brakes DODGE TRUCK 1993 Service Repair Manual
[x] Cancel search | Manufacturer: DODGE, Model Year: 1993, Model line: TRUCK, Model: DODGE TRUCK 1993Pages: 1502, PDF Size: 80.97 MB
Page 4 of 1502
GROUP TAB LOCATOR
Introduction
0
Lubrication
and
Maintenance
2
Front Suspension
and
Axle
3
Rear Suspension
and
Axles
5
Brakes
6
Clutch
7
Cooling System
8
Electrical
9
Engines
11
Exhaust System
and
Intake
Manifold
13
Frame
and Bumpers
14
Fuel
System
16
Propeller Shafts
19
Steering
21
Transmission
and
Transfer Case
22
Wheels and Tires
23
Body Components
24
Heating
and Air
Conditioning
25
Emission Control Systems Component and System Index
Service Manual Comment Forms (Rear
of
Manual)
Page 7 of 1502
2 INTRODUCTION
•
MFD
BY
GAWR
FRONT
GAWR REAR
CHRYSLER
CORPORATION
DATE
OF MFR
GVWR
WITH
TIRES
WITH
TIRES
RIMS
AT
RIMS
AT
PSI
COLD
PSI
COLD
THIS
VEHICLE CONFORMS
TO
ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY
STANDARDS
IN
EFFECT ON
THE
DATE
OF
MANUFACTURE SHOWN ABOVE.
SINGLE
DUAL
MDH:
BAR
CODE
VEHICLE MADE
IN
4648503
J9HN-25
Fig. 1 Vehicle Safety Certification Label
The Vehicle Identification Number is also im
printed on the:
• Body Code Plate
• Equipment Identification Plate
• Vehicle Safety Certification Label
• And on a frame rail.
VEHICLE CODE PLATE
A metal vehicle code plate (Fig. 2) is attached to
top,
right side of cowl below cowl grille. There can be a maximum of seven rows of vehicle information im
printed on the plate. The information should be read
from left to right, starting with line 1 at the bottom
of the plate up to line 7 (as applicable) at the top of
the code plate. Refer to the decoding chart to decode lines 1
through 3.
Lines 4 through 7 on the plate are imprinted in se
quence according to the following descriptions:
• 3-character sales code • 3-digit numerical code
• 6-digit SEC code If there is not enough space left in the row for all
of the 6-digit SEC code:
• The unused space will remain blank
• The code will be listed in the next row.
The last nine positions of row 7 will contain a
2-digit code and a 6-digit serial number.
The last code on a vehicle code plate will be fol
lowed by the imprinted word END. When two plates
are required, the last available spaces on the first
plate will be imprinted with the letters CTD (for con tinued).
When a second vehicle code plate is necessary, the
first four spaces on each row will not be used because of the plate overlap.
To retrieve information from a vehicle code plate:
• Illuminate the plate with a shop light
• View the plate via the cowl grille slots
• Record the needed coded information.
ENGINE AND TRANSMISSION/TRANSFER CASE
IDENTIFICATION
Refer to Group 9—Engines for all engine identifi
cation data. Refer to Group 21—Transmissions for all transmis
sion/transfer case identification data.
VEHICLE IDENTIFICATION NUMBER (VIN) DECODING
Country
1
=
United States
2
=
Canada
3
=
Mexico Vehicle Type
4
=
Multipurpose
Passenger
5
=
Bus
6
=
Incomplete
7
=
Truck
GVWR
and
Hydraulic Brakes
0001 3001
4001
5001 6001
7001 8001
9001
10,001
Bus
or I
3000
4000
5000 6000
7000 8000
9000
10,000
14,000
nc.
Truck Line
E
=
Ramcharger
4x2
Chassis
Cab
4x2
Pickup
4x2
M
=
Ramcharger
4x4
Chassis
Cab
4x2
Pickup
4x4
Engines
X
=
3.9L
(MPI)
Y = 5.2L
(MPI)
Z
=
5.9L
(EFI)
5
=
5.9L HDC
8
=
5.9L Turbo Diesel Sequential
Serial Number
Six
Digit Numbers
Series
0 =
150S Job Rated
1
= 150
Job Rated
2
= 250
Job Rated
3
= 350
Job Rated
Body
3
=
Club Cab 6
=
Conventional Cab
9
=
Sport
Utility
2 DR
Plant Location
S
=
Dodge City
M
=
Lago
Alberto J931N-18
Page 49 of 1502
0 - 30
LUBRICATION
AND
MAINTENANCE
— - •
Fig.
2 Front
Wheel
Bearing—2WD Vehicles
Fig.
3 Front
Wheel
&
Spindle
Bearings—4WD
Vehicles
(5) Position nut lock on the nut with one pair of
slots aligned with the cotter pin hole. Install the cot
ter pin.
(6) Install the dust cap and wheel/tire. Tighten the
wheel lug nuts to 115 N*m (85 ft. lbs.) torque. Install
the wheel cover.
LUBRICANT SPECIFICATION
Use a high temperature, multi-purpose NLGI
GC-LB lubricant (MOPAR®Wheel Bearing Lubricant,
or an equivalent lubricant).
REAR
WHEEL BEARINGS
LUBRICATION
DANA
60
AND
70
AXLES
The rear wheel bearings for vehicles equipped with
a Dana 60 or 70 axle should be cleaned and re
packed whenever the rear brakes are serviced. Refer
to Group 3—Rear Axles for the service procedure.
CHRYSLER
AXLES
, Vehicles equipped with 8 3/8-inch and 9
1/4-inch
axles have axle shaft bearings instead of wheel bear
ings.
These bearings are lubricated by the axle hous
ing sump.
LOWER
AND UPPER
SUSPENSION
ARM
BUSHINGS
INSPECTION
SCHEDULE
The lower and upper suspension arm bushings
should be inspected each time the underside of the
vehicle is serviced.
INSPECTION
The lower suspension arm bushings can be visually
inspected by raising the vehicle on a hoist and in specting from underneath. The upper suspension arm
bushings can be inspected after removing the front wheels. If failure exists, replace the bushing (refer to Group 2—Front Suspension for the proper proce
dures).
The suspension arm bushings never should be
lubricated.
GUIDELINES
(1) Faulty bushings are detected by the bushing
being off-center in relation to the outer sleeve.
(2) Total failure is evident by excessive movement
within the bushing.
(3)
Small cracks in the outer, non-confined rubber
does not indicate failure of the rubber. '
POWER BRAKE SYSTEM
Vehicles are equipped with power disc brakes at
the front wheels and drum brakes at the rear wheels.
MASTER CYLINDER
FLUID
LEVEL INSPECTION
The brake fluid level should be inspected at the
same time as other underhood service is done (Fig.
4).
If necessary, add fluid to raise the level to the
bottom of the split rings. With disc-brakes, the fluid level can be expected to lower as the brake pads
wear. However, a low fluid level can also be caused
by a leak, and repair will then be necessary.
Page 51 of 1502
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.
Page 57 of 1502
2 - 4 FRONT SUSPENSION AND AXLE
•
I
FRONT END
|
|*?£E;
LOOSE
OR WORN
FRONT WHEEL
BEARINGS
LOOSE
C
SHOCKS
MOUNTir
WAR
SHOCK
A )RWORN
JSORBER
nIG
HARD-
E
OR
BSORBER
EXCiSSIVE
PLAY
STEERING
LINKAGE
LOOSE
OR WORN
FRONT WHEEL
BEARINGS
LOOSE
C
STEERINC
SHAFT
C
)RWORN
7
COLUMN
OUPLING
DIFFICULT
STEERING
LOOSE
OR WORN
WHEEL BEARINGS
TIRE/V
OUT OF
f
VHEEL
JA
LANCE
LOW OR UNEVEN
TIRE
AIR
PRESSURE
LO(
WHEEL B
DSE
EARINGS
LOW OR UNEVEN
TIRE AIR
PRESSURE
1vsnciEi
I
1
PULLS
TO I
I
|
ONE SIDE
j
LOOSE,
WORN
OR
GLAZED
P/S PUMP BELT LOW OR UNEVEN
TIRE PRESSURE
WHILE BR
REFE
BRAKES
AKING—
R
TO
SERVICE
LOOSE
STEERING
GEAR-TO-FRAME
RAIL BOLTS
LOOSE
STEERING
GEAR-TO-FRAME
RAIL BOLTS UNEVEN TIRE TREAD
WEAR,
OR
EX
CESSIVELY
WORN TIRE TREAD
BROKEN
OR WEAK
REAR
SPRING LOW
POWER STEERING
FLUID
LEVEL
BROKEN
OR WEAK
REAR
SPRING
WORN
UPPER
SUSPENSION ARM BUSHINGS WORN TIE-
ROD
END
BALL
STUDS WORN TIE-
ROD
END
BALL
STUDS
SHOCK
ABSORBER
NOT FUNCTIONING
CORRECTLY
LACK
OF ASSIST
FROM POWER
STEERING
PUMP
LOOSE
OR WORN
SUSPENSION
BUSHINGS
WORN LOWER
SUSPENSION
ARM
PIVOT
BUSHINGS INCORRECT
STEERING
GEAR ADJUSTMENT
LOOSE
OR WORN
SUSPENSION
ARM
BUSHINGS
INCORRECT
STEERING
GEAR ADJUSTMENT
BALL
STUDS
REQUIRE
LUBRICATION INCORRECT FRONT
WHEEL ALIGNMENT (EITHER CASTER OR CAMBER)
LOOSE
LOWER
SUSPENSION
ARM
LOOSE
OR WORN
UPPER
SUSPENSION ARM BALL STUDS
LOOSE
OR WORN
SUSPENSION
ARM
BUSHINGS
STEERING
GEAR
LUBRICANT LEVEL LOW
WORN ISOLATOR
PAD
BETWEEN COIL
SPRING
AND
FRAME
BRACKET INCORRECT FRONT-
WHEEL ALIGNMENT (PARTICULARLY
CASTER)
INCORRECT FRONT
WHEEL ALIGNMENT INCORRECT
STEERING
GEAR ADJUSTMENT
STEERING
GEAR
MALFUNCTION
INCORRECT FRONT
WHEEL ALIGNMENT (PARTICULARLY
CASTER)
J9002-97
SUSPENSION AND STEERING
SYSTEM
DIAGNOSIS
Page 61 of 1502
2
- 8
FRONT SUSPENSION
AND
AXLE
• INSTALLATION
(1) If a bearing and cup must be replaced, remove
the cup from the wheel hub/rotor bore (Fig. 1). Use a
brass drift or an appropriate removal tool to tap out
the cup.
(2) Install the replacement bearing cup(s) with an
appropriate installation tool. (3) Apply lubricant to surface area of the wheel
hub/rotor bore. Install the inner wheel bearing in the
hub/rotor. Install a replacement bearing seal with an appropriate seal installation tool. (4) Inspect the bearing and seal contact surfaces on
the steering knuckle spindle for burrs and/or rough ness (Fig. 1).
(5) Remove all the rough contact surfaces from the
spindle. Apply a coating of multi-purpose NLGI,
grade 2, EP-type lubricant to the spindle surface.
CAUTION: Us© 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
be
damaged.
(6) Carefully slide the wheel hub/rotor onto the
spindle.
Install the outer wheel bearing, the washer and
nut.
(7) Tighten the nut to 41 to 54 Nnn (30 to 40 ft.
lbs.) torque while rotating the wheel hub/rotor. Stop
the hub/rotor and loosen the nut to completely re
lease the bearing preload torque. Next, tighten the
nut finger-tight, install the nut lock. Install a re
placement cotter pin.
(8) The wheel bearing adjustment (above) should
have 0.001 to 0.003 inch (0.254 to 0.0762 mm) end
play.
(9) Clean the dust cap. Apply a coating of multi
purpose NLGI, grade 2, EP-type lubricant to internal surface. Install the cap. Do not fill the dust cap with lubricant. (10) Install the brake caliper, refer to Group 5,
Brakes. (11) Install the wheel and tire, refer to Wheel and
Tire Installation in this section. Lower the vehicle.
LOWER SUSPENSION ARM STRUT
REMOVAL (1) Raise and support the vehicle.
(2) Use a small drift and a hammer to drive the
spring pin from the front of the strut. Remove the
spring pin, nut, retainer and bushing from the end of
the strut (Fig. 2).
(3) Remove the strut rear bolts and jounce bumper
from the bracket. Remove the strut from the vehicle (Fig. 2).
NUT
FRONT
RETAINER
STRUT
J9002-120
Fig. 2 Lower Suspension Arm Strut Removal/ Installation INSTALLATION
(1) Position the rear retainer and rear bushing on
the front end of the strut (Fig. 2).
(2) Carefully slide the strut into position. Install
the rear bolts. Tighten the bolts to 182 Nnn (135 ft. lbs.) torque.
(3) Install the front bushing, front retainer and
nut at the front end of the strut. Tighten the nut
with 70 Nnn (52 ft. lbs.) torque.
(4) Install the spring pin.
STABILIZER
BAR
REMOVAL
(1) Remove the link rod nut at each end of the sta
bilizer bar (Fig. 3). Fig. 3 Stabilizer Bar
Page 62 of 1502
4
FRONT
SHOCK ABSORBER
J9017-29
Fig.
4
Coil Spring Suspension INSTALLATION
(1) Extend shock fully, install retainer on shock
absorber. Install bushing and sleeve, make sure they
are not worn or broken.
(2) Guide shock up through coil spring. Install top
retainer and nut. Tighten nut to 34 Nnn (25 ft. lbs.)
torque.
(3) Align lower end of shock and install mounting
bolts.
Tighten bolts to 23 Nnn (200 in. lbs.) torque.
FRONT SUSPENSION
AND
AXLE
2 - i
Fig.
5
Spring Compressor
&
Ball
Stud Loosening
Tools
Installed (8) Remove the loosening tool. Slowly loosen the
coil spring compressor tool until all tension is re lieved from the spring. Remove the spring compres
sor and spring with the rubber isolation pad.
(2) Remove the outer retainers and rubber bush
ings from the link rods (Fig. 3).
(3) Remove the bolts or nuts from the U-shaped
stabilizer bar support brackets. Remove the stabilizer
bar from the vehicle (Fig. 3).
INSTALLATION
(1) Position the stabilizer bar ends over the link
rods.
Install the U-shaped support brackets and bolts/ nuts (Fig. 3). Tighten the bolts/nuts to 23 Nnn (200
in.
lbs.) torque. (2) Install the outer retainers and rubber bushings
on the link rods (Fig. 3).
(3) Install the link rod nuts (Fig. 3). Tighten the
nuts to 11 Nnn (100 in. lbs.).
SHOCK ABSORBER
REMOVAL
(1) Raise vehicle on hoist. Position support stands
on frame and lower front hoist.
(2) Remove upper nut and retainer.
(3) Remove two lower mounting bolts, lower shock
from suspension arm (Fig. 4). (4) Remove support stands and lower vehicle to
ground.
COIL
SPRINGS
REMOVAL
(1) Raise vehicle on hoist. Position support stands
on frame and lower front hoist. Remove front tire. (2) Remove brake caliper assembly, refer to Group
5, Brakes. (3) Remove shock absorber.
(4) Remove lower control arm strut.
(5) Install Spring Compressor DD-1278 in the
spring (Fig. 5). Tighten the nut finger-tight, and
then loosen the nut 1/2 of-a-turn.
(6) Remove cotter pins and ball joint nuts.
(7) Install Ball Stud Remover C-3564-A on the
lower ball stud (Fig. 4). Turn the threaded portion of
the tool and lock the tool securely against the lower stud (Fig. 5). Expand the tool enough to place force
on the lower ball stud. Strike the steering knuckle sharply with a hammer to loosen the stud. Do not
attempt to force the stud out of the steering
knuckle with the loosening tool.
Page 63 of 1502
2
- 10
FRONT SUSPENSION
AND
AXLE
• INSTALLATION
(1) Position the spring and isolation pad on the
suspension arm. Install the spring compressor tool.
Compress the spring until the lower suspension arm
can be properly positioned in the steering knuckle.
(2) Install the nuts on the ball studs. Tighten the
upper nut to 142 Nnn (105 ft. lbs.) torque. Tighten
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.
(3) Install the strut.
(4) Connect the stabilizer bar.
(5) Install the shock absorber.
(6) Install the brake splash shield on the steering
knuckle. Tighten the screws to 23 Nnn (200 in. lbs.)
torque.
(7) Carefully install the hub/rotor and bearings.
(8) Install the brake caliper, refer to Group 5, Brakes.
(9) Install the wheel and tire, refer to Wheel and Tire
Installation within this section. Lower the vehicle. (10) Test the vehicle brakes and the suspension for
proper operation.
LOWER SUSPENSION
ARM
REMOVAL
(1) Follow procedure under Coil Spring Removal.
(2) Remove hex-head mounting bolt from the cross-
member. (3) Remove the lower suspension arm from vehicle.
INSTALLATION (1) Position lower suspension arm on vehicle.
(2) Install mounting bolt, tighten finger-tight.
(3) Follow procedure under Coil Spring Installa
tion.
(4) Lower the vehicle to the surface with the
wheels/tires supporting the vehicle weight. Tighten
the lower suspension arm mounting bolt to 305 Nnn (225 ft. lbs.) torque.
LOWER
BALL
STUD
INSPECTION
(1) Raise the front of the vehicle. Install safety
floor stands under both lower suspension arms as far outboard as possible. The upper suspension arms
must not contact the rebound bumpers. (2) Install a dial indicator and clamp assembly to
the lower suspension arm. (3) Position indicator plunger against knuckle arm
and zero indicator. (4) Raise and lower the wheel with a pry bar under
the center of the tire. Measure the axial movement of
the knuckle with respect to the suspension arm.
(5) If the travel of the suspension arm is 0.020
inch (0.51 mm) or more, replace the ball joint. REMOVAL
(1) Follow procedure under Coil Spring Removal.
(2) Remove ball joint seal. Use assembled Remov
er/Installer C-4212 to force the ball stud out of the
lower suspension arm bore (Fig. 6).
Fig.
6
Lower
Bail
Stud
Removal
INSTALLATION (1) Force the replacement ball stud into the lower
suspension arm bore with assembled Remover/In
staller C-4212 (Fig. 7).
Fig.
7
Lower
Ball
Stud
Installation
Page 66 of 1502
•
Fig.
11 Upper Suspension Arm Bushing installation
STEERING KNUCKLE
REMOVAL
(1) Block the brake pedal in the up position. Raise
the vehicle and remove the wheel cover and wheel/
tire.
Remove the brake caliper, refer to Group 5,
Brakes. (2) Remove the brake rotor from the spindle. Refer
to Wheel Hub and Bearings service procedures
within this Group.
(3) Remove the brake splash shield. Remove and
discard the dust seal.
(4) Remove the cotter pin and the nut from the tie-
rod end ball stud.
(5)
Install Puller Tool C-3894A (Fig. 12) and apply
sufficient force with the tool to loosen the tie-rod end
ball stud from the steering knuckle arm bore.
Fig.
12 Tie-Rod End
Ball
Stud
Removal
FRONT SUSPENSION
AND
AXLE
2 - 13
Fig.
13 Steering
Knuckle
(16) Remove the brake adapter and steering
knuckle bolts from the steering knuckle. Separate
the components.
INSTALLATION (1) Install the brake adaptor on the steering
knuckle. Tighten the bolts to 136 Nnn (100 ft-lbs)
torque.
(2) Align the steering knuckle arm bolt holes with
the steering knuckle bolt holes. Install the bolts and
tighten to 291 Nnn (215 ft-lbs) torque. (6) Remove the shock absorber from the vehicle,
refer to the removal procedures. (7) Install Spring Compressor Tool DD-1278 in the
spring (Fig. 5). Tighten the nut finger-tight, and
then loosen the nut 1/2 of-a-turn.
(8) Remove the cotter pins and the lower and up
per ball stud nuts at the steering knuckle.
(9) Install Ball Stud Loosening Tool C-3564-A on
the lower ball stud (Fig. 4). Turn the threaded por
tion of the tool and lock the tool securely against the lower stud (Fig. 5). Expand the tool enough to place
force on the lower ball stud. Strike the steering
knuckle sharply with a hammer to loosen the stud.
Do not attempt to force the stud out of the steer
ing knuckle with the loosening tool.
(10) Remove the loosening tool and remove the
lower ball stud from the steering knuckle bore with an appropriate tool.
(11) Reverse the position of Ball Stud Loosening
Tool C-3564-A, and remove the upper ball stud.
(12) Remove the loosening tool.
(13) Remove the upper ball stud from the steering
knuckle bore with an appropriate tool. (14) Slowly loosen the coil spring compressor tool
(Fig. 5) until all tension is relieved from the spring.
(15) Separate the steering knuckle and the steer
ing knuckle arm from the ball studs (Fig. 13).
Page 67 of 1502
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.