Attachment III - Technical Information

OVERVIEW

This program involves replacing both front coil springs of the affected vehicles.

SERVICE PROCEDURE

REMOVAL

1. Remove the tire and wheel assembly.

2. CAUTION: Do not use power tools to remove the stabilizer nut. Damage to the boot or ball joint can result.

NOTE:
To remove the stabilizer nut, first loosen the nut, then use the hex holding feature to keep the stabilizer bar link ball joint from turning while removing the nut. Remove the upper stabilizer bar attaching nut. Discard the nut.

3. Remove the caliper brake hose support bolt.

4. Remove the caliper assembly and brake pads. Support the caliper using mechanic's wire.

5. Remove the brake caliper anchor plate bolts and remove the anchor plate and rotor.

6. Remove and discard the tie rod attaching cotter pin and nut.

7. Using special tool 211-001, remove the tie rod from the knuckle.

8. Remove the ABS sensor bolt and position the sensor and the support clip out of the way.

9. Remove the lower strut pinch nut. Discard the nut. Do not remove the pinch bolt at this time.

10. Remove the lower ball joint nut. Discard the nut.

11. Install the special tool 211-003 Steering Arm Puller, 211-S200 Adapter and 211-212 Ball Joint Thread Protector.

12. Remove the lower ball joint from the lower control arm.

13. Remove the special tool 211-003 Steering Arm Puller, 211-S200 Adapter and 211-212 Ball Joint Thread Protector.

14. Mark the strut-to-knuckle position to ensure that the strut and knuckle are reassembled in the original position.

15. Remove the windshield washer hose from the right side inner stud of the upper strut plate bolt.

16. Remove the halfshaft nut.

17. Install the special tool 204-069 Front Hub Remover/Installer, 205-237 Wheel Hub Adapter and 204-067 Halfshaft Installer.

18. Disconnect the halfshaft from the hub and bearing assembly.

19. Secure the halfshaft to the lower control arm with mechanic's wire.

20. Remove the special tool 204-069 Front Hub Remover/Installer, 205-237 Wheel Hub Adapter and 204-067 Halfshaft Installer.

21. Remove the lower strut pinch bolt.

22. Remove the knuckle assembly.

23. Remove the upper strut plate mounting bolts.

24. Remove the strut assembly.

25. Mount strut and spring assembly in a suitable coil spring compressor fixture.

26. Compress spring and remove upper strut mount nut.

27. Remove the old spring and install the new spring.

28. Install the original strut to the new spring and install the upper strut mount and nut. Tighten the nut to 62 Nm (46 lb-ft).

INSTALLATION

1. Install the strut and attach the upper strut plate mounting nuts. Tighten the nuts to 35 Nm (26 lb-ft).

2. Install the windshield washer hose on right side inner stud of the upper strut plate bolt.

3. Install the knuckle assembly on the lower strut and install the lower strut pinch bolt and a new nut. Tighten the nut to 115 Nm (55 lb-ft).

4. Install the special tool 204-069 Front Hub Remover/Installer, 205-237 Wheel Hub Adapter and 204-067 Halfshaft Installer.

5. Install the halfshaft into the knuckle assembly.

6. Remove the special tool 204-069 Front Hub Remover/Installer, 205-237 Wheel Hub Adapter and 204-067 Halfshaft Installer.

7. Install the lower ball joint into the lower control arm.

8. Install a new nut. Tighten the nut to 80 Nm (59 lb-ft).

9. Install the tie rod and a new nut. Tighten the nut to 55 Nm (41 lb-ft).

10. Install a new cotter pin.

11. Install the ABS sensor retaining clip and bolt. Tighten the bolt to 12 Nm (9 lb-ft).

12. Install the front brake rotor.

13. Install the brake caliper anchor plate and the anchor plate bolts. Tighten the bolts to 103 Nm (76 lb-ft).

14. Install the brake pads, caliper and bolts. Tighten the bolts to 35 Nm (26 lb-ft).

15. Install the caliper brake hose assembly and support bolt. Tighten the bolt to 15 Nm (11 lb-ft).

16. CAUTION: Do not use power tools to install the stabilizer nut. Damage to the boot or ball joint can result.

NOTE:
To install the stabilizer nut use the hex holding feature to keep the stabilizer bar link ball joint from turning while installing the nut. Install a new nut.

Tighten the nut to 80 Nm (59 lb-ft).

17. Install the wheel and tire assembly.

18. Lower the vehicle and install the wheel hub washer and nut. Tighten the nut to 250 Nm (184 lb-ft).