Front
FRONT SUSPENSIONSHOCK ASSEMBLY
REMOVAL
NOTE: Before proceeding, refer to SERVICE PRECAUTIONS.
(1) Raise and support vehicle.
(2) Remove the wheel and tire assembly.
(3) If both shock assemblies are removed, mark the shock assemblies right and left according to which side of the vehicle they were removed from.
Fig.39 Wheel Speed Sensor Cable Routing Bracket:
(4) Remove the wheel speed sensor cable routing bracket from the steering knuckle (Fig. 39).
(5) Remove the nut from the upper ball joint stud.
Fig.40 Ball Joint Stud Removal Front Steering Knuckle:
(6) Remove the upper ball joint stud from the steering knuckle using Puller, Special Tool, C-3894-A (Fig. 40). Pull steering knuckle outward and position toward the rear of the front wheel opening.
Fig.41 Shock Absorber Clevis Bracket Pinch Bolt:
(7) Remove pinch bolt attaching shock absorber clevis to shock absorber (Fig. 41).
Fig.42 Clevis To Lower Control Arm Attaching Bolt:
(8) Remove the nut and thru-bolt attaching the shock absorber clevis to the lower control arm (Fig. 42).
(9) Remove the clevis from the shock absorber by carefully tapping the clevis off the shock absorber using a soft (brass) drift.
Fig.43 Shock Assembly Attachment To Shock Tower:
(10) Remove the four bolts (Fig. 43) attaching the shock absorber/upper control arm mounting bracket to the shock tower of the vehicle.
(11) Remove the shock assembly from the vehicle through the front area of the wheel well.
DISASSEMBLY
The shock assembly must be removed from the vehicle for it to be disassembled and assembled. For the disassembly and assembly of the shock assembly, use strut spring compressor Pentastar Service Equipment (PSE) tool W-7200, or equivalent, to compress the coil spring. Follow the manufacturer's instructions closely.
(1) If both shocks are being serviced at the same time, mark the coil spring and shock assembly according to which side of the vehicle the shock was removed from, and which shock the coil spring was removed from.
Fig.44 Lower Hooks And Clamp:
Fig.45 Upper Hooks Positioned:
(2) Position the shock assembly in the strut coil spring compressor following the manufacturer's instructions. Set the lower hooks and install the clamp on the lower end of the coil spring, so the shock is held in place once the shock shaft nut is removed (Fig. 44). Rotate the shock assembly so the upper control arm ball joint sits directly below the front upper hook as shown (Fig. 45). Position the upper hooks on top of the upper mounting bracket (Fig. 45).
WARNING: DO NOT REMOVE THE SHOCK ROD NUT BEFORE THE COIL SPRING IS COMPRESSED. THE COIL SPRING IS HELD UNDER PRESSURE AND MUST BE COMPRESSED, REMOVING SPRING TENSION FROM THE UPPER MOUNTING BRACKET BEFORE THE ROD NUT IS REMOVED.
(3) Compress the coil spring until all coil spring tension is removed from the upper mounting bracket.
Fig.46 Retainer Nut Removal/Installation:
(4) Hold the shock rod from rotating using special socket Snap-On A136, or an equivalent, and remove the retainer nut (Fig. 46).
Fig.47 Washer:
(5) Remove the upper bushing retainer washer (Fig. 47) from the shock absorber rod.
NOTE: While removing the shock absorber from the coil spring, the dust shield and cup, and perhaps the jounce bumper will get caught inside coil spring requiring it to be left until the coil spring is removed from the compressor. It may be left there until the shock absorber is installed if removal is not necessary. Use care not to misplace the lower bushing retainer washer.
(6) Remove the clamp from the bottom of the coil spring and remove the shock absorber, lower spring isolator, jounce bumper, cup, dust boot, and lower bushing retainer washer out through the bottom of the coil spring.
NOTE: If the coil spring, upper mounting bracket, rod bushings, upper coil spring isolator, or upper control arm need to be serviced, proceed with the next step, otherwise, proceed with step 11.
NOTE: Before removing the coil spring from the spring compressor, note the position of the lower coil spring end to the spring compressor. The coil spring will need to be in this position on reassembly for proper coil spring-to-shock absorber and upper mounting bracket orientation.
(7) Release the tension from the coil spring by backing off the compressor drive fully. Push back the compressor upper hooks and remove the upper mounting bracket and upper control arm from the coil spring.
(8) Note the position of the coil spring in the spring compressor as listed in the above note before removal. This is necessary for proper alignment of the shock assembly components when reassembly is made. Remove the coil spring from the spring compressor.
Fig.48 Shock Absorber Rod Upper Isolator Bushing:
(9) Remove the shock absorber rod upper isolator bushing from the upper (shock absorber/upper control arm) mounting bracket (Fig. 48).
Fig.49 Shock Absorber Rod Lower Isolator Bushing:
(10) Remove the shock absorber rod lower isolator bushing and sleeve from the upper (shock absorber/upper control arm) mounting bracket (Fig. 49). Remove upper coil spring isolator from mounting bracket.
Fig.50 Shock Assembly Components:
(11) Remove the lower shock rod bushing retainer washer from the shock absorber rod (Fig. 50).
(12) If not already removed, remove the jounce bumper (Fig. 50) and metal collar from the shock absorber rod.
(13) Remove the lower spring isolator (Fig. 50) from the lower spring seat on the shock absorber.
(14) Inspect the shock assembly components for the following and replace as necessary:
- Inspect the shock for any condition of rod binding over the full stroke of the shaft.
- Check the upper mounting bracket for cracks, distortion and any sign of damage.
- Inspect the upper mounting bracket-upper control bushings for deterioration.
- Check the upper and lower shock rod isolator bushings for severe deterioration.
- Check the upper and lower spring isolators for severe deterioration.
- Inspect the dust shield for rips and deterioration.
- Inspect the jounce bumper for cracks and signs of deterioration.
- Inspect the coil spring for any sign of damage to the coating.
ASSEMBLY
For the disassembly and assembly of the shock assembly, use strut spring compressor Pentastar Service Equipment (PSE) tool W-7200, or the equivalent, to compress the coil spring. Follow the manufacturer's instructions closely.
NOTE: If the coil spring, upper mounting bracket, rod bushings, upper coil spring isolator, and upper control arm have been removed from the spring compressor, proceed with the next step, otherwise, proceed with Step 8.
(1) Install the sleeve into the lower shock absorber rod isolator bushing (Fig. 49). Install the shock absorber rod lower isolator bushing and sleeve in the bottom of the upper (shock absorber/upper control arm) mounting bracket as shown (Fig. 49). From the top, install the shock absorber rod upper isolator bushing into the center of the upper mounting bracket over the sleeve protruding from the lower isolator bushing (Fig. 48). The smaller end of each bushing is to face away from the upper mounting bracket once installed.
(2) Place the lower end (smaller diameter) of the coil spring in the spring compressor supported by the lower hooks, following the manufacturer's instructions. Position the coil spring lower end tip at the position it was at before coil spring removal from the compressor as noted in Step 8 of DISASSEMBLY. Proper orientation of the spring in the compressor is necessary for proper alignment of all shock assembly components.
(3) Place the dust shield and cup inside the coil spring (Fig. 50). Secure the lower shock rod bushing retainer washer over the cup.
(4) Install the upper coil spring isolator on top of the spring matching the built-in step in the isolator to the tip of the coil spring.
(5) Position the upper control arm ball joint so it lies directly below the front upper hook as shown (Fig. 45), then install the upper (shock absorber/upper control arm) mounting bracket on top of the coil spring isolator placed on the coil spring.
(6) Position the upper hooks on top of the upper mounting bracket as shown (Fig. 45).
(7) Compress the coil spring.
(8) Install the lower spring isolator on the lower spring seat of the shock absorber (Fig. 50). When installing the spring isolator, be sure the isolator sets in the notch made for the lower coil spring end.
Fig.51 Jounce Bumper Installation:
(9) Install the jounce bumper on the shock rod (Fig. 51). Install the jounce bumper with the pointed end pointing downward.
Fig.52 Shock Absorber Rod Collar Installation:
(10) Install the collar, undercut side facing down, on the rod of the shock absorber (Fig. 52). Be sure the collar is positioned squarely on the step of the shock absorber rod.
(11) Install the shock through the bottom of the coil spring, then through the dust boot, cup and retainer washer until the lower spring seat contacts the lower end of the coil spring. The lower coil spring end should set into the notch of the shock absorber lower seat and isolator. Install the clamp temporarily securing the shock absorber to the coil spring (Fig. 44).
(12) Install the upper shock rod bushing retainer washer. Make sure the concave side is facing up (curved outer edge up).
(13) Install the shock assembly retainer nut. Hold the shock rod from rotating using special socket Snap-On A136, or an equivalent, and tighten the retainer nut using a crow foot wrench (on the end of a torque wrench and extension) to 45 Nm (33 ft. lbs.) (Fig. 46).
(14) Slowly release the tension from the coil spring by backing off the compressor drive fully. As the tension is relieved, make sure the upper mounting bracket, isolator, and coil spring align properly. Remove the clamp from the lower end of the coil spring and shock. Push back the spring compressor upper and lower hooks, then remove the shock assembly from the spring compressor.
(15) Install shock assembly on the vehicle.
INSTALLATION
(1) Install the shock assembly, with the clevis removed, into the shock tower. Align the two locating pins and the four mounting holes on the upper control arm shock absorber mount with the mounting holes in the shock tower. Install the four upper control arm mount to shock tower mounting bolts (Fig. 43). Tighten the bolts to 92 Nm (68 ft. lbs.).
Fig.53 Clevis Correctly Installed On Shock Absorber:
(2) Install the clevis onto the shock absorber by tapping it on with a soft (brass) drift until fully seated against the locating tab on the shock absorber (Fig. 53). The orientation tab on the locating tab must be positioned in the split of the clevis (Fig. 53).
(3) Install the pinch bolt retaining the shock clevis to the shock absorber (Fig. 41). Tighten the pinch bolt to 71 Nm (52 ft. lbs.).
(4) Install the clevis-to-lower control arm thru-bolt (Fig. 42). Do not tighten the thru-bolt at this time.
(5) Install the upper ball joint into the steering knuckle. Install the nut on the ball joint stud and tighten it to 88 Nm (65 ft. lbs.).
(6) Install the routing bracket for the wheel speed sensor cable (Fig. 39) on the steering knuckle. Install and securely tighten the routing bracket attaching bolt (Fig. 39).
Fig.54 Lower Control Arm Correctly Supported By Jack Stand:
CAUTION: When supporting the lower control arm with a jack stand, do not position the jack stand under the ball joint cap on the lower control arm. Position in the area of the lower control arm as shown (Fig. 54).
(7) Lower the vehicle to the ground with a jack stand positioned under the lower control arm (Fig. 54). Continue to lower the vehicle so the total weight of the vehicle is supported by the jack stand and lower control arm.
(8) Tighten the shock absorber clevis to lower control arm bushing thru-bolt nut to a torque of 92 Nm (68 ft. lbs.).
(9) Raise the vehicle, then remove the jack stand.
(10) Install the tire and wheel assembly. Progressively tighten the wheel mounting nuts in a crisscross sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.).
(11) Lower the vehicle.