wheel torque DODGE TRUCK 1993 Service Repair Manual

INTRODUCTION

INTRODUCTION

DESIGNATIONS,
LABELS/PLATES/DECALS,
CODES
AND DIMENSIONS/WEIGHTS .
CONTENTS

page
MEASUREMENT
AND TORQUE
... 1 SPECIFICATIONS
page

. 11

DESIGNATIONS, LABELS/PLATES/DECALS, CODES
AND
DIMENSIONS/WEIGHTS
INDEX

page

Engine
and
Transmission/Transfer
Case
Identification
2

Engine/Transmission/GVWR
4

Equipment
Identification
Plate
3
International
Vehicle Control
and
Display
Symbols
10

Major Component
Identification 3
VEHICLE DESIGNATIONS The Vehicle Code chart lists description and code
for Ram Truck and Sport Utility vehicles. The codes are used to identify vehicle types in charts, captions
and in service procedures. The vehicle codes are
dif­

ferent than the Vehicle Identification Number (VIN) or the wheelbase/model code.
VEHICLE SAFETY CERTIFICATION
LABEL
A certification label is attached to the left side
B-pillar. The label certifies that the vehicle conforms
to Federal Motor Vehicle Safety Standards (FMVSS).
The label also lists the: • Month and year of vehicle manufacture
• Gross Vehicle Weight Rating (GVWR). The gross
front and rear axle weight ratings (GAWR's) are
based on a minimum rim size and maximum cold tire inflation pressure Vehicle Identification Number (VIN)
Type of vehicle
Type of rear wheels (single or dual) Bar code
Month, Day and Hour (MDH) of final assembly
VEHICLE IDENTIFICATION NUMBER (VIN) PLATE The Vehicle Identification Number (VIN) plate is
attached to the top left side of the instrument panel.
The VIN contains 17 characters that provide data
concerning the vehicle. Refer to the decoding chart to
determine the identification of a vehicle.
page

Trailer
Towing Specifications
4

Vehicle Code Plate
2

Vehicle Designations
1

Vehicle Dimension
4

Vehicle
Identification
Number (VIN) Plate
1

Vehicle Safety
Certification
Label
............. 1

Vehicle Weights
4
VEHICLE CODE
DESIGNATIONS
VEHICLE CODE
= AD
(DODGE
RAM

PICKUP
&
CHASSIS
CAB)

VEHICLE
FAMILY LINE DESCRIPTION
AD1
D150

AD2
D250

AD3
D350
PICKUP

4x2

AD5
W150
AD6
W250

AD7
W350
PICKUP

4x4

AD2
D250
AD3
D350
CHASSIS
CAB

4x2

AD6
W250
AD7
W350
CHASSIS
CAB

4x4

AD4
AD100

AD4
AD150
SPORT
UTILITY
4x2

AD8
AD100

AD8 AD
150
SPORT
UTILITY
4x4
J90IN-32

•

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-

•

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 - 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.

•

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.

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

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

•

FRONT
SUSPENSION
AND
AXLE
2 - 11 (2) Position the seal over the ball stud (if neces­
sary, use a replacement seal). Force portion of the
seal downward on the ball stud housing with an ap­
propriate size socket wrench until it is securely locked in place.
(3) Install lower suspension arm using procedure
under Lower Suspension Arm Installation.

LOWER SUSPENSION
ARM
BUSHING

REMOVAL (1) Follow procedure under Coil Spring and Lower
Suspension Arm Removal.
(2) Use an arbor press and an appropriate size
sleeve to force the original bushing from the lower
suspension arm bore.
INSTALLATION (1) Use an arbor press and an appropriate size
sleeve to force the replacement bushing into the
lower suspension arm bore. Ensure that it is com­
pletely seated in the bore.
(2) Install the lower suspension arm according to in­
structions provided within the installation procedure.

UPPER SUSPENSION
ARM REMOVAL (1) Raise the vehicle. Position support stands un­
der the frame rail and lower the front of the hoist.
Remove the wheel/tire.
(2) Remove shock absorber, refer to above proce­

dures.

(3) Install Spring Compressor DD-1278 (Fig. 5).
Tighten the nut finger-tight and then loosen it 1/2 of- a-turn.
(4) Remove the cotter pins and the ball stud nuts.
(5) Install Ball Stud Remover C^3564-A (Fig. 8).
Turn the threaded portion of the tool to lock it se­ curely against the upper ball stud (Fig. 8). Spread
the tool enough to apply force against the upper ball stud. Strike the steering knuckle sharply with a
hammer to loosen the upper ball stud. Do not at­
tempt to force the ball stud out of the steering knuckle bore with the loosening tool.
(6) Remove the loosening tool. Remove the nuts,
eccentric (cam) bolts and suspension arm from the
vehicle (Fig. 9).
INSTALLATION (1) Position the suspension arm and install the ec­
centric (cam) bolts (Fig. 9). and nuts finger-tight.
(2) Install upper ball stud into steering knuckle.
Install nuts on the ball studs. Tighten to 142 N« (105
ft. lbs.) torque. Install replacement cotter pins.
(3) Remove the spring compressor tool (Fig. 5).
Fig.
8
Ball
Stud
Loosening
Tool Installed
(4) Install the shock absorber. Tighten nut to 34
N*m (25 ft. lbs.) torque and lower bolts to 23 N*m (200 in. lbs.) torque.
(5) Install the wheel/tire. Raise the vehicle, remove
the support stands and lower the vehicle to the surface.
(6) Adjust the caster and camber angles. Tighten
the eccentric (cam) nuts to 95 N*m (70 ft. lbs.)
torque.

UPPER BALL STUD
INSPECTION (1) Position a floor jack under the lower suspension
arm. Raise the wheel and allow the tire to lightly
contact the floor (vehicle weight relieved from the

tire).

(2) Grasp the top of the tire and apply force in and
out. Look for any movement at the ball joints be­
tween the upper suspension arm and steering knuckle.
(3) If any lateral movement is evident, replace the
ball joint.
REMOVAL (1) Position a support under the outer end of the
lower suspension arm. Lower the vehicle so that the
support compresses the coil spring.
(2) Remove the wheel/tire.
(3) Remove the ball stud nuts. Use Ball Stud Re­
mover C-3564-A to loosen the upper ball stud (Fig.

8).
(4) Use Wrench C-3561 to un-thread the upper ball
stud from the upper suspension arm.

2
- 12
FRONT
SUSPENSION
AND
AXLE

•
1—Nut

2—Lockwasher

3—Cam
4—Bushing

5—Ball Joint
6—Locknut
7—Upper
Suspension
Arm
8—Upper Ball Joint Seal

9—Bumper
10—Sleeve

11—Cam
and Bolt
J9202-98

SP-3952A
Fig.
9 Upper
Suspension
Arm Removal/Installation

INSTALLATION
(1) Thread the replacement ball stud into the up­
per suspension arm bore as far as possible by hand.
Use Wrench C-3561 to tighten the ball stud to 169
N«m (125 ft. lbs.) torque. Ensure that the ball stud
is completely seated against the arm.
(2) Install and seat the replacement ball stud seal.
(3) Insert the upper ball stud into steering
knuckle. Install ball stud nuts. Tighten the nuts to 142 N#m (105 ft. lbs.) torque. Install replacement cot­
ter pins.
(4) Install the wheel/tire. Remove the support and
lower the vehicle to the surface.
BUSHING

SP-3953

RH393
UPPER
SUSPENSION
ARM BUSHING

REPLACEMENT

REMOVAL

(1) Follow procedure under Upper Suspension Arm
Removal.
(2) Place the upper suspension arm in a vise. As­
semble Remover/Installer C-3962 and Adaptor
SP-3953 (Fig. 10) over the bushing. Tighten the nuts and force the bushing out of the arm bore.

INSTALLATION
Be sure the suspension arm is supported
firmly at the area where the bushing is being
Fig.
10 Upper
Suspension
Arm
Bushing
Removal

forced in the bore. Do not use oil or any other
lubricant to aid the installation. (1) Position flange end of the replacement bushing
in Remover/Installer C-3962. Support suspension arm
firmly and force the bushing in the suspension arm
bore (from outside). Tighten until the flanged end is seated on the arm (Fig. 11).
(2) Follow procedure under Upper Suspension Arm
Installation.