replaced if any serious damage exists.
(4) Re-pack the bearings with a high temperature,
multi-purpose NLGI GC-LB lubricant. The use of a
bearing packer is recommended. A small amount of fresh lubricant also should be added to the hub cav­ ity.
BEARING INSTALLA TION/ADJUSTMENT (1) Install the hub/rotor (with inner bearing and
seal) on steering knuckle spindle.
(2) Install the outer bearing, the thrust washer
and the nut.
(3) Tighten wheel bearing nut to 27-34 N^m (240-
300 in. lbs.) torque while rotating hub/rotor. This
will seat the bearings.
(4) Loosen the nut 1/4 of-a-turn (90°), then tighten
it finger-tight.

0
- 32
LUBRICATION
AND
MAINTENANCE

•

Fig.
5 Parking Brake Ratio Lever Lubrication (2) Note any indication of brake overheating,
wheel dragging or the vehicle pulling to one side.
(3) Evaluate any performance complaints received
from the owner/operator. (4) Repair the brake system as necessary (refer to
Group 5—Brakes for additional information and ser­
vice procedures).

BODY
COMPONENT
MECHANISMS
LUBRICATION REQUIREMENTS
All operating mechanisms and linkages should be
lubricated when necessary. This will maintain ease of operation and provide protection against rust and
excessive wear. The door weatherstrip seals should
be lubricated to prolong their life as well as to im­ prove door sealing.

LUBRICANT SPECIFICATIONS
All applicable exterior and interior vehicle operat­
ing mechanisms should be:
• Inspected • Cleaned
• All the pivoting/sliding contact areas on the mech­ anisms should then be lubricated.
MOPAR®Multi-Mileage Lubricant or an equiva­
lent, should be used to lubricate the mechanisms.
The door weatherstrip seals should be lubricated
with silicone lubricant spray. Refer to the Body Lu­
bricant Specifications chart below for additional lu­
bricant applications.

LUBRICATION
(1) When necessary, lubricate the cab and cargo
box operating mechanisms with the specified lubri­
cants.

(2) Apply silicone lubricant to a cloth and wipe it
on door seals to avoid over-spray that can soil pas­
senger clothing. (3) Before applying lubricant, the component
should be wiped clean. After lubrication, any excess
lubricant should be removed.
(4) The hood latch, latch release mechanism, latch
striker and safety latch should be lubricated periodi­
cally.
(5) The door lock cylinders should be lubricated 2
times each year (preferably autumn and spring): • Spray a small amount of lock cylinder lubricant di­
rectly into the lock cylinder
• Apply a small amount to the key and insert it into
the lock cylinder • Rotate it to the locked position and then back to
the unlocked position several times
• Remove the key. Wipe the lubricant from it with a
clean cloth to avoid soiling of clothing.

TIRES
RECOMMENDED MAINTENANCE
The condition of the tires should be inspected. The
inflation pressures tested/corrected at the same time as the engine oil is changed and the oil filter is re­
placed.
The tires/wheels should be rotated periodically to
ensure even tread wear. The tires/wheels should be
rotated at the first 12 000 km (7,500-miles) interval.
Thereafter, at each 24 000 km (15,000-miles) inter­
val.
INSPECTION
Inspect the tires for excessive wear, damage. Test
the tires for the recommended inflation pressure and adjust the pressure accordingly. Refer to the tire in­
flation pressure decal located on the left door face. Also to Group 22—Tires And Wheels for tire pres­sure charts, tire replacement, and treadwear indica­

tors.

ROTATION
Tires/wheels should be rotated according to the rec­
ommended interval. The first tire/wheel rotation is
the most important for establishing the prevention of uneven tread wear. After rotation, adjust the tire in­
flation pressure to the air pressure recommended on
the decal located on the left door face.
Refer to Group 22—Tires And Wheels for the rec­
ommended method of tire/wheel rotation.

HEADLAMPS

MAINTENANCE SCHEDULE
Every six months check the headlamp beams to en­
sure that the headlamp beams are correctly posi­
tioned.

AIM
ADJUSTMENT
Refer to Group 8L—Lamps for headlamp aim ad­
justment procedures.

•

LUBRICATION
AND
MAINTENANCE
0 - 33 BODY LUBRICANT SPECIFICATIONS

COMPONENT
SERVICE
INTERVAL
LUBRICANT

Door
Hinges
As
Required
Engine
Oil

Door
Latches
As
Required Multi-Purpose Grease
NLGI
GC-LB

(Water
Resistant)
(1)

Hood
Latch Release Mechanism
&
Safety Latch
As
Required
(When Performing Other Underhood Services) Multi-Purpose Grease
NLGI
GC-LB
2
EP
(2)

Hood
Hinges
As
Required
Engine
Oil

Seat Regulator
&
Track Release Mechanism
As
Required Multi-Purpose Grease
NLGI
GC-LB
2
EP
(2)

Tailgate Hinge
As
Required Multi-Purpose Grease
NLGI
GC-LB
2
EP
(2)

Tailgate Support Arms
As
Required

Engine
Oil

Tailgate Latches
As
Required
White
Spray Lubricant
(3)

Tailgate Release Handle (Pivot & Slide Contact Surfaces)
As
Required Multi-Purpose Grease
NLGI
GC-LB
2
EP
(2)

Window System Components (Regulators, Tracks,
Rods

&
Channel Areas — Except
Glass
Run Weatherstrips
and
Felt
Lubricator,
if
Equipped)
As
Required

White
Spray Lubricant
(3)

Lock
Cylinders Twice/Year
Lock
Cylinder Lubricant
(4)

Parking Brake Mechanism
As
Required Multi-Purpose Grease
NLGI
GC-LB
(1)

1.
Mopar
Wheel
Bearing Grease (High
Temperature)

2. Mopar Multi-Mileage Lubricant 3. Mopar Spray
White
Lube
4. Mopar Lock Cylinder Lubricant

J9200-58

SPEEDOMETER
CABLE

SERVICE INFORMATION Speedometer cable lubrication is not necessary. For
service information involving noisy or erratic cables,
refer to Group 8E—Instrument Panel and Gauges.

•

FRONT SUSPENSION
AND
AXLE
2 - 1
CONTENTS

page

FRONT SUSPENSION—2WD VEHICLES
......
7

FRONT SUSPENSION—4WD VEHICLES
14

FRONT WHEEL
ALIGNMENT
...............
3

GENERAL INFORMATION
1
page

MODEL
44
FRONT AXLE
17

MODEL
80
FRONT AXLE
49

TORQUE SPECIFICATIONS
75

GENERAL
INFORMATION

FRONT SUSPENSION—2WD VEHICLES
All two-wheel drive (2WD)
Ram
Truck
and
Ram­
charger vehicles
are
equipped with (Fig
1);

• Steering knuckles
• Stabilizer
bar
(optional) • Suspension arms
• Strut
rod

• Coil springs
• Dual-action shock absorbers
• Jounce bumpers (used
to
limit
the
travel
of the

suspension) The upper and lower suspension arms (Fig.
1)
have
replaceable bushings located
at the
inboard end.
Re­

placeable ball studs
are
located
at
the
outboard end.
The lower suspension arms
are
equipped with ten­ sion-type ball studs. The upper suspension arms also
provide
for
caster
and
camber adjustments.
STABILIZER
BAR
J9102-67

Fig. 1 Front Suspension—2WD Vehicles

FRONT SUSPENSION—4WD VEHICLES
All four-wheel drive (4WD) Ram Truck
and
Ram­
charger vehicles
are
equipped with (Fig
2);
• Leaf-springs (fixed-rate type)
• Dual-action shock absorbers • Stabilizer
bar
(optional)
• Jounce bumpers (used
to
limit
the
travel
of the

suspension)
Air-adjustable shock absorbers
are
installed
on
ve­

hicles equipped with
the
Heavy Duty Snow Plow Package with
the
Diesel engine. Refer
to
the Own­
ers Manual
for
additional information.
FRONT DRIVE AXLE The front axle
on 4WD Ram
Truck
and
Ram­
charger vehicles
has a
hypoid gear differential.
Model
44
and
60
axles consists
of
an iron center cast­
ing with axle shaft tubes extending from either side.
Ram Truck
and
Ramcharger vehicles equipped
for

standard duty 4WD operation use
the
Model
44
front
axle.
Vehicles equipped
for
heavy duty 4WD operation
use

a Model 60 front axle. The Model 60 front axle has lock­
ing hubs that must
be
engaged
for
4WD operation.
The steel cover provides
a
means
for
service with­
out removing
the
complete axle. A metal axle gear ratio identification
tag is at­

tached
to the
housing cover
via one of the
cover

bolts.
This
tag
also identifies
the
number
of
ring and
pinion gear teeth.
IDENTIFICATION Model
44 and 60
axles have
the
assembly part
number
and
gear ratio listed
on a
tag. The
tag
is at­

tached
to
the
left side
of
the housing cover (Fig.
3,
4).
Build date identification codes
on
axles
are
stamped
on
the
axle shaft tube cover side.

LUBRICANTS
Multi-purpose API
GL
5
quality hypoid gear lubri­
cant should
be
used
for
front axles. MOPAR Hypoid Gear Lubricant conforms
to
these specifications. The axle
has a
fitting
for a
vent hose used
to re­

lieve internal pressure. If the front axle
is
submerged
in
water,
the
lu­

bricant must
be
replaced immediately.

FRONT
SUSPENSION
AND
AXLE

•

FRONT
SUSPENSION
AND
AXLE
2 - 5 (4) Front wheels for excessive radial, lateral
runout and unbalance. Refer to Group 22, Wheels and Tires for diagnosis information.
(5) Suspension components for wear and noise. Check
components for correct torque. Refer to Groups 2 and 3, Suspension and Axle for additional information.

WHEEL
ALIGNMENT
MEASUREMENTS/ADJUSTMENTS
The front wheel alignment positions must be set to
the specified limits. This will prevent abnormal tire
tread wear. The equipment manufacturer's recommenda­
tions for use of their
equipment
should always
be followed. All
damaged
front suspension sys­
tem components
should
be replaced. Do not at­ tempt to straighten any
bent
component.

CAMBER AND CASTER-2WD VEHICLES Camber and caster angle adjustments involve repo­
sitioning the upper suspension arm cam adjustment
bolts (Fig. 2). Alignment adjustments are accom­
plished by loosening the nuts and changing the posi­
tion of the cam bolt.
(1) Remove all foreign material from the adjust­
ment bolt threads.
(2) Record the camber and caster measurements
before loosening the adjustment bolt nuts.
(3) The camber angle should be adjusted as near as
possible to the preferred angle. The caster should be
the same at both sides of the vehicle. Refer to the Specifications chart.
CAMBER AND CASTER—4WD VEHICLES For 4WD vehicles, the correct wheel camber (verti­
cal tilt) angle is factory preset at zero degree (0°).
Camber cannot be altered by adjustment.
CAUTION: Do not attempt to
adjust
the
camber
an­
gle by
heating
or bending the axle or any
suspen­

sion
component. If camber angle is
incorrect,
the
component(s)
causing
an
incorrect
angle must be replaced.
(1) It is important that the camber (vertical tilt)
angle be the same for both front wheels.
(2) The camber angle should be measured with ac­
curate wheel alignment equipment. The acceptable
range is -1° to +1°. Refer to the Specifications chart.
Road test the vehicle and observe the steering
wheel return-to-center position. Before road testing,
check
and
correct
the tire
inflation pressures. Inflate
both
of the front tires
with exactly the
same
pressure.
During the road test, make vehicle turns to both
the left and right. If the steering wheel returns to­
ward the center position unassisted, the caster angle is correct. However, if the steering wheel does not re­ turn toward the center position unassisted, an incor­
rect caster angle is probable.
(1) The caster angle is factory preset at positive
two degrees
(
+
2°).
The acceptable range is +1/2° to +
3
1/2°.
(2) The caster angle should be measured with ac­
curate wheel alignment equipment.
(3) Caster angle can be adjusted by installing ta­
pered shims between the front axle pads and the spring brackets. The caster angle should be adjusted
as near as possible to the preferred angle.
(4) Record the caster measurement before remov­
ing the original shims from the spring pads.
(5) The caster should be the same at both sides of
the vehicle. Refer to the Specifications chart.
RN1030

Fig.
2 Caster &
Camber
Adjustment Location—2WD
Vehicles

WHEEL TOE POSITION The wheel toe position adjustment should be the fi­
nal front wheel alignment adjustment. In all in­ stances, follow the equipment manufacturer's
recommended procedure.
(1) Secure the steering wheel with the front wheels
in the straight-ahead position. For vehicles equipped
with power steering, start the engine before straight­ ening the wheels.
With power steering, the engine should be op­
erating during the wheel toe position adjust­
ment.
(2) Loosen the tie rod adjustment sleeve clamp
bolts (Fig. 3).
(3) Adjust the wheel toe position by rotating the
tie rod adjustment sleeve (Fig. 3). Rotate each tie-rod end in the direction of
sleeve rotation during the adjustment (Fig. 3).
This will ensure that both tie-rod ends are at the center of their travel.
(4) If applicable, turn the ignition switch off.

•

FRONT
SUSPENSION
AND
AXLE
2 • 7
FRONT SUSPENSION
—2WD
VEHICLES

INDEX

page

Coil Springs
9
Lower Ball Stud
. 10

Lower Suspension
Arm 10

Lower Suspension
Arm
Bushing
11

Lower Suspension
Arm
Strut
8

Service
Information
7

Shock
Absorber
9
page

Stabilizer
Bar 8

Steering Knuckle
13
Upper Ball Stud
11

Upper Suspension
Arm 11

Upper Suspension
Arm
Bushing Replacement
. . . 12

Wheel
Hub and
Bearings
7

SERVICE
INFORMATION
Periodic lubrication of the front suspension (steer­
ing) system components is required. Refer to Group 0, Lubrication And Maintenance for the service in­
terval.
Rubber bushings must never be lubricated.
All front suspension components that are
cushioned by rubber should be tightened with
the suspension system at the normal height.

WHEEL
HUB
AND
BEARINGS

REMOVAL (1) Block the brake pedal in the up (non-depressed)
position.
(2) Raise and support the vehicle.
(3) Remove the wheel.
(4) Remove bolts from the disc brake caliper.
(5) Separate the disc brake caliper from the rotor.
Position and support the caliper away from the im­
mediate work area. Do not allow the caliper to
hang from the brake fluid hose.
(6) Remove the dust cap, cotter pin, and remaining
hub components from the spindle (Fig. 1).

CAUTION:
Use care
to
prevent
the
inner wheel bear­
ing
and
bearing seal from contacting
the
steering
knuckle spindle threads during removal
(Fig. 1).

Otherwise,
the
threads, bearing,
and
seal could
all
be damaged.

(7) Carefully slide the wheel hub/rotor from steer­
ing knuckle spindle (Fig. 1).
(8) For bearing cleaning or replacement, remove
the seal and inner wheel bearing from the wheel
hub/rotor bore (Fig. 1).
CLEANING AND INSPECTION (1) Thoroughly clean both wheel bearings and in­
terior of the hub/rotor (Fig. 1). Remove all of the residual lubricant.
(2) To clean the bearings:
• Soak them in an appropriate cleaning solvent
BRAKE
INNER
Fig.
1 Front
Wheel
Bearings
&
Hub/Rotor

• Strike the flat of each bearing against a hardwood
block several times • Flush bearing between strikes
• Repeat the procedure above until each bearing is
clean
• Dry the bearings with compressed air but do not spin them
(3) After cleaning, apply engine oil to each bear­
ing. (4) Rotate each bearing slowly while applying
downward force. Examine the rollers for pitting and
roughness. Replace worn or otherwise defective bear­
ings.
If a bearing has pitted and/or rough surfaced
rollers, replace both the bearing and bearing cup (Fig. 1).
(5) If reusable, remove the engine oil from each
bearing. Pack each bearing with multi-purpose NLGI, grade 2, EP-type lubricant. Place the bearings
in a clean, safe place.
Ensure that lubricant is forced into all the cav­
ities between the bearing cage and rollers.

2
- 14
FRONT SUSPENSION
AND
AXLE

• (3) Mount the knuckle to the suspension arms and
install the nuts. Tighten the upper nut to 142 Nnn (105 ft-lbs) torque and the lower nut.
• 11/16-16 bolt, to 183 Nnn (135 ft-lbs) torque
• 3/4-16 bolt, to 237 Nnn (175 ft-lbs) torque Install replacement cotter pins. (4) Connect the tie-rod end. Install and tighten the
nut to 61 Nnn (45 ft-lbs) torque. Install a replace­
ment cotter pin. (5) Position a replacement dust seal on the steer­
ing knuckle. Install the splash shield and tighten the
bolts to 24 Nnn (18 ft. lbs.) torque. (6) Install the shock absorber, refer to the installa­
tion procedures.
(7) Install the hub/rotor, refer to the procedures
above.
(8) Install the brake caliper, refer to Group 5,
Brakes for additional installation information.

(9)
Install the wheel and tire, refer to Wheel and
Tire Installation in this section. Lower the vehicle.
(10) Test the vehicle brakes and the front suspen­
sion for proper operation.

FRONT
SUSPENSION—4WD VEHICLES

STABILIZER
BAR REMOVAL
(1) Remove the link rod nut at each end of the sta­
bilizer bar (Fig. 1).
STABILIZER BAR

FRONT

STABILIZER BAR BUSHING
RETAINER

LINK
ROD

J9017-37

Fig.
1
Stabilizer
Bar (2) Remove the outer retainers and rubber bush­
ings from the link rods (Fig. 1). (3) Remove the bolts or nuts from the U-shaped
stabilizer bar support brackets. Remove the stabilizer
bar from the vehicle (Fig. 1).
INSTALLATION (1) Position the stabilizer bar ends over the link

rods.
Install the U-shaped support brackets and bolts/
nuts (Fig. 1). Tighten the bolts/nuts to 23 Nnn (200
in. lbs.) torque.
(2) Install the outer retainers and rubber bushings
on the link rods (Fig. 1). (3) Install the link rod nuts (Fig. 1). Tighten the
nuts to 11 Nnn (100 in. lbs.).
SHOCK
ABSORBER

SERVICE INFORM
A TION Air-adjustable shock absorbers are installed on ve­
hicles equipped with the Heavy Duty Snow Plow Package and Diesel engine.

REMOVAL
(1) Remove the shock absorber upper nut and re­
tainer from the frame bracket (Fig. 2).
PLATE
BRACKET
NUT
AXLE NUT
AXLE

J9202-99

Fig.
2
Shock
Absorber
(4
WD)
(2) Remove the shock absorber lower nut and re­
tainer from the axle. Pull the shock outward at top and swing down to remove.
(3) Remove the inner retainers from the mounting

studs.

INSTALLATION (1) Before installing the shock absorber, ensure
that the bushing is inserted in the shock absorber
eye.