Suspension JEEP LIBERTY 2002 KJ / 1.G Owner's Manual

SUSPENSION
TABLE OF CONTENTS
page page
FRONT
SPECIAL TOOLS
FRONT SUSPENSION...................1
BUSHINGS
REMOVAL
REMOVAL - LOWER CONTROL ARM
BUSHING............................2
REMOVAL - CLEVIS BRACKET BUSHING....2
REMOVAL - UPPER CONTROL ARM
BUSHINGS...........................3
INSTALLATION
INSTALLATION - LOWER CONTROL ARM
BUSHING............................3
INSTALLATION - CLEVIS BRACKET
BUSHING............................4
INSTALLATION - UPPER CONTROL ARM
BUSHINGS...........................4
LOWER BALL JOINT
REMOVAL.............................5INSTALLATION..........................5
REAR
SPECIAL TOOLS
REAR SUSPENSION....................6
UPPER BALL JOINT
REMOVAL.............................6
INSTALLATION..........................6
BUSHINGS
REMOVAL
REMOVAL - LOWER SUSPENSION ARM
BUSHING............................7
REMOVAL - UPPER SUSPENSION ARM
BUSHING............................7
INSTALLATION
INSTALLATION - LOWER SUSPENSION
ARM BUSHING........................8
INSTALLATION - UPPER SUSPENSION ARM
BUSHING............................8
FRONT
SPECIAL TOOLS
FRONT SUSPENSION
BALL JOINT PRESS - C-4212F
Remover C-4150A
REMOVER / INSTALLER FRONT LOWER BALL
JOINT - 8859
KJSUSPENSION 2s - 1

BUSHINGS
REMOVAL
REMOVAL - LOWER CONTROL ARM BUSHING
(1) Remove the lower control arm (Refer to 2 -
SUSPENSION/FRONT/LOWER CONTROL ARM -
REMOVAL).
(2) Secure the control arm in a vise.
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
(3) Press the bushing out using special tools
8858-5 (Receiver), 8858-6 (Driver) and 8839 with the
threaded rod and the bearing as shown (Fig. 1)
REMOVAL - CLEVIS BRACKET BUSHING
(1) Remove the clevis bracket from the shock
(Refer to 2 - SUSPENSION/FRONT/CLEVIS
BRACKET - REMOVAL).
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
FRONT LOWER CONTROL ARM & CLEVIS
BUSHING REMOVER/INSTALLER - 8858
REAR LOWER CONTROL ARM BUSHING
REMOVER/INSTALLER - 8862
FRONT LOWER CONTROL BUSHING REMOVER/
INSTALLER - 8830
Fig. 1 LOWER CONTROL ARM BUSHING -
REMOVAL
1 - 8858-5 RECEIVER
2 - 8858-6 DRIVER
3 - 8839 THREADED ROD
2s - 2 SUSPENSIONKJ
FRONT (Continued)

(2) Press the bushing out using special tools
8858-1 (receiver), 8858-3 (driver) and 8839 with the
threaded rod 8839 and the bearing as shown (Fig. 2)
REMOVAL - UPPER CONTROL ARM BUSHINGS
(1) Remove the upper control arm (Refer to 2 -
SUSPENSION/FRONT/UPPER CONTROL ARM -
REMOVAL).
(2) Secure the control arm in a vise.
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
(3) Install bushing remover tools 8830-3, 8830-2
and 8830±4 with the threaded rod 8838 and the bear-
ing as shown (Fig. 3)
(4) Press out the bushing.
INSTALLATION
INSTALLATION - LOWER CONTROL ARM
BUSHING
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.(1) Install the new lower control arm bushings into
the lower control arm using tools 8858-5 (driver),
8858-6 (receiver) and the bearing with the threaded
rod 8839 (Fig. 4) making sure to properly orient the
bushing in the control.
Fig. 2 CLEVIS BRACKET BUSHING
1 - 8839 THREADED ROD
2 - 8858-1 RECEIVER
3 - 8858-3 DRIVER
Fig. 3 UPPER CONTROL ARM BUSHING REMOVAL
1 - 8830-3
2 - 8830-2
3 - 8830-4
4 - 8838
Fig. 4 LOWER CONTROL ARM BUSHING -
INSTALLATION
1 - 8858-5 DRIVER
2 - 8858-6 RECEIVER
3 - 8839 THREADED ROD
KJSUSPENSION 2s - 3
BUSHINGS (Continued)

(2) Remove the control arm from the vise.
(3) Install the lower control arm (Refer to 2 - SUS-
PENSION/FRONT/LOWER CONTROL ARM -
INSTALLATION).
(4) Reset the vehicle ride height (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
(5) Perform a wheel alignment (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
INSTALLATION - CLEVIS BRACKET BUSHING
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
(1) Install the new clevis bracket bushing into the
lower control arm using tools 8858-2 (driver), 8858-1
(receiver) and the bearing with the threaded rod
8839 (Fig. 5) making sure to properly orient the
bushing in the control.
(2) Install the clevis bracket (Refer to 2 - SUS-
PENSION/FRONT/CLEVIS BRACKET - INSTALLA-
TION).
INSTALLATION - UPPER CONTROL ARM
BUSHINGS
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
(1) Install the new upper control arm bushings
into the upper control arm using tools 8830-3, 8830-1
and 8830-2 the bearing with the threaded rod 8838
(Fig. 6) making sure to properly orient the bushing in
the control arm.
(2) Remove the control arm from the vise.
(3) Install the upper control arm (Refer to 2 - SUS-
PENSION/FRONT/UPPER CONTROL ARM -
INSTALLATION).
(4) Reset the vehicle ride height (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
(5) Perform a wheel alignment (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
Fig. 5 CLEVIS BRACKET BUSHING
1 - 8858-2 DRIVER
2 - 8858-1 RECEIVER
3 - 8839 THREADED RODFig. 6 UPPER CONTROL ARM BUSHING -
INSTALLATION
1 - 8830-3
2 - 8830-1
3 - BUSHING
4 - 8830-2
5 - 8838
2s - 4 SUSPENSIONKJ
BUSHINGS (Continued)

LOWER BALL JOINT
REMOVAL
(1) Remove the tire and wheel assembly.
(2) Remove the brake caliper and rotor (Refer to 5
- BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
REMOVAL).
(3) Disconnect the tie rod from the steering
knuckle (Refer to 19 - STEERING/LINKAGE/TIE
ROD END - REMOVAL).
(4) Remove the steering knuckle (Refer to 2 - SUS-
PENSION/FRONT/KNUCKLE - REMOVAL).
(5) Move the halfshaft to the side and support the
halfshaft out of the way (If Equipped).
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
(6) Secure the steering knuckle in a vise.
(7) Press the ball joint from the steering knuckle
using special tools C-4212±F (PRESS), 8859-2
(RECEIVER) and 8859-1 (DRIVER) (Fig. 7).
INSTALLATION
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.(1) Install the ball joint into the steering knuckle
and press in using special tools C-4212±F (press),
8859-3 (driver) and 6761 (receiver) (Fig. 8).
(2) Install the ball joint boot.
(3) Remove the support for the halfshaft and
install into position (If Equipped).
(4) Install the steering knuckle (Refer to 2 - SUS-
PENSION/FRONT/KNUCKLE - INSTALLATION).
(5) Install the tie rod end into the steering knuckle
(Refer to 19 - STEERING/LINKAGE/TIE ROD END -
INSTALLATION).
(6) Install and tighten the halfshaft nut to 136
N´m (100 ft. lbs.).
(7) Install the brake caliper and rotor (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
INSTALLATION).
(8) Install the tire and wheel assembly (Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(9) Check the vehicle ride height (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
(10) Perform a wheel alignment (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
Fig. 7 LOWER BALL JOINT
1 - 8859-1 DRIVER
2 - C-4212F PRESS
3 - 8859-2 RECEIVER
Fig. 8 LOWER BALL JOINT
1 - 6761 RECEIVER
2 - 8859-3 DRIVER
3 - C-4212F PRESS
KJSUSPENSION 2s - 5

REAR
SPECIAL TOOLS
REAR SUSPENSION
UPPER BALL JOINT
REMOVAL
(1) Raise and support the vehicle.
(2) Support the rear axle with a hydraulic jack.
(3) Remove the ball joint pinch bolt from the top of
the axle. (Fig. 9)(4) Separate the ball joint arm assembly from the
differential housing by prying upwards.
(5) Remove the upper suspension arm from the
vehicle (Refer to 2 - SUSPENSION/REAR/UPPER
CONTROL ARM - REMOVAL).
(6) Secure the suspension arm in a vise.
(7) Install special tools C-4212F (press), 8861-3
(driver) and 8861-2 (receiver) (Fig. 10)
(8) Press out the old ball joint.
INSTALLATION
(1) Install special tools C-4212F (press), 8861-1
(receiver) and 8861-2 (driver) with the ball joint in
place (Fig. 11).
BALL JOINT PRESS - C-4212F
REMOVER / INSTALLER REAR UPPER BALL JOINT
- 8861
REMOVAL / INSTALLATION REAR UPPER
CONTROL ARM BUSHINGS - 8860
Fig. 9 BALL JOINT PINCH BOLT
1 - UPPER BALL JOINT
2 - PINCH BOLT
Fig. 10 UPPER BALL JOINT - REMOVAL
1 - C-4212F PRESS
2 - 8861-3 DRIVER
3 - 8861-2 RECEIVER
2s - 6 SUSPENSIONKJ

(2) Press the ball joint in the upper suspension
arm.
(3) Remove the upper suspension arm from the
vise.
(4) Reinstall the upper suspension arm (Refer to 2
- SUSPENSION/REAR/UPPER CONTROL ARM -
INSTALLATION).
(5) Raise the rear axle with a hydraulic jack to
align the ball joint with the differential housing
bracket.
(6) Insert the ball joint into the differential hous-
ing bracket.
(7) Install the ball joint pinch bolt and tighten to
95 N´m (70 ft. lbs.). (Fig. 9).
(8) Remove the supports and lower the vehicle.
BUSHINGS
REMOVAL
REMOVAL - LOWER SUSPENSION ARM
BUSHING
(1) Remove the lower suspension arm (Refer to 2 -
SUSPENSION/REAR/LOWER CONTROL ARM -
REMOVAL).
(2) Secure the suspension arm in a vise.
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.(3) Install special tools 8862-4 (receiver), 8862-5
(spacer) and 8862-1 or 8862- 2 (driver) with the
threaded rod 8839 and the bearing as shown (Fig. 12)
(4) Press out the bushing.
REMOVAL - UPPER SUSPENSION ARM
BUSHING
(1) Remove the upper suspension arm (Refer to 2 -
SUSPENSION/REAR/UPPER CONTROL ARM -
REMOVAL).
(2) Secure the suspension arm in a vise.
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
(3) Install special tools 8853-3 (driver), 8860-1
(receiver) and with the threaded rod 8838 and the
bearing as shown (Fig. 13)
(4) Press out the bushing.
Fig. 11 UPPER BALL JOINT - INSTALLATION
1 - C-4212F PRESS
2 - 8861-1 RECEIVER
3 - 8861-2 DRIVER
Fig. 12 LOWER SUSPENSION ARM BUSHING
REMOVAL
1 - 8839 THREADED ROD
2 - 8862-4 RECEIVER
3 - 8862-5 SPACER
4 - 8862-1 OR 8862-2 DRIVERS
KJSUSPENSION 2s - 7
UPPER BALL JOINT (Continued)

INSTALLATION
INSTALLATION - LOWER SUSPENSION ARM
BUSHING
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
(1) Install the new lower suspension arm bushings
into the lower suspension arm using tools 8862-3
(driver), 8862-4 (receiver), 8862-5 (spacer) and the
bearing with the threaded rod 8839 (Fig. 14) making
sure to properly orient the bushing in the suspension
arm.
(2) Remove the suspension arm from the vise.
(3) Install the lower suspension arm (Refer to 2 -
SUSPENSION/REAR/LOWER CONTROL ARM -
INSTALLATION).
INSTALLATION - UPPER SUSPENSION ARM
BUSHING
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
(1) Install the new upper suspension arm bushings
into the upper suspension arm using tools 8835-3(receiver), 8860-2 (driver) and the bearing with the
threaded rod 8838 (Fig. 15) making sure to properly
orient the bushing in the suspension arm.
(2) Remove the suspension arm from the vise.
(3) Install the upper suspension arm (Refer to 2 -
SUSPENSION/REAR/UPPER CONTROL ARM -
INSTALLATION).
Fig. 13 UPPER SUSPENSION ARM BUSHING -
REMOVAL
1 - 8853-3 DRIVER
2 - 8860-1 RECEIVER
3 - 8838 THREADED ROD
Fig. 14 LOWER SUSPENSION ARM BUSHING
INSTALLATION
1 - 8862-3 DRIVER
2 - 8862-5 SPACER
3 - 8862-4 RECEIVER
4 - 8839 THREADED ROD
Fig. 15 UPPER SUSPENSION ARM BUSHING -
INSTALLATION
1 - 8838 THREADED ROD
2 - 8835-3 RECEIVER
3 - 8860-2 DRIVER
2s - 8 SUSPENSIONKJ
BUSHINGS (Continued)

REMOVAL
(1) Raise and support the vehicle.
(2) Position a lift/jack under the axle and secure
axle to device.
(3) Remove wheels and tires.
(4) Mark propeller shaft and pinion yoke for
installation reference.
(5) Remove propeller shaft and suspend under the
vehicle.
(6) Remove brake drums, parking brake cables and
speed sensor from the axle.
(7) Disconnect the brake hose at the body junction
block.
(8) Remove brakes and backing plates.
(9) Remove vent hose from the axle shaft tube.
(10) Remove the stabilizer bar (Fig. 5).
(11) Remove upper control arm ball joint pinch
bolt from bracket (Fig. 6).
(12) Remove shock absorbers from axle brackets
(Fig. 7).
(13) Loosen all lower control arms mounting bolts
(Fig. 8).
(14) Lower axle enough to remove coil springs and
spring insulators.
(15) Remove lower control arm bolts from the axle
brackets.
(16) Lower and remove the axle.
INSTALLATION
CAUTION: The weight of the vehicle must be sup-
ported by the springs before the lower control arms
are tightened. This must be done to maintain vehi-
cle ride height and prevent premature bushing fail-
ure.(1) Raise the axle under the vehicle.
(2) Install lower control arms onto the axle brack-
ets and loosely install the mounting bolts.
(3) Install coil spring isolators and spring.
(4) Raise axle up until springs are seated.
(5) Install upper control arm ball joint into axle
bracket and tighten pinch bolt to torque specification.
(6) Install shock absorbers and tighten nuts to
torque specification.
(7) Install stabilizer bar and tighten nuts to torque
specification.
(8) Install brake backing plates, parking brake
cables, brake drums and speed sensor.
(9) Install brake hose to the body junction block
and bleed the brakes.
Fig. 5 STABILIZER BAR MOUNTS
1 - STABILIZER BAR MOUNTING BOLTS
2 - LOWER SUSPENSION ARM
Fig. 6 BALL JOINT PINCH BOLT
1 - UPPER BALL JOINT
2 - PINCH BOLT
Fig. 7 SHOCK ABSORBER
1 - UPPER MOUNTING BOLT
2 - LOWER MOUNTING BOLT
3 - 54 REAR AXLE - 198RBIKJ
REAR AXLE - 198RBI (Continued)

(10) Install axle vent hose.
(11) Install propeller shaft with reference marks.
(12) Install the wheels and tires.
(13) Add gear lubricant to specifications, if neces-
sary.
(14) Remove lifting device from axle and lower the
vehicle.
(15) Tighten the lower control arm bolts to torque
specification.
ADJUSTMENTS
ADJUSTMENT
Ring and pinion gears are supplied as matched
sets only. The identifying numbers for the ring and
pinion gear are etched into the face of each gear (Fig.
9). A plus (+) number, minus (±) number or zero (0) is
etched into the face of the pinion gear. This number
is the amount (in thousandths of an inch) the depth
varies from the standard depth setting of a pinion
etched with a (0). The standard setting from the cen-
ter line of the ring gear to the back face of the pinion
is 96.850 mm (3.813 in.). The standard depth pro-
vides the best teeth contact pattern. Refer to Back-
lash and Contact Pattern Analysis Paragraph in this
section for additional information.
Compensation for pinion depth variance is
achieved with select shims. The shims are placed
under the inner pinion bearing cone (Fig. 10).
If a new gear set is being installed, note the depth
variance etched into both the original and replace-
ment pinion gear. Add or subtract the thickness of
the original depth shims to compensate for the differ-
ence in the depth variances. Refer to the Depth Vari-
ance charts.Note where Old and New Pinion Marking columns
intersect. Intersecting figure represents plus or
minus amount needed.
Note the etched number on the face of the drive
pinion gear (±1, ±2, 0, +1, +2, etc.). The numbers rep-
resent thousands of an inch deviation from the stan-
dard. If the number is negative, add that value to the
required thickness of the depth shim(s). If the num-
ber is positive, subtract that value from the thickness
of the depth shim(s). If the number is 0 no change is
necessary. Refer to the Pinion Gear Depth Variance
Chart.
Fig. 8 LOWER SUSPENSION ARM
1 - AXLE BRACKET BOLT
2 - LOWER CONTROL ARM
3 - BODY BRACKET BOLTFig. 9 PINION GEAR ID NUMBERS
1 - PRODUCTION NUMBERS
2 - PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER
Fig. 10 Shim Locations
1 - PINION GEAR DEPTH SHIM
2 - DIFFERENTIAL BEARING SHIM
3 - RING GEAR
4 - DIFFERENTIAL BEARING SHIM
5 - COLLAPSIBLE SPACER
KJREAR AXLE - 198RBI 3 - 55
REAR AXLE - 198RBI (Continued)