KJ SUSPENSION 2-1

SUSPENSION
TABLE OF CONTENTS

page page

SUSPENSION WHEEL ALIGNMENT ......................3

DIAGNOSIS AND TESTING - SUSPENSION FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
AND STEERING SYSTEM . . . . . . . . . . . . . . . . 1 REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

SUSPENSION
DIAGNOSIS AND TESTING - SUSPENSION AND
STEERING SYSTEM

CONDITION POSSIBLE CAUSES CORRECTION

FRONT END NOISE 1. Loose or worn wheel bearings. 1. Replace wheel bearings.

2. Loose or worn steering or 2. Tighten or replace components as

suspension components. necessary.

EXCESSIVE PLAY IN 1. Loose or worn wheel bearings. 1. Replace wheel bearings.

STEERING
2. Loose or worn steering or 2. Tighten or replace components as
suspension components. necessary.
3. Loose or worn steering gear. 3. Adjust or replace steering gear.

FRONT WHEELS SHIMMY 1. Loose or worn wheel bearings. 1. Replace wheel bearings.

2. Loose or worn steering or 2. Tighten or replace components as

suspension components. necessary.
3. Tires worn or out of balance. 3. Replace or balance tires.
4. Alignment. 4. Align vehicle to specifications.

VEHICLE INSTABILITY 1. Loose or worn wheel bearings. 1. Replace wheel bearings.

2. Loose or worn steering or 2. Tighten or replace components as

suspension components. necessary.
3. Tire pressure. 3. Adjust tire pressure.
4. Alignment. 4. Align vehicle to specifications.

EXCESSIVE STEERING 1. Loose or worn steering gear. 1. Adjust or replace steering gear.
EFFORT
2. Power steering fluid low. 2. Add fluid and repair leak.
3. Column coupler binding. 3. Replace coupler.
4. Tire pressure. 4. Adjust tire pressure.
5. Alignment. 5. Align vehicle to specifications.

VEHICLE PULLS TO ONE 1. Uneven tire pressure. 1. Adjust tire pressure.

SIDE DURING BRAKING
2. Worn brake components. 2. Repair brakes as necessary.
3. Air in brake line. 3. Repair as necessary.
2-2 SUSPENSION KJ
SUSPENSION (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

VEHICLE LEADS OR 1. Radial tire lead. 1. Cross front tires.

DRIFTS FROM STRAIGHT
AHEAD DIRECTION ON 2. Brakes dragging. 2. Repair brake as necessary.
UNCROWNED ROAD 3. Weak or broken spring. 3. Replace spring.
4. Uneven tire pressure. 4. Adjust tire pressure.
5. Wheel Alignment. 5. Align vehicle.
6. Loose or worn steering or 6. Repair as necessary.
suspension components.
7. Cross caster out of spec. 7. Align vehicle.

KNOCKING, RATTLING 1. Worn shock bushings. 1. Replace shock.

OR SQUEAKING
2. Loose, worn or bent steering/ 2. Inspect, tighten or replace components
suspension components. as necessary.
3. Shock valve. 3. Replace shock.

IMPROPER TRACKING 1. Loose, worn or bent track bar. 1. Inspect, tighten or replace component as
necessary.
2. Loose, worn or bent steering/ 2. Inspect, tighten or replace components
suspension components. as necessary.
KJ WHEEL ALIGNMENT 2-3

WHEEL ALIGNMENT

TABLE OF CONTENTS
page page

WHEEL ALIGNMENT STANDARD PROCEDURE - TOE

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ....3 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . ....3 STANDARD PROCEDURE - CAMBER,
STANDARD PROCEDURE CASTER AND TOE ADJUSTMENT . . . . . . . . . . 5
STANDARD PROCEDURE - HEIGHT SPECIFICATIONS
MEASUREMENT . . . . . . . . . . . . . . . . . . . ....4 ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 6
STANDARD PROCEDURE - CAMBER AND
CASTER ADJUSTMENT . . . . . . . . . . . . . . ....5

WHEEL ALIGNMENT
DESCRIPTION
Wheel alignment involves the correct positioning of
the wheels in relation to the vehicle. The positioning
is accomplished through suspension and steering
linkage adjustments. An alignment is considered
essential for efficient steering, good directional stabil-
ity and to minimize tire wear. The most important
measurements of an alignment are caster, camber
and toe (Fig. 1).

CAUTION: Never attempt to modify suspension or

steering components by heating or bending.

NOTE: Periodic lubrication of the front suspension/ Fig. 1 Wheel Alignment Measurements
steering system components may be required. Rub- 1 - FRONT OF VEHICLE
ber bushings must never be lubricated. Refer to 2 - STEERING AXIS INCLINATION
Lubrication And Maintenance for the recommended 3 - PIVOT POINT
4 - TOE-IN
maintenance schedule.

• TOE is the difference between the leading inside

OPERATION edges and trailing inside edges of the front tires.
• CASTER is the forward or rearward tilt of the Wheel toe position out of specification cause’s unsta-
steering knuckle from vertical. Tilting the top of the ble steering, uneven tire wear and steering wheel off-
knuckle forward provides negative caster. Tilting the center. The wheel toe position is the final front
top of the knuckle rearward provides positive caster. wheel alignment adjustment (Fig. 1)
Positive caster promotes directional stability. This • THRUST ANGLE is the angle of the rear axle
angle enables the front wheels to return to a straight relative to the centerline of the vehicle. Incorrect
ahead position after turns (Fig. 1) thrust angle can cause off-center steering and exces-
• CAMBER is the inward or outward tilt of the sive tire wear. This angle is not adjustable, damaged
wheel relative to the center of the vehicle. Tilting the component(s) must be replaced to correct the thrust
top of the wheel inward provides negative camber. angle (Fig. 1)
Tilting the top of the wheel outward provides positive
camber. Incorrect camber will cause wear on the
inside or outside edge of the tire (Fig. 1)
2-4 WHEEL ALIGNMENT KJ
WHEEL ALIGNMENT (Continued)

STANDARD PROCEDURE REAR RIDE HEIGHT Rear ride height is defined

by the relative vertical distance between the top of
STANDARD PROCEDURE - HEIGHT the lower spring seat strike surface and the bottom
of the jounce cup (true metal to metal jounce travel).
MEASUREMENT This is to be measured vertically inside the coil from
the point intersecting the inboard edge and the for/
RIDE HEIGHT aft center of the jounce cup (point C) down to the
strike surface (point D). (Fig. 3)
NOTE: The suspension is non-adjustable.

The vehicle suspension height should be measured

before performing wheel alignment procedure. Also
when front suspension components have been
replaced. This measure must be performed with the
vehicle supporting it’s own weight and taken on both
sides of the vehicle.
Front and rear ride heights are not adjustable. The
spring selections at assembly determine ride height
for acceptable appearance of the vehicle. Ride height
dimensions assume full fluids (including fuel) and
zero passengers. Refer to the table below for front
ride height dimensions.
Vehicle ride height audits should be performed uti-
lizing the following procedure:
(1) Drive the vehicle straight and forward on a
non-tacky surface for a minimum of 20 feet to neu- Fig. 3 REAR RIDE HEIGHT MEASUREMENT
tralize track width. 1 - POINT - C
(2) Bounce the front of the vehicle five times. 2 - POINT - D
(3) Measure and record the dimensions
FRONT RIDE HEIGHT Front ride height is
defined by the relative vertical distance between the Measurement Target Minimum Maximum
spindle center line and the rear pivot point of the Front Ride 48.8 mm 38.8mm 58.8mm
front lower control arm to cradle attachment. The Height Z=996.81
spindle center line is to be measured at the outer Distance AB - 948.03
wheel face (point A). The rear pivot point is to be
Front Cross 0.0 mm -10.0 mm 10.0 mm
measured at the center of the cam bolt (point B) at
Ride Height
its rearward most end (nut end). (Fig. 2)
Left - Right
Rear Ride 116.1 mm 106.1 mm 126.1 mm
Height
Distance CD
Rear Cross 0.0 mm -10.0 mm 10.0 mm
Ride Height
Left - Right

Fig. 2 FRONT RIDE HEIGHT MESUREMENT

1 - POINT - A
2 - POINT - B
KJ WHEEL ALIGNMENT 2-5
WHEEL ALIGNMENT (Continued)

STANDARD PROCEDURE - CAMBER AND CASTER

CASTER ADJUSTMENT Moving the rear position of the cam bolt in or out,
Camber and caster angle adjustments involve will change the caster angle significantly and camber
changing the position of the lower suspension arm angle only slightly. To maintain the camber angle
cam bolts. (Fig. 4) while adjusting caster, move the rear of the cam bolt
in or out. Then move the front of the cam bolt
slightly in the opposite direction. (Fig. 4)
To increase positive caster angle, move the rear posi-
tion of the cam bolt outward (from the engine). Move
the front of cam bolt inward (toward the engine) slightly
until the original camber angle is obtained. (Fig. 4)

CAMBER
Move both of the cam bolts together in or out. This
will change the camber angle significantly and caster
angle slightly. (Fig. 4)
After adjustment is made tighten the cam bolt nuts
to proper torque specification.

TOE ADJUSTMENT
The wheel toe position adjustment is the final
adjustment.
Fig. 4 LOWER CONTROL ARM (1) Start the engine and turn wheels both ways before
1 - FRONT CAM BOLT straightening the wheels. Secure the steering wheel with
2 - OUTER TIE ROD END the front wheels in the straight-ahead position.
3 - LOWER BALL JOINT NUT (2) Loosen the tie rod jam nuts.
4 - LOWER CONTROL ARM
5 - REAR CAM BOLT NOTE: Each front wheel should be adjusted for
one-half of the total toe position specification. This
will ensure the steering wheel will be centered
STANDARD PROCEDURE - TOE ADJUSTMENT
when the wheels are positioned straight-ahead.
4X4 SUSPENSION HEIGHT MESUREMENT MUST
BE PERFORMED BEFORE AN ALIGNMENT. (3) Adjust the wheel toe position by turning the tie
The wheel toe position adjustment is the final rod as necessary (Fig. 5).
adjustment. (4) Tighten the tie rod jam nut to 75 N·m (55 ft. lbs.).
(1) Start the engine and turn wheels both ways (5) Verify the specifications
before straightening the wheels. Secure the steering (6) Turn off engine.
wheel with the front wheels in the straight-ahead
position.
(2) Loosen the tie rod jam nuts.

NOTE: Each front wheel should be adjusted for

one-half of the total toe position specification. This
will ensure the steering wheel will be centered
when the wheels are positioned straight-ahead.

(3) Adjust the wheel toe position by turning the tie

rod as necessary (Fig. 5).
(4) Tighten the tie rod jam nut to 75 N·m (55 ft. lbs.).
(5) Verify the specifications
(6) Turn off engine.

STANDARD PROCEDURE - CAMBER, CASTER

AND TOE ADJUSTMENT Fig. 5 TIE ROD END
Camber and caster angle adjustments involve 1 - JAM NUT
changing the position of the lower suspension arm 2 - TIE ROD - INNER
cam bolts. (Fig. 4) 3 - TIE ROD END - OUTER
2-6 WHEEL ALIGNMENT KJ
WHEEL ALIGNMENT (Continued)

SPECIFICATIONS REAR

ALIGNMENT SPECIFICATIONS

NOTE: Specifications are in degrees. DESCRIPTION SPECIFICATION

PREFERRED CAMBER THRUST TOTAL
FRONT –.25°± ANGLE TOE-IN
SPECIFICATIONS .375° 0° to ± .25° to ±
0.25° .41°
DESCRIPTION SPECIFICATION RANGE –.625° to –.25° to –.16° to
.125° +.25° .66°
PREFERRED CASTER CAMBER TOTAL
3.5° ± .6° 0° ± .375° TOE-IN
.20° ±
.125°
RANGE 2.9° to + –.375° to .07° to +
4.1° +.375° .33°
MAX RT/LT 0.5° 0.7° .13°
DIFFERENCE
KJ FRONT 2-7

FRONT

TABLE OF CONTENTS
page page

FRONT REMOVAL - RIGHT SIDE . . . . . . . . . . . . . . . . 11

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7 INSTALLATION
WARNING .............................7 INSTALLATION - LEFT SIDE . . . . . . . . . . . . . 12
SPECIFICATIONS INSTALLATION - RIGHT SIDE . . . . . . . . . . . . 12
TORQUE CHART ......................8 SPRING
SPECIAL TOOLS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . 8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
BUSHINGS CLEVIS BRACKET
REMOVAL - STABILIZER BAR BUSHINGS . . . . . 9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION - STABILIZER BAR BUSHINGS . . 9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
HUB / BEARING STABILIZER BAR
REMOVAL .............................9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
KNUCKLE STABILIZER LINK
REMOVAL .............................9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
LOWER BALL JOINT UPPER CONTROL ARM
DIAGNOSIS AND TESTING - LOWER BALL REMOVAL
JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 REMOVAL - RIGHT SIDE . . . . . . . . . . . . . . . . 14
LOWER CONTROL ARM REMOVAL - LEFT SIDE . . . . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION - RIGHT SIDE . . . . . . . . . . . . 15
SHOCK INSTALLATION - LEFT SIDE . . . . . . . . . . . . . 15
REMOVAL
REMOVAL - LEFT SIDE . . . . . . . . . . . . . . . . . 11

FRONT
DESCRIPTION
The front suspension is designed to allow each
wheel to adapt to different road surfaces indepen-
dently. The wheels are mounted to hub bearings on
the steering knuckle spindles. The double-row hub
bearings are sealed and lubricated for life. The steer-
ing knuckles turn (pivot) on ball joints riveted to the
outboard portion of the control arms. The ball joints
are lubricated for life. (Fig. 1)

WARNING Fig. 1 FRONT SUSPENSION

1 - SWAY BAR
WARNING:: Suspension components with rubber 2 - SWAY BAR BUSHING/BRACKET
bushings must be tightened with the vehicle at nor- 3 - UPPER CONTROL ARM
mal ride height. It is important to have the springs 4 - SPRING / SHOCK ASSEMBLY
supporting the weight of the vehicle when the fas- 5 - STEERING KNUCKLE
teners are torqued. If springs are not at their normal 6 - OUTER TIE ROD END
ride position, vehicle ride comfort will be affected 7 - LOWER CONTROL ARM
8 - SWAY BAR LINK
and cause premature bushing wear.
9 - CLEVIS BRACKET
2-8 FRONT KJ
FRONT (Continued)

SPECIFICATIONS

TORQUE CHART
TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Front Shock Absorber Clevis Bracket Upper Nut 136 100 —
Front Shock Absorber Clevis Bracket Lower Nut 150 110 —
Front Shock Absorber Top (4) Mounting Nuts 108 80 —
Front Shock to Spring and Insulator Nut 41 30 —
Upper Suspension Arm Front Nut 122 90 —
Upper Suspension Arm Rear Nut 122 90 —
Lower Suspension Arm Front Nut 170 125 —
Lower Suspension Arm Rear Nut 170 125 —
Stabilizer Bar Clamp Nut 149 110 —
Stabilizer Bar Link Upper Nut 136 100 —
Stabilizer Bar Link Lower Nut 115 85 —
Hub/Bearing 130 96 —
Bolt
Hub/Bearing 135 100 —
Halfshaft Nut
Upper Ball Joint Nut 81 60 —
Lower Ball Joint Nut 81 60 —
Wheel Speed Sensor 13.5 10 —

SPECIAL TOOLS
FRONT SUSPENSION

Bolt, Special 7604

Remover/Installer Suspension Bushing 7932

Remover C-4150A

Nut, Long 7603

KJ FRONT 2-9

BUSHINGS BRAKES/ELECTRICAL/FRONT WHEEL SPEED

SENSOR - INSTALLATION).
(6) Install the disc brake rotor (Refer to 5 -
REMOVAL - STABILIZER BAR BUSHINGS
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
(1) Raise vehicle on hoist.
INSTALLATION).
(2) Remove the stabilizer bushing clamps.
(7) Install the disc brake caliper adapter. Tighten
(3) Remove the stabilizer bushings from the stabi-
the nut to 135 N·m (100 ft.lbs.) (Refer to 5 -
lizer bar.
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
INSTALLATION).
INSTALLATION - STABILIZER BAR BUSHINGS (8) Install the tire and wheel assembly. (Refer to
(1) Install the stabilizer bushings to the stabilizer 22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
bar. CEDURE).
(2) Install the stabilizer bushing clamps. Tighten
the nuts to 149 N·m (110 ft.lbs.).
(3) Lower the vehicle. KNUCKLE

HUB / BEARING REMOVAL

(1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly.
REMOVAL (3) Remove the caliper adapter. (Refer to 5 -
(1) Raise and support the vehicle.
BRAKES/HYDRAULIC/MECHANICAL/DISC
(2) Remove the tire and wheel assembly.
BRAKE CALIPER ADAPTER - REMOVAL).
(3) Remove the caliper adapter (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC CAUTION: Never allow the disc brake caliper to
BRAKE CALIPERS - REMOVAL). hang from the brake hose. Damage to the brake
hose will result. Provide a suitable support to hang
CAUTION: Never allow the disc brake caliper to
the caliper securely.
hang from the brake hose. Damage to the brake
hose will result. Provide a suitable support to hang (4) Remove the disc brake rotor. (Refer to 5 -
the caliper securely. BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
REMOVAL).
(4) Remove the disc brake rotor (Refer to 5 -
(5) Remove the wheel speed sensor. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
BRAKES/ELECTRICAL/FRONT WHEEL SPEED
REMOVAL).
SENSOR - REMOVAL).
(5) Remove the wheel speed sensor (Refer to 5 -
(6) Remove the axle shaft nut. (if equipped with
BRAKES/ELECTRICAL/FRONT WHEEL SPEED
four wheel drive)
SENSOR - REMOVAL).
(7) Remove the hub/bearing. (Refer to 2 - SUS-
(6) Remove the bracket securing the wheel speed
PENSION/FRONT/HUB / BEARING - REMOVAL).
sensor wire.
(8) Remove the outer tie rod end. (Refer to 19 -
(7) Remove the axle shaft nut. (if equipped with
STEERING/LINKAGE/TIE ROD END - REMOVAL).
four wheel drive)
(9) Remove the lower ball joint nut.
(8) Remove the three mounting bolts for the hub/
(10) Seperate the lower ball joint from the suspen-
bearing assembly.
sion arm using tool C–4150A.
(9) Remove the hub/bearing.
(11) Remove the upper ball joint nut.
(12) Seperate the upper ball joint from the knuckle
INSTALLATION using tool C–4150A.
(1) Install the hub/bearing assembly to the vehicle. (13) Remove the knuckle from the vehicle.
(2) Install the three mounting bolts for the hub/
bearing. Tighten the bolt to 130 N·m (96 ft.lbs.). INSTALLATION
(3) Install the axle shaft nut. Tighten the nut to
(1) Install the knuckle to the vehicle.
135 N·m (100 ft.lbs.). (if equipped with four wheel
(2) Install the upper ball joint nut. Tighten the nut
drive)
to 81 N·m (60 ft.lbs.).
(4) Install the bracket to the wheel speed sensor
(3) Install the lower ball joint nut. Tighten the nut
wire.
to 81 N·m (60 ft.lbs.).
(5) Install the wheel speed sensor to the hub.
(4) Install the outer tie rod end. (Refer to 19 -
Tighten the bolt to 13.5 N·m (10 ft.lbs.) (Refer to 5 -
STEERING/LINKAGE/TIE ROD END - INSTALLA-
TION).
2 - 10 FRONT KJ
KNUCKLE (Continued)
(5) Install the hub/bearing. (Refer to 2 - SUSPEN- (6) Record the ball joint movement on each side of
SION/FRONT/HUB / BEARING - INSTALLATION). the vehicle. The end play is acceptable with no more
(6) Install the axle shaft nut. Tighten the nut to than 1.5mm of end play back to back.
135 N·m (96 ft.lbs.).(if equipped with four wheel
drive).
(7) Install the wheel speed sensor. (Refer to 5 -
BRAKES/ELECTRICAL/FRONT WHEEL SPEED
SENSOR - INSTALLATION).
(8) Install the disc brake rotor. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
INSTALLATION).
(9) Install the caliper adapter. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - INSTALLATION).
(10) Install the tire and wheel assembly. (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(11) Perform the set toe procedure (Refer to 2 -
SUSPENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
Fig. 2 SUSPENSION IN THE CURB POSITION
1 - PRY BAR
LOWER BALL JOINT 2 - BALL JOINT
3 - DIAL INDICATOR
4 - WOODEN BLOCK OR SUPPORT
DIAGNOSIS AND TESTING - LOWER BALL 5 - CLAMP
JOINT
(1) Raise the vehicle on a drive-on hoist.
LOWER CONTROL ARM
NOTE: If a drive-on hoist is not available, use
wooden blocks with jack stands to support the REMOVAL
lower control arm in the ball joint area. Place the (1) Raise and support the vehicle.
jack stands appropriately and lower the hoist plac- (2) Remove the tire and wheel assembly.
ing weight on the lower control arm. The lower con- (3) Remove the lower clevis bracket bolt at the
trol arms should now be supporting the vehicle lower control arm.
weight. (4) Remove the stabilizer link bolt at the lower
control arm.
(2) With the use of jack stands, lift the front end (5) Remove the lower ball joint nut.
off the hoist and position wooden blocks underneath (6) Separate the lower ball joint from the lower
both lower control arms supporting the vehicles control arm using tool C-4150A.
weight.
(3) Remove the tire and wheel assembly. NOTE: Marking the lower control arm pivot bolts
(4) Attach a dial indicator to the base of the lower front and rear will aid in the assembly procedure.
control arm and align the dial indicator’s contact
point with the direction of the stud axis, touch the (7) Mark the lower control arm pivot bolts front
machined flat on the knuckle and zero the dial indi- and rear.
cator. (Fig. 2) (8) Remove the front cam/pivot bolt. (Fig. 3)
(9) Remove the rear cam/pivot bolt. (Fig. 3)
NOTE: Use care when applying the load to the (10) Remove the lower control arm from the vehi-
knuckle, so the parts are not damaged using care cle.
not to tear the boot.
INSTALLATION
(5) From the front of the vehicle, insert a pry bar (1) Install the lower control arm to the vehicle.
to get it rested on the lower control arm and use (2) Install the rear cam/pivot bolt.
lever principle to push the knuckle up until the arm (3) Install the front cam/pivot bolt.
of the dial indicator no longer moves. (4) Install the lower ball joint nut. Tighten the nut
to 81 N·m (60 ft.lbs.)
KJ FRONT 2 - 11
LOWER CONTROL ARM (Continued)
(8) Remove the left tire and wheel assembly.
(9) Remove the lower bolt at the lower control
securing the clevis bracket.
(10) Remove the stabilizer link (Refer to 2 - SUS-
PENSION/FRONT/STABILIZER LINK - REMOVAL).
(11) Remove the lower ball joint nut.
(12) Seperate the lower ball joint from the lower
control arm using tool C-4150A.
(13) Rotate the lower control arm downward to
allow access.
(14) Remove the clevis bracket at the shock.
(15) Remove the shock assembly from the vehicle.
(Fig. 4)
(16) Remove the spring from the shock (if needed).

Fig. 3 LOWER CONTROL ARM

1 - FRONT CAM BOLT
2 - OUTER TIE ROD END
3 - LOWER BALL JOINT NUT
4 - LOWER CONTROL ARM
5 - REAR CAM BOLT

(5) Align the marks front and rear at the cam/

pivot bolts and tighten the bolts. Tighten the bolts to
170 N·m (125 ft.lbs.)
(6) Install the stabilizer link bolt at the lower con-
trol arm. Tighten the bolt to 136 N·m (100 ft.lbs.)
(7) Install the lower clevis bracket bolt at the
lower control arm. Tighten the bolt to 150 N·m (110
ft.lbs.) Fig. 4 SHOCK ASSEMBLY
(8) Install the tire and wheel assembly. (Refer to 1 - SPRING
22 - TIRES/WHEELS/WHEELS - STANDARD PRO- 2 - JOUNCE BUMPER
CEDURE). 3 - SHOCK
(9) Perform a full wheel alignment (Refer to 2 - 4 - UPPER CONTROL ARM
SUSPENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
REMOVAL - RIGHT SIDE
(1) Remove the air box (Refer to 9 - ENGINE/AIR
SHOCK INTAKE SYSTEM/AIR CLEANER ELEMENT -
REMOVAL).
(2) Remove the two cruise control servo mounting
REMOVAL nuts.
(3) Remove the upper shock mounting nuts.
REMOVAL - LEFT SIDE (4) Raise and support the vehicle.
(1) Disconnect the battery. (5) Remove the right side tire assembly.
(2) Remove the battery (Refer to 8 - ELECTRI- (6) Remove the lower bolt at the lower control
CAL/BATTERY SYSTEM/BATTERY - REMOVAL). securing the clevis bracket.
(3) Unclip the power center and move it to the side (7) Remove the stabilizer link (Refer to 2 - SUS-
out of the way. PENSION/FRONT/STABILIZER LINK - REMOVAL).
(4) Remove the battery tray (Refer to 8 - ELEC- (8) Remove the lower ball joint nut.
TRICAL/BATTERY SYSTEM/TRAY - REMOVAL). (9) Seperate the lower ball joint from the lower
(5) Disconnect the battery temperature sensor control arm using tool C-4150A.
from the battery tray. (10) Rotate the lower control arm downward to
(6) Remove the four upper shock mounting nuts. allow access.
(7) Raise and support the vehicle.
2 - 12 FRONT KJ
SHOCK (Continued)
(11) Remove the clevis bracket at the shock. (Fig. (7) Install the lower stabilizer link at the lower
5) control arm. Tighten the bolt to 136 N·m (100 ft.lbs.)
(12) Remove the shock assembly from the vehicle. (Refer to 2 - SUSPENSION/FRONT/STABILIZER
(Fig. 5) LINK - INSTALLATION).
(13) Remove the spring from the shock (if needed). (8) Install the left tire and wheel assembly. (Refer
(Refer to 2 - SUSPENSION/FRONT/SPRING - to 22 - TIRES/WHEELS/WHEELS - STANDARD
REMOVAL). PROCEDURE).
(9) Lower the vehicle.
(10) Reconnect the battery temperature sensor.
(11) Install the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - INSTALLA-
TION).
(12) Install the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - INSTALLA-
TION).
(13) Reconnect the battery cables.

INSTALLATION - RIGHT SIDE

(1) Install the spring to the shock (if removed).
(Refer to 2 - SUSPENSION/FRONT/SPRING -
INSTALLATION).
(2) Install the shock assembly to the vehicle.
(3) Install the four upper shock mounting nuts.
Tighten the nuts to 108 N·m (80 ft.lbs.).
(4) Install the clevis bracket at the shock. (Refer to
2 - SUSPENSION/FRONT/CLEVIS BRACKET -
INSTALLATION). Tighten the bolt to 88 N·m (65
ft.lbs.).
(5) Raise the lower control into place and recon-
Fig. 5 SHOCK & CLEVIS ASSEMBLY nect the lower ball joint nut. Tighten the nut to 81
N·m (60 ft.lbs.).
1 - FRONT CRADLE
(6) Install the clevis bracket at the lower control
2 - SPRING & SHOCK ASSEMBLY
3 - STEERING KNUCKLE arm. (Refer to 2 - SUSPENSION/FRONT/CLEVIS
4 - CLEVIS BRACKET BRACKET - INSTALLATION). Tighten the bolt to
5 - LOWER CONTROL ARM 150 N·m (110 ft.lbs.).
(7) Install the lower stabilizer link at the lower
control arm. Tighten the bolt to 136 N·m (100 ft.lbs.)
INSTALLATION (Refer to 2 - SUSPENSION/FRONT/STABILIZER
LINK - INSTALLATION).
INSTALLATION - LEFT SIDE (8) Install the right tire and wheel assembly.
(1) Install the spring to the shock (if removed). (Refer to 22 - TIRES/WHEELS/WHEELS - STAN-
(2) Install the shock assembly to the vehicle. DARD PROCEDURE).
(3) Install the four upper shock mounting nuts. (9) Lower the vehicle.
Tighten the nuts to 108 N·m (80 ft.lbs.). (10) Install the cruise control servo mounting nuts.
(4) Install the clevis bracket at the shock. (Refer to (11) Install the airbox (Refer to 9 - ENGINE/AIR
2 - SUSPENSION/FRONT/CLEVIS BRACKET - INTAKE SYSTEM/AIR CLEANER ELEMENT -
INSTALLATION). Tighten the bolt to 88 N·m (65 INSTALLATION).
ft.lbs.).
(5) Raise the lower control into place and recon-
nect the lower ball joint nut. Tighten the nut to 81
N·m (60 ft.lbs.).
(6) Install the clevis bracket at the lower control
arm. (Refer to 2 - SUSPENSION/FRONT/CLEVIS
BRACKET - INSTALLATION). Tighten the bolt to
150 N·m (110 ft.lbs.).
KJ FRONT 2 - 13

SPRING CLEVIS BRACKET

REMOVAL REMOVAL
(1) Raise and support the vehicle. (1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly. (2) Remove the tire and wheel assembly.
(3) Remove the shock. Refer to the proper side (3) Remove the lower clevis bolt at the lower con-
shock removal procedure being worked on. (Refer to 2 trol arm. (Fig. 7)
- SUSPENSION/FRONT/SHOCK - REMOVAL). (4) Remove the upper clevis bolt at the shock. (Fig.
(4) Secure the shock assembly into a Pentastar 7)
Service Equipment W-7200 Spring compressor. (Fig.
6)
(5) Compress the spring.

Fig. 7 CLEVIS BRACKET

1 - UPPER BOLT
2 - CLEVIS BRACKET
Fig. 6 SPRING COMPRESSOR 3 - LOWER BOLT
1 - SPRING COMPRESSOR
2 - SPRING (5) Remove the lower stabilizer link bolt at the
lower control arm.
(6) Remove the shock mount nut. (6) Remove the lower ball joint nut.
(7) Remove the shock from the spring compressor. (7) Seperate the lower ball joint from the lower
(8) Transfer the necessary parts to the type of control arm using tool C-4150A.
repair being done (Insulator, Spring, shock and (8) Swing the lower control arm downward to
mount). allow clearence to remove the clevis braket.
(9) Remove the clevis bracket from the vehicle.
INSTALLATION
(1) Install the shock to the spring and spring com- INSTALLATION
pressor, After the transfer of the necessary parts to (1) Install the clevis bracket to the shock. Tighten
the type of repair being done (Insulator, Spring, the bolt to 136 N·m (100 ft.lbs.) (Fig. 7).
shock and mount). (2) Raise the lower control arm to the lower ball
(2) Install the shock mounting nut. Tighten the joint.
bolt to 41 N·m (30 ft.lbs.). (3) Install the nut to the lower ball joint. Tighten
(3) Loosen the compressed spring. the nut to 81 N·m (60 ft.lbs.).
(4) Remove the shock assembly from the spring (4) Install the clevis bracket to the lower control
compressor. arm. Tighten the bolt to 150 N·m (110 ft.lbs.).
(5) Install the shock to the vehicle. (Refer to 2 - (5) Install the lower stabilizer link bolt at the
SUSPENSION/FRONT/SHOCK - INSTALLATION). lower control arm. Tighten the bolt to 115 N·m (85
(6) Install the tire and wheel assembly. (Refer to ft.lbs.).
22 - TIRES/WHEELS/WHEELS - STANDARD PRO- (6) Install the tire and wheel assembly. (Refer to
CEDURE). 22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
(7) Remove the support and lower the vehicle. CEDURE).
(7) Lower the vehicle.
2 - 14 FRONT KJ

STABILIZER BAR
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly.
(3) Remove the upper stabilizer link bolts at the
stabilizer bar.
(4) Remove the stabilizer bar bushing clamps from
the frame (Fig. 8).
(5) Remove the stabilizer bar from the vehicle.

Fig. 9 STABILIZER BAR LINK

1 - STABILIZER BAR
2 - STABILIZER BAR LINK

INSTALLATION
(1) Install the stabilizer link (Fig. 9).
(2) Install the upper stabilizer link bolt and
washer at the stabilizer bar. Tighten the bolt to 136
N·m (100 ft.lbs.).
(3) Install the lower stabilizer link bolt and
Fig. 8 SWAY BAR washer at the lower control arm. Tighten the nut to
115 N·m (85 ft.lbs.).
1 - SWAY BAR
2 - SWAY BAR BUSHINGS (4) Install the tire and wheel assembly. (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
INSTALLATION
(1) Install the stabilizer bar to the vehicle.
(2) Install the stabilizer bar bushing clamps (Fig. UPPER CONTROL ARM
8). Tighten the nuts to 149 N·m (110 ft.lbs.).
(3) Install the upper stabilizer link bolts and
washer at the stabilizer bar. Tighten the bolt to 136 REMOVAL
N·m (100 ft.lbs.).
(4) Install the tire and wheel assembly. (Refer to REMOVAL - RIGHT SIDE
22 - TIRES/WHEELS/WHEELS - STANDARD PRO- (1) Raise and support the vehicle.
CEDURE). (2) Remove the right side tire and wheel assembly.
(5) Lower the vehicle. (3) Remove the upper ball joint nut.
(4) Separate the upper ball joint from the steering
knuckle using tool C-4150A.
STABILIZER LINK (5) Lower the vehicle.
(6) Remove the air box (Refer to 9 - ENGINE/AIR
REMOVAL INTAKE SYSTEM/AIR CLEANER ELEMENT -
(1) Raise and support the vehicle. REMOVAL).
(2) Remove the tire and wheel assembly. (7) Remove the cruise control servo mounting nuts.
(3) Remove the lower stabilizer link bolt at the (8) Remove the upper control arm rear bolt.
lower control arm. (9) Remove the upper control arm front bolt.
(4) Remove the upper stabilizer link bolt at the (10) Remove the upper control arm from the vehi-
stabilizer bar. cle.
(5) Remove the stabilizer link. (Fig. 9)
KJ FRONT 2 - 15
UPPER CONTROL ARM (Continued)

REMOVAL - LEFT SIDE (5) Install the air box (Refer to 9 - ENGINE/AIR
(1) Raise and support the vehicle. INTAKE SYSTEM/AIR CLEANER ELEMENT -
(2) Remove the left side tire and wheel assembly. INSTALLATION).
(3) Remove the upper ball joint nut. (6) Install the upper ball joint nut. Tighten the nut
(4) Separate the upper ball joint from the steering to 81 N·m (60 ft.lbs.).
knuckle using tool C-4150A. (7) Install the right side tire and wheel assembly.
(5) Lower the vehicle. (Refer to 22 - TIRES/WHEELS/WHEELS - STAN-
(6) Remove the battery (Refer to 8 - ELECTRI- DARD PROCEDURE).
CAL/BATTERY SYSTEM/BATTERY - REMOVAL). (8) Lower the vehicle.
(7) Unclip the power center and move it to the side (9) Set the toe and center the steering wheel
out of the way. (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
(8) Remove the battery tray (Refer to 8 - ELEC- STANDARD PROCEDURE).
TRICAL/BATTERY SYSTEM/TRAY - REMOVAL).
(9) Disconnect the battery temperature sensor INSTALLATION - LEFT SIDE
from the battery tray. (1) Install the upper control arm to the vehicle.
(10) Remove the upper control arm rear bolt by (2) Install the upper control arm front bolt (Fig.
using a ratchet and extension under the steering 11). Tighten the bolt to 122 N·m (90 ft.lbs.).
shaft and positioned by the power steering reservoir. (3) Install the upper control arm rear bolt (Fig.
(Fig. 10) 11). Tighten the bolt to 122 N·m (90 ft.lbs.).
(4) Reconnect the battery temperature sensor to
the battery tray.
(5) Install the battery tray (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/TRAY - INSTALLATION).
(6) Install the battery (Refer to 8 - ELECTRICAL/
BATTERY SYSTEM/BATTERY - INSTALLATION).
(7) Reclip and mount the power center.
(8) Install the upper ball joint nut (Fig. 11).
Tighten the nut to 81 N·m (60 ft.lbs.).

Fig. 10 REAR BOLT

1 - STEERING SHAFT
2 - REAR BOLT
3 - RATCHET WITH AN EXTENSION

(11) Remove the upper control arm front bolt.

(12) Remove the upper control arm from the vehi-
cle.
Fig. 11 UPPER CONTROL ARM
INSTALLATION (9) Install the left side tire and wheel assembly.
(Refer to 22 - TIRES/WHEELS/WHEELS - STAN-
INSTALLATION - RIGHT SIDE DARD PROCEDURE).
(1) Install the upper control arm to the vehicle. (10) Lower the vehicle.
(2) Install the upper control arm front bolt. (11) Set the toe and center the steering wheel
Tighten the bolt to 122 N·m (90 ft.lbs.). (Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
(3) Install the upper control arm rear bolt. Tighten STANDARD PROCEDURE).
the bolt to 122 N·m (90 ft.lbs.).
(4) Install the cruise control servo mounting nuts.
2 - 16 REAR KJ

REAR

TABLE OF CONTENTS
page page

REAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16 UPPER BALL JOINT
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DIAGNOSIS AND TESTING - REAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . 17 UPPER CONTROL ARM
SPECIFICATIONS DESCRIPTION - UPPER SUSPENSION ARM,
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 17 BUSHINGS, AND BALL JOINT . . . . . . . . . . . . 20
SHOCK OPERATION - UPPER SUSPENSION ARM,
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 BUSHINGS, AND BALL JOINT . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SPRING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 LOWER CONTROL ARM
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21
JOUNCE BUMPER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
STABILIZER BAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

REAR
DESCRIPTION
The rear suspension (Fig. 1) is comprised of :
• Drive axle
• Shock absorbers
• Coil springs
• Lower suspension arms
• Upper suspension arm
• Stabilizer bar

CAUTION: Suspension components with rubber/ure-

thane bushings should be tightened with the vehi-
cle at normal ride height. It is important to have the
springs supporting the weight of the vehicle when
the fasteners are torqued. This will maintain vehicle
ride comfort and prevent premature bushing wear. Fig. 1 REAR SUSPENSION
1 - COIL SPRING
2 - UPPER SUSPENSION ARM
WARNING 3 - STABILIZER BAR
4 - LOWER SUSPENSION ARM
WARNING:: Suspension components with rubber 5 - SHOCK
bushings must be tightened with the vehicle at nor-
mal ride height. It is important to have the springs
supporting the weight of the vehicle when the fas-
teners are torqued. If springs are not at their normal
ride position, vehicle ride comfort will be affected
and cause premature bushing wear.
KJ REAR 2 - 17
REAR (Continued)

DIAGNOSIS AND TESTING - REAR SUSPENSION

CONDITION POSSIBLE CAUSES CORRECTION

VEHICLE INSTABILITY 1. Loose or worn wheel bearings. 1. Replace wheel bearings.

2. Loose, worn or bent suspension 2. Inspect, tighten or replace components

components. as necessary.
3. Tire pressure. 3. Adjust tire pressure.

VEHICLE PULLS TO ONE 1. Weak or broken spring. 1. Replace spring.

SIDE
2. Alignment. 2. Align vehicle to specifications.
3.Tires. 3. Replace tires.
4. Brakes. 4. Repair as necassary.

KNOCKING, RATTLING 1. Worn shock bushings. 1. Replace shock.

OR SQUEAKING
2. Loose shock mounting. 2. Tighten to specifications.
3. Shock valve. 3. Replace shock.
4. Loose upper ball joint. 4. Replace ball joint.
5. Loose, worn or bent suspension 5. Inspect, tighten or replace components
components. as necessary.

IMPROPER TRACKING 1. Loose, worn or bent suspension 1. Inspect, tighten or replace components
components. as necessary.
2. Bent axle. 2.Replace axle.

SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Shock Absorber Upper Nut 108 80 —
Shock Absorber Lower Nut 115 85 —
Suspension Arm Upper Ball Joint Nut 95 70 —
Suspension Arm Upper Frame Bolts 100 74 —
Rear Upper Ball Joint Bracket Bolts 136 100 —
Suspension Arms Lower Body/Axle Bracket Nut 163 120 —
Suspension Arms Lower Frame Bracket Nut 163 120 —
Stabilizer Bar Bolts 99 73 —
2 - 18 REAR KJ

SHOCK SPRING
REMOVAL REMOVAL
(1) Raise and support the vehicle. Position a (1) Raise and support the vehicle. Position a
hydraulic jack under the axle to support the axle. hydraulic jack under the axle to support the axle.
(2) Remove the shock absorber lower bolt from the
CAUTION: Do not allow the axle to hang from the axle bracket.
upper suspension arm ball joint. (3) Lower the hydraulic jack and tilt the axle and
remove the coil spring (Fig. 3).
(2) Remove the upper nut and bolt from the frame (4) Remove and inspect the upper and lower
bracket (Fig. 2). spring isolators (Fig. 3).
(3) Remove the lower nut and bolt from the axle
bracket. Remove the shock absorber.

Fig. 3 COIL SPRING

1 - UPPER INSULATOR
Fig. 2 SHOCK ABSORBER 2 - JOUNCE BUMPER
1 - UPPER MOUNTING BOLT 3 - COIL SPRING
2 - LOWER MOUNTING BOLT

INSTALLATION
INSTALLATION (1) Install the upper isolator (Fig. 3).
(1) Install the shock absorber in the frame bracket (2) Install the lower isolator (Fig. 3).
and install the bolt and nut (Fig. 2). (3) Pull down on the axle and position the coil
(2) Install the shock absorber in the axle bracket spring in the lower isolator.
and install the bolt and nut (Fig. 2).
(3) Remove the supports and lower the vehicle. CAUTION: Ensure the spring is positioned on the
(4) Tighten the upper mounting nuts to 108 N·m lower isolator.
(80 ft. lbs.). Tighten the lower mounting nuts to 115
N·m (85 ft. lbs.). (4) Raise the axle with the hydraulic jack.
(5) Install the shock absorber to the axle bracket
and tighten to 115 N·m (85 ft. lbs.).
(6) Remove the supports and lower the vehicle.
(7) Tighten the stabilizer bar links to 99 N·m (73
ft. lbs.).
KJ REAR 2 - 19

JOUNCE BUMPER
REMOVAL
(1) Remove the shock (Refer to 2 - SUSPENSION/
REAR/SHOCK - REMOVAL).
(2) Remove the coil spring (Refer to 2 - SUSPEN-
SION/REAR/SPRING - REMOVAL).
(3) Pull the jounce bumper downwards to remove.
(Fig. 4)

Fig. 5 REAR STABILIZER BAR

1 - MOUNTING HOLES
2 - STABILIZER BAR

Fig. 4 JOUNCE BUMPER

INSTALLATION
(1) Install the jounce bumper into the mount by
twisting the bumper into place (Fig. 4).
(2) Install the coil spring (Refer to 2 - SUSPEN-
SION/REAR/SPRING - INSTALLATION).
(3) Install the shock (Refer to 2 - SUSPENSION/
REAR/SHOCK - INSTALLATION).

STABILIZER BAR Fig. 6 STABILIZER BAR MOUNTS

1 - STABILIZER BAR MOUNTING BOLTS
REMOVAL 2 - LOWER SUSPENSION ARM
(1) Raise and support the vehicle.
(2) Remove the stabilizer bar bolts from the lower
suspension arm. (Fig. 5).
(3) Remove the stabilizer bar.

INSTALLATION
(1) Position the stabilizer bar over the axle and
install the bolts to the lower suspension arm (Fig. 6).
Ensure the bar is centered with equal spacing on
both sides. Tighten the bolts to 99 N·m (73 ft. lbs.).
(2) Remove support and lower the vehicle.
2 - 20 REAR KJ

UPPER BALL JOINT REMOVAL

(1) Raise and support the vehicle.
REMOVAL (2) Support the rear axle with a hydraulic jack.
(1) Raise and support the vehicle. (3) Remove the ball joint pinch bolt from the top of
(2) Support the rear axle with a hydraulic jack. the differential housing bracket (Fig. 7).
(3) Remove the ball joint pinch bolt from the top of (4) Remove partial nuts from the heat shield in
the axle. (Fig. 7) order to lower the shield down enough to get the
(4) Seperate the ball joint arm assembly from the proper clearence to remove the right side bolt from
differential housing by prying upwards. the body.
(5) Remove the upper suspension arm mounting
bolts from the body and remove the arm (Fig. 8).

Fig. 7 BALL JOINT PINCH BOLT

1 - UPPER BALL JOINT
2 - PINCH BOLT Fig. 8 UPPER CONTROL ARM
1 - BODY MOUNTS
2 - UPPER BALL JOINT
INSTALLATION 3 - STABILIZER BAR
(1) Raise the rear axle with a hydraulic jack to align 4 - UPPER CONTROL ARM
the ball joint with the differential housing bracket. 5 - LOWER CONTROL ARM
(2) Insert the ball joint into the differential hous-
ing bracket. (6) Remove the support bracket mounting bolts if
(3) Install the ball joint pinch bolt and tighten to needed. (Fig. 9)
95 N·m (70 ft. lbs.). (Fig. 7).
(4) Remove the supports and lower the vehicle.

UPPER CONTROL ARM

DESCRIPTION - UPPER SUSPENSION ARM,
BUSHINGS, AND BALL JOINT
The suspension arm uses vertical spool bushings to
isolate road noise. The suspension arm is bolted
through bushings to cage nuts in the body and a ball
joint to the top of the differential housing.

OPERATION - UPPER SUSPENSION ARM,

BUSHINGS, AND BALL JOINT
The upper suspension arm provides fore/aft and Fig. 9 BALL JOINT BRACKET
lateral location of the rear axle. The suspension arm 1 - UPPER BALL JOINT
travel is limited through the use of jounce bumpers 2 - SUPPORT BRACKET BOLTS
in compression and shock absorbers in rebound.
KJ REAR 2 - 21
UPPER CONTROL ARM (Continued)

INSTALLATION
(1) Position the upper suspension arm in the
frame rail brackets (Fig. 8).
(2) Install the mounting bolts and tighten to 100
N·m (74 ft. lbs.).
(3) Retighten the heat shield back into place.
(4) Pull the arm down on the differential housing
bracket and install the pinch bolt and nut. Tighten
the nut to 95 N·m (70 ft. lbs.) (Fig. 7).
(5) Remove the supports and lower the vehicle.

LOWER CONTROL ARM

DESCRIPTION
The lower suspension arms are stamped steel and
welded and use voided round bushings at the axle Fig. 10 LOWER SUSPENSION ARM
end and solid rubber at the body end of the arm. 1 - AXLE BRACKET BOLT
2 - LOWER CONTROL ARM
OPERATION 3 - BODY BRACKET BOLT
The bushings provide isolation from the axle. The
arms mount to the unibody frame rail bracket and NOTE: The end of the arm with the voided round
the axle brackets. The arm and bushings provide bushing attaches to the axle bracket.
location and react to loads.
(2) Install the axle bracket bolt and nut finger
REMOVAL tight (Fig. 10).
(1) Raise the vehicle and support the rear axle.
(2) Remove the stabilizer bar retaining bolts from NOTE: When installing the right side suspension
the suspension arm. arm to the frame rail it will be necessary to pry the
(3) Remove the lower suspension arm nut and bolt exhaust over slightly to allow enough clearance to
from the axle bracket (Fig. 10). install the bolt.

NOTE: When removing the right side suspension (3) Install the frame rail bracket bolt and nut fin-
arm from the frame rail it will be necessary to pry ger tight.
the exhaust over slightly to allow enough clearance (4) Install the stabilizer bar retaining bolts to the
to remove the bolt. suspension arm.
(5) Remove the supports and lower the vehicle.
(4) Remove the nut and bolt (Fig. 10) from the (6) With the vehicle on the ground tighten the nut
frame rail and remove the lower suspension arm. at the frame to 163 N·m (120 ft. lbs.). Tighten the
nut at the axle bracket to 163 N·m (120 ft. lbs.).
INSTALLATION
(1) Position the lower suspension arm in the axle
bracket and frame rail bracket.