SECTION : 2C

FRONT SUSPENSION
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2C1 General Specifications . . . . . . . . . . . . . . . . . . . . . 2C1 Fastener Tightening Specifications . . . . . . . . . . . 2C1 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C2 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . . 2C2 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C4 Strut Dampener . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C4 Ball Joint and Knuckle . . . . . . . . . . . . . . . . . . . . . 2C4 Excessive Friction Check . . . . . . . . . . . . . . . . . . . 2C5 COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . 2C6 Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . 2C6 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 2C8 ONVEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 2C8 Stabilizer Shaft Link . . . . . . . . . . . . . . . . . . . . . . . . 2C8 Strut Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C9 Control Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C12 Steering Knuckle . . . . . . . . . . . . . . . . . . . . . . . . . 2C13 Crossmember Assembly . . . . . . . . . . . . . . . . . . Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ball Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C14 2C16 2C18 2C18

Hub and Bearing . . . . . . . . . . . . . . . . . . . . . . . . . 2C18 Control Arm Bushings . . . . . . . . . . . . . . . . . . . . 2C20 Front Strut Assembly . . . . . . . . . . . . . . . . . . . . . . 2C21 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C23 Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . 2C23

SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Center of Front Wheel to Bottom of Front Wheel Well Center of Rear Wheel to Bottom of Rear Wheel Well Trim Height 344 mm (13.5 in.) 343 mm (13.5 in.)

FASTENER TIGHTENING SPECIFICATIONS

Application Ball JointtoControl Arm Nuts Ball JointtoKnuckle/Strut Nut Control Arm Front Mounting Bolts Drive AxletoHub Caulking Nut Piston Rod Nut Stabilizer ShafttoIink nut Strut AssemblytoBody Nuts Strut Cartridge Closure Nut NSm 50 55 110 300 60 50 60 200 LbFt 37 41 81 221 44 37 44 148 LbIn 444 487 972 2655 531 531 1776

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SPECIAL TOOLS
SPECIAL TOOLS TABLE

50020 Hex Nut

J37105B3 Hub Adapter

J366612 Forcing Screw

KM158 Remover/Installer

J37105B1 Support Bridge

KM307B Removal Plate

J37105B2 Bearing Adapter

KM329A Spring Compressor

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J42468 Front Strut Mount Nut Wrench

KM507B Ball Joint Remover

KM465A Front Spring Compressor

KM508A Remover/Installer

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DIAGNOSIS
STRUT DAMPENER
A strut dampener is basically a shock absorber. However, strut dampeners are easier to extend and retract by hand than are shock absorbers. Strut dampeners are used only on the front in most vehicles, including this vehicle. Shock absorbers are used on the rear wheels.

Struts Seem Weak

Checks Check the tire pressures. Check the load conditions under which the vehicle is normally driven. Check the compression and rebound effectiveness of the strut dampener. Action Adjust the tire pressures to the specifications on the tire placard. Consult with the owner to confirm the owner's understanding of normal load conditions. Quickly push down and then lift up on the corner of the bumper nearest the strut dampener being tested. Compare the compression and rebound with those of a similar vehicle that has an acceptable ride quality. Replace the strut dampener, if needed.

Struts Are Noisy

Checks Check the mountings for looseness or damage. Check the compression and rebound effectiveness of the strut dampener. Action Tighten the strut dampener. Replace the strut dampener, if needed. Quickly push down and then lift up on the corner of the bumper nearest the strut dampener being tested. Compare the compression and rebound with those of a similar vehicle that has an acceptable ride quality. Replace the strut dampener, if needed.

Leaks
Checks Check for a slight trace of fluid. Check the seal cover on the fully extended strut. Check for an excessive amount of fluid on the strut dampener. Action The strut dampener is OK. Replace the strut dampener. Replace the strut dampener. S S The ball stud is loose at the knuckle. The ball stud can be twisted in its socket with finger pressure.

BALL JOINT AND KNUCKLE

Ball Joint Inspection
1. 2. 3. 4. 5. Raise the front of the vehicle to allow the front suspension to hang free. Grasp the tire at the top and the bottom. Move the top of the tire in an inandout motion. Look for any horizontal movement of the knuckle relative to the control arm. Ball joints must be replaced under the following conditions: S S S The joint is loose. The ball seal is cut. The ball stud is disconnected from the knuckle.

Ball Stud Inspection

Make sure to check the tightness of the ball stud in the knuckle boss during each inspection of the ball joint. One way to inspect the ball stud for wear is to shake the wheel and feel for movement of the stud end or the castellated nut at the knuckle boss. Another way to inspect the ball stud for wear is to check the fastener torque at the castellated nut. A loose nut can indicate a stressed stud or a hole in the knuckle boss. Worn or damaged ball joints and knuckles must be replaced.
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EXCESSIVE FRICTION CHECK

Use the following procedure to check for excessive friction in the front suspension: 1. Enlist the help of another technician to lift up on the front bumper, raising the vehicle as high as possible. 2. Slowly release the bumper, allowing the vehicle to assume its normal trim height. See General Specifications in this section.

3. 4. 5. 6.

Measure the distance from the street level to the center of the bumper. Push down on the bumper, release slowly, and allow the vehicle to assume its normal trim height. Measure the distance from the street level to the center of the bumper. The difference between the two measurements should be less than 12.7 mm (0.5 inch). If the difference exceeds this limit, inspect the control arms, the struts, and the ball joints for damage or wear.

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COMPONENT LOCATOR
FRONT SUSPENSION

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1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Stabilizer bar Stabilizer link nut Stabilizer link Crossmember Crossmember nut (front direction) Control arm connecting bolt Stabilizer bar nut Control arm Ball joint connecting bolt Ball joint Piston rod nut Washer Strut upper nut Strut mount Bearing 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. Spring upper seat Spring upper insulator Hallow bumper Coil spring Thrust Thrust bracket bolt Steering knuckle Cover seat Wheel bearing Retaining ring Wheel hub Brake disc Washer Caulking nut

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MAINTENANCE AND REPAIR

ONVEHICLE SERVICE STABILIZER SHAFT LINK
Removal Procedure
1. 2. 3. Lift and suitably support the vehicle, allowing the front suspension to hang free. Remove the front wheel. Refer to Section 2E, Tires and Wheels. Remove the stabilizer shafttoknuckle nut and the shafttolink nut.

4.

Disconnect the stabilizer shaft from the knucle by removing the stabilizer shaft link assembly.

Installation Procedure
1. 2. Install the stabilizer shaft into the vehicle. Install the stabilizer shafttoknuckle nut and the shafttolink nut.

Tighten
Tighten the stabilizer shaft link nuts to 50 NSm (37 lb ft).

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STRUT ASSEMBLY
Tools Required KM507B Ball Joint Remover

Removal Procedure
1. Loosen the strut assembly tobody nut that attach the top of the strut assembly to the vehicle.

2. 3. 4.

5. 6.

7.

Raise and suitably support the vehicle. Place the jackstands under the frame of the vehicle. Lower the vehicle slightly so the weight of the vehicle rests on the jackstands and not on the control arms. Remove the wheel. Refer to Section 2E, Tires and Wheels. Disconnect the brake caliper from the knuckle/strut assembly and support the caliper. Do not hang the caliper from the hydraulic brake hose. Refer to Section 4D, Front Disc Brakes. Disconnect the ABS speed sensor electrical connector, if applicable. Remove the ball jointtoknucklestrut nut.

8.

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Notice : Failure to use the recommended tool for separating the ball joint from the steering knuckle assembly may damage the ball joint and seal. 9. Separate the steering knuckle assembly from the ball joint using the ball joint remover KM507B. 10. Remove the outer tie rod from the steering knuckle assembly. Refer to Section 6C, Power Steering Gear [Includes Rack & Pinion Gear] or Section 6D, Manual Steering Gear [Includes Rack & Pinion Gear]. Notice : Take care to prevent the axle joints from being overextended. When either end of the shaft is disconnected, the joint can become overextended. This overextension can cause the internal components to separate. This separation can cause joint failure. Use drive axle joint seal protectors during any service on or near the drive axles. Failure to use joint seal protectors can damage the interior joint seal and cause joint failure. 11. Push the drive axle shaft from the front wheel hub. 12. Support the drive axle. 13. Lower the vehicle in order to gain access to the struttobody nuts and the washers. Notice : Chipping or scratching the spring coating when handling the front suspension coil spring can cause the spring to fail. 14. Remove the strut assemblytobody nuts. 15. Remove the strut assembly from the vehicle.

Installation Procedure
Notice : Chipping or scratching the spring coating when handling the front suspension coil spring can cause the spring to fail. 1. nstall the strut assembly into the vehicle with the strut assemblytobody nuts.

Tighten
Tighten the strut assemblytobody nut to 60 NSm (44 lbft).

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2. Connect the drive axle to the front wheel hub.

3.

4. 5.

Connect the outer tie rod to the steering knuckle assembly. Refer toSection 6C, Power Steering Gear [Includes Rack & Pinion Gear] or Section 6D, Manual Steering Gear [Includes Rack & Pinion Gear]. Connect the ball joint to the steering knuckle assembly. Install the ball jointtoknuckle/strut nut.

Tighten
Tighten the ball jointtoknuckle/strut nut to 55 NSm (41 lbft).

6.

Connect the ABS speed sensor electrical connector, if applicable.

7. 8. 9.

Connect the brake caliper to the knuckle/strut assembly. Refer to Section 4D, Front Disc Brakes. Install the wheel. Refer to Section 2E, Tires and Wheels. Install a new drive axletohub caulking nut.

Tighten
Tighten the drive axletohub caulking nut to 300 NSm (221 lbft). 10. Crimp the caulking nut sleeve onto the drive axle shaft.

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CONTROL ARM
Tools Required KM507B Ball Joint Remover

Removal Procedure
1. 2. 3. Raise and suitably support the vehicle. Place the jackstands under the frame of the vehicle. Lower the vehicle slightly so the weight of the vehicle rests on the jackstands and not on the control arms. Remove the wheel. Refer to Section 2E, Tires and Wheels. Disconnect the stabilizer shaft from the control arm by removing the control armlink bolt assembly.Refer to Stabilizer Shaft and Insulators in this section. Remove the retaining clip and the ball jointto knuckle/strut nut from the ball joint. Disconnect the ball joint from the steering knuckle using the ball joint remover KM507B.

4. 5.

6. 7.

8. 9.

Remove the control arm front mounting bolt. Remove the control arm rear mounting bolts and the bracket. 10. Remove the control arm from the vehicle.

Installation Procedure
1. 2. Install the control arm onto the vehicle. Connect the front of the control arm to the body of the vehicle with the front mounting bolt and the washer. 3. Apply a thread sealer to the control arm rear mounting bolts. 4. Connect the rear of the control arm to the body of the vehicle with the rear mounting bracket and bolts. Important : Do not tighten the control arm bolts at this point. Notice : Use a new selflocking nut to install the control arm link bolt assembly. Failure to do so will allow the normal vibration of the vehicle to loosen the nut and damage the vehicle. 5. Install the stabilizer shaft link bolt assembly. Refer to Stabilizer Shaft and Insulators in this section. 6. Connect the ball joint to the steering knuckle. 7. Tighten the ball jointtoknuckle/strut nut.

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Tighten the ball jointtoknuckle/strut nut to 55 NSm (41 lbft). 8. Connect the retaining clip to the ball joint stud. 9. Install the wheel. Refer to Section 2E, Tires and Wheels. 10. Raise the vehicle. 11. Place the jackstands under the control arms. 12. Lower the vehicle.

Important : The control arms must support the weight of the vehicle while the control arm mounting bolts are being tightened. 13. Tighten the control arm rear mounting bolts.

Tighten
Tighten the control arm rear mounting bolts to 110 NSm (81lbft). 14. Tighten the control arm front mounting bolt.

Tighten
Tighten the control arm front mounting bolt to 110 NSm (81 lbft). 15. Raise the vehicle. 16. Remove the jackstands. 17. Lower the vehicle.

STEERING KNUCKLE
Removal Procedure
1. 2. 3. 4. 5. 6. 7. Remove the front wheels.Refer to Section 2E, Tires and Wheels. Remove the caulking nut. Remove the tie rod end from the knuckle. Remove the control arm ball joint. Remove the brake caliper. Remove the brake disk.Refer to Section 4E, Front Disk Brakes.

Remove the ABS wheel speed sensor, if equipped Refer to Section 4F, ABS from the knuckle. 8. Remove the backing plate. 9. Remove the front strut bolts. 10. Remove the knuckle assembly.

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1. Install the knuckle assembly to the front strut with bolt and nuts.

Tighten
Tighten the knuckle assembly to the front strut with bolt and nuts to 100 NSm (74lbft). 2. Install the backing plate with the screws.

Tighten
Tighten the backing plate with the screws to 4 NSm (3lbft). 3. 4. 5. 6. Install the ABS wheel speed sensor. Install the brake disk and caliper.Refer to Section 4D, Front Disk Brakes. Install the control arm ball joint.Refer to this Section, Unit Repair Install the tie rod end to the knucke. Refer to this Section.

CROSSMEMBER ASSEMBLY
Removal Procedure
1. 2. 3. 4. Remove the front wheels. Remove the control arm ball joint and stabilizer shaft link nut (lower). Refer to this Section. Remove the tie rod end ball joint. Refer to this Section. Remove the engine mounting reaction rod bolts.

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5. Drain the power steering fluid. 6. Remove the power steering pipe fittings. 7. Remove the interm shaft lower joint. CAUTION : When the engine is hot, do not remove the above parts from the vehicle otherwise, personal injury can be caused by hot components of the vehicle.

8. Remove the crossmember assembly. CAUTION : To avoid personal injury or vehicle damage, the crossmember should be supported by jackstand prior to the removal.

9.

Remove the stabilizer bar, power steering gear set and control arm from the crossmember.

Installation Procedure
1. 2. Install the stabilizer bar, power steering gearset and control arm from the crossmember. Install the crossmember assembly front to body nut and the crossmember assembly rear to body bolt.

Tighten
Tighten the crossmember assembly front to body nut and rear to body bolt to 150 NSm (111 lbft).

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3. Connect the interm shaft lower joint and power steering pipe fittings.

Tighten
4. 5. Tighten the power steering pipe fittings to 22 NSm (16 lbft). Fill the fluid reservoir with the power steering fluid. Inspect for leaks. If there are leaks, correct the cause of the leaks and bleed the system. Refer toSection 6A, Bleeding the Power Steering System.

6.

Install the engine mounting reaction rod bolts.

Tighten
Tighten the engine mounting reaction rod bolts to 60 NSm (44 lbft).

7.

Install the tie rod end ball joint nut.

Tighten
8. Tighten the tie rod end ball joint nut to 45 NSm (33 lb ft). Install the control arm ball joint and stabilizer shaft link nut (lower). Refer to this Section.

STABILIZER BAR
Removal Procedure
1. 2. Remove the crossmember assmbly. Refer to this Section Remove the stabilizer bar from the crossmember assembly by unscrewing the uclamp bolts.

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1. Install the uclamp bolts to the stabilizer bar.

Tighten
2. Tighten the uclamp bolts to the stabilizer bar to 25 NSm (18 lbft). Remove the crossmember assmbly. Refer to this Section

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UNIT REPAIR BALL JOINT

Disassembly Procedure
1. 2. Raise and suitably support the vehicle. Place the jackstands under the frame of the vehicle and lower the vehicle slightly so the weight of the vehicle rests on the jackstands and not on the control arms. Remove the wheel. Refer to Section 2E, Tires and Wheels. Remove the control arm. Refer to Control Arm in this section. Remove the ball joint mounting bolts.

3. 4. 5.

Assembly Procedure
1. 2. Connect the ball joint to the control arm with the mounting bolts. Install the nuts to secure the bolts from below the control arm.

Tighten
3. Tighten the ball jointtocontrol arm nuts to 64 NSm (47 lbft). Install the control arm. Refer to Control Arm in this section.

HUB AND BEARING

Tools Required 50020 Hex Nut J366612 Forcing Screw J37105B1 Support Bridge J37105B2 Bearing Adapter J37105B3 Hub Adapter

Disassembly Procedure
1. 2. Remove the drive axle from the front wheel hub. Refer to Strut Assembly in this section. Remove the wheel hub with the support bridge J37105B1, the hub adapter J37105B3, the hex nut 50020, and the forcing screw J366612.

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3. 4. Remove the brake shield. Refer to Section 4D, Front Disc Brakes. Remove the outer snap ring.

5.

6.

Remove the wheel bearing with the support bridge J37105B1, the bearing adapter J37105B2, the hex nut 50020, and the forcing screw J366612. Clean the bore of the knuckle.

Assembly Procedure
1. Install the outer snap ring and push the wheel bearing into place with the support bridge J37105B1, the bearing adapter J37105B2, the hex nut 50020, and the forcing screw J366612.

2. 3.

4.

Install the brake shield. Refer to Section 4D, Front Disc Brakes. Push the wheel hub into place with the hub adapter J37105B3, the bearing adapter J37105B2, the hex nut 50020, and the forcing screw J366612. Install the drive axle into the front wheel hub. Refer to Strut Assembly in this section.

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CONTROL ARM BUSHINGS

Tools Required KM508A Remover/Installer KM158 Remover/Installer KM307B Removal Plate

Disassembly Procedure
1. 2. Remove the control arm. Refer to Control Arm in this section. Press off the rear bushing using a press, the remover/installer KM158, and the removal plate KM307B. Press out the front bushing using the remover/installer KM508A, and the remover/installer KM158.

3.

Assembly Procedure
1. 2. Coat the control arm rear shaft with a multipurpose lubricant. Refer to Section 0B, General Information. Press the rear bushing onto the shaft. The flat of the bushing must be on the top side, the same as the ball joint. Use the remover/installer KM508A to support the control arm.

3.

4.

5. 6.

Coat the outside of the front bushing and the inside of the lower control arm with a multipurpose lubricant. Refer to Section 0B, General Information. Press the new bushing into the control arm from the back to the front, using the remover/installer KM508A. Center the bushing. Install the control arm. Refer to Control Arm in this section.

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FRONT STRUT ASSEMBLY

Tools Required KM329A Spring Compressor J42468 Front Strut Mount Nut Wrench

Disassembly Procedure
1. 2. Remove the strut assembly. Refer to Strut Assembly in this section. Fasten the strut assembly to the spring compressor KM329A. Make sure the hooks are seated on the strut spring properly. Compress the front spring with the front spring compressor KM329A. Use an open end wrench to hold the threaded piston rod while removing the piston rod nut with J42468 front strut mount nut wrench.

3.

4.

5.

Remove the strut mount, strut bearing, spring upper seat, spring upper insulator, hallow bumper, coil spring and strut step by step. Important : Record the position of the front spring seat relative to the strut assemblytoknuckle bracket. Place the front spring locator back in the same position during assembly.

Assembly Procedure
1. 2. 3. Install the lower spring insulator and the spring. Comopress the spring using the spring compressor KM329A. Install the strut mount, strut bearing spring upper seat, spring upper insulator, hallow bumper, coil spring and strut step by step.

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4. Use an open end wrench to hold the threaded piston rod while installing the piston rod nut with J42468 front strut mount nut wrench.

Tighten
Tighten the piston rod nut to 60 NSm (44 lbft). Important : Locate the coil spring to the original position on th coil spring seat. Check the installation condition of the coil spring.

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GENERAL DESCRIPTION AND SYSTEM OPERATION

FRONT SUSPENSION
The front suspension for this vehicle is a combination knuckle/strut and spring design. The control arms pivot from the body. The lower control arm pivots use rubber bushings. The upper end of the strut is isolated by a rubber mount and contains a bearing to allow the wheel to turn.

The lower end of the steering knuckle pivots on a ball joint bolted to the control arm. The ball joint is fastened to the steering knuckle with a nut, and to the lower control arm with rivets. When servicing the control armtobody attachment and the stabilizer shafttobody insulators, make sure the attaching bolts are loose until the control arms are moved to the trim height, which is curb height. Trim height is the normal position to which the control arms move when the vehicle is sitting on the ground. Refer to General Specifications in this section.

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