1993 CHEVROLET PLYMOUTH ACCLAIM air suspension

control arm. Be sure that the flanges of the bushing
are fully expanded around the control arm bushing
holes. (5) If the position of the large lower control arm
pivot bushing (Fig. 11) moved during bushing instal-
lation. Install a nut and bolt through the bushing
sleeve and tighten it down (Fig. 11). Using a wrench
rotate the bolt until the bushing is in the correct po-
sition (Fig. 10)
BALL JOINTS
The lower front suspension ball joints operate with
no free play. See Inspection Ball Joint Wear to deter-
mine if the ball joint is worn and requires replace-
ment. The ball joints are replaceable as an assembly, do
not attempt any type of repair on the ball joint as-
sembly. The replacement procedure for the ball joint
assembly is detailed in this section. The ball joint housing is a pressed fit into the
lower control arm with the joint stud retained in the
steering knuckle by a (clamp) bolt.
INSPECTION BALL JOINT WEAR
With the weight of the vehicle resting on the road
wheels. Grasp the grease fitting as shown in (Fig. 12)
and with no mechanical assistance or added force at-
tempt to move the grease fitting.
If the ball joint is worn the grease fitting will move
easily. If movement is noted,replacement of the ball
joint is recommended.
BALL JOINT REMOVAL
(1) Pry off seal.
(2) Position Receiving Cup Special Tool C-4699-2
to support lower control arm while receiving ball
joint assembly (Fig. 13). (3) Install Remover/Installer Special Tool,
C-4699-1 (Fig. 13) over ball joint stud and against
the ball joint upper housing. (4) Press down against the ball joint upper hous-
ing, to remove ball joint assembly from lower control
arm.
Fig. 9 Bushing Installer Tools
Fig. 10 Bushing And Tool Position For Installation In Control Arm
Fig. 11 Positioning Control Arm Bushing
Fig. 12 Checking Ball Joint Wear
Ä SUSPENSION AND DRIVESHAFTS 2 - 13

BALL JOINT INSTALLATION
(1) By hand, position ball joint assembly into the
ball joint bore of the lower control arm. Be sure the
ball joint assembly is not cocked in the bore of the
control arm, this will cause binding of the ball joint
assembly. (2) Position assembly in press with Installer Tool
C-4699-2 supporting control arm (Fig. 14). (3) Install the Remover/Installer, Special Tool
C-4699-1 over the ball joint stud and down on the
lower body of the ball joint assembly (Fig. 14). (4) Carefully align all pieces. Using an arbor press
apply pressure against the ball joint assembly, until
ball joint is fully seated against bottom surface of
control arm. Do not apply excessive pressure against
the control arm.
BALL JOINT SEAL INSTALLATION
(1) Support ball joint housing with Installer, Spe-
cial Tool C-4699-1 (Fig. 15). Position new seal over
ball joint stud and against ball joint housing.
(2) With 1-1/2 inch socket, press seal onto ball
joint housing until it is squarely seated against top
surface of control arm as shown in (Fig. 15).
SWAY BAR
The sway bar interconnects the front lower control
arms of the vehicle and attaches to the crossmember
(Fig. 1). Jounce and rebound movements affecting one
wheel are partially transmitted to the opposite wheel
to stabilize body roll. Attachment to the crossmember, and front lower
control arms is through rubber-isolated bushings. All
parts are serviceable, and the sway bar to crossmem-
ber bushings are split for easy removal and installa-
tion. The split in the sway bar to crossmember
bushing should be positioned toward the front of the
vehicle.
LOWER CONTROL ARM SWAY BAR RETAINER ATTACHMENT HOLE THREAD REPAIR
If threaded holes in lower control arm, for attach-
ment of sway bar retainers (Fig. 1) become damaged.
The threaded holes are repairable and do not require
replacement of lower control arm. If threads are damaged or stripped on the lower
control arm. An initial repair attempt should be
Fig. 13 Removing Ball Joint
Fig. 14 Installing Ball Joint
Fig. 15 Installing Ball Joint Seal
2 - 14 SUSPENSION AND DRIVESHAFTS Ä

made by using a (M10 x 1.5 - 6H) thread chasing tap
on the holes to restore the threads to a usable condi-
tion. If threads can be restored to a usable condition,
install sway bar retainer attaching bolts and torque
to 68 N Im (50 ft. lbs.).
CAUTION: When performing repair procedure listed
below. Be sure replacement bolts and nuts meet the
same requirements as the original equipment man-
ufactures specifications.
If damage to threaded holes in lower control arm,
can not be restored to a usable condition using the
above procedure. Drill out holes in lower control arm
using an 11 mm drill bit. Then use a bolt and nut for
attachment of sway bar retainer to lower control
arm. Torque the nut and bolt to 68 N Im (50 ft. lbs.).
REMOVAL
(1) Raise and support the vehicle. See Hoisting in
Lubrication and Maintenance, Group 0. (2) Remove the bolts and sway bar retainers at the
front lower control arms (Fig. 16). (3) Remove the bolts at sway bar crossmember
clamps, and remove clamps and sway bar from vehi-
cle (Fig. 16).
INSPECTION
Inspect for broken or distorted clamps, retainers,
and bushings. If bushing replacement is required, the
inner bushing can be removed by opening the split.
The outer bushing must be cut or hammered off the
bar. If replaced, the outer bushings should be forced
on so that approximately 1/2 inch of the bar pro-
trudes. The sway bar to crossmember bushings, should be positioned when installed, so the void on the
bushing is positioned toward the rear of the vehicle
(Fig. 17). Note that the control arm retainers are
symmetric and bend slightly upon installation.
INSTALLATION
(1) If inspection of the sway bar assembly, deter-
mined that sway bar to lower control arm bushings
require replacement. Install the new bushings, by
forcing them onto sway bar using a rotating motion.
Bushings should be installed on sway bar so that sway
bar extends 1/2 inch out past the end of the bushing. (2) If required position sway bar to crossmember
bushings on sway bar with external rib up and void in
the bushing facing the rear of vehicle (Fig. 17). Lift the
bar assembly into the crossmember, and install
Fig. 16 Front Sway Bar
Fig. 17 Sway Bar To Crossmember Bushing Posi- tion
Ä SUSPENSION AND DRIVESHAFTS 2 - 15

the lower clamps and bolts. The center offset in the
sway bar should be oriented toward the front of the
vehicle (Fig. 16)(3) Position bushing retainers on lower control arms
and install bolts (Fig. 16). (4) With lower control arms raised to design height,
tighten all retainer attaching bolts to 70 N Im (50 ft.
lbs.) torque. (5) Lower vehicle.
KNUCKLE (FRONT SUSPENSION)
The front suspension knuckle (Fig. 1) provides for
steering control of the vehicle. Supports the brake
caliper and absorbs the loads exerted during vehicle
braking. It also supports the front (driving) hub and
bearing and stub axle assembly. The front suspension knuckle also provides the abil-
ity to align the front wheels of the vehicle. This is done
by allowing for front wheel camber adjustment and the
ability for front tire Toe adjustments The front suspension knuckle is not a serviceable
component. Do not attempt to straighten or repair the
front suspension knuckle in any way. Service repair or replacement of the front (drive) hub
and bearing, can be done with the front suspension
knuckle remaining on the vehicle.
REMOVAL
(1) Remove the cotter pin, hub nut lock and spring
washer from the front axle (Fig. 2). (2) Loosen hub nut while the vehicle is on the floor
with the brakes applied (Fig. 3). The hub and drive-
shaft are splined together through the knuckle
(bearing) and retained by the hub nut. (3) Raise and support the vehicle. See Hoisting in
Lubrication and Maintenance, Group 0. (4) Remove the wheel lug nuts, front tire and
wheel assembly and hub nut and washer. (5) Remove the brake caliper adapter to steering
knuckle attaching bolts and washers (Fig. 1). Re-
move the brake caliper and adapter from the steering
knuckle and braking disc. Support brake caliper/
adapter assembly using a wire hook and not by hy-
draulic hose (Fig. 4). (6) Remove the braking disc from the front hub/
bearing assembly (Fig. 5). (7) Remove the cotter pin and nut from the tie rod
end. Remove the tie rod end from the steering
knuckle arm using Puller, Special Tool C-3894-A
(Fig. 6). (8) Remove the clamp nut and bolt (Fig. 7) secur-
ing the ball joint stud into the steering knuckle. (9) Separate ball joint stud from knuckle assembly
by prying down on lower control arm. Pull knuckle
assembly out and away from driveshaft (Fig. 8).
Fig. 2 Remove Cotter Pin, Hub Nut Lock, & Spring Washer
Fig. 3 Loosen Hub Nut
Fig. 1 Front Knuckle Assembly (Typical)
2 - 16 SUSPENSION AND DRIVESHAFTS Ä

ing, do not remove the heavy spacer ring from the
shaft, G.K.N. only (Fig. 4).
(7) With joint separated from the interconnecting
shaft proceed as follows:
² If outer C/V joint was operating satisfactorily and
grease does not appear to be contaminated, just re-
place boot. Bypass the following disassembly proce-
dure for the C/V joint assembly, See Boots Install.
² If outer joint is noisy or badlyworn. Bypass the
following disassembly and replace entire unit. It is
also recommended that the boot be replaced. The
Boot Package includes the boot, clamps, retaining
ring (circlip), and lubricant. See boots install. (8) Hold joint vertically in vise by clamping on
splined shaft, using soft jaws to prevent damage. (9) Wipe off surplus grease and mark relative po-
sition of inner cross, cage and housing with a dab of
paint (Fig. 5). (10) Press down on one side of inner race to tilt
cage and remove ball from opposite side (Figs.5 and
6). If joint is tight, use a hammer and brass drift to
tap inner race. Do not hit the cage. Repeat this step
until all 6 balls are removed. A screwdriver may be
used to pry balls loose. (11) Tilt the cage and inner race assembly verti-
cally and position two opposing cage windows in area
between the ball grooves. Remove the cage and inner
race assembly by pulling upward away from the
housing (Fig. 7). (12) Turn inner cross (driver) 90É to cage and align
one of the race spherical lands with cage window.
Raise land into cage window and remove inner race
by swinging out (Fig. 8).
INSPECT
Check grease for contamination and all parts for
defects as follows: (1) Wash all parts in suitable solvent and dry,
preferably with compressed air. (2) Inspect housing ball races for excessive wear
and scouring.
Fig. 3 Circlip Retainer in Cross S.S.G.
Fig. 4 Remove Circlip
Fig. 5 Rotate Cage & Cross to Remove Balls
Fig. 6 Ball Released
2 - 38 SUSPENSION AND DRIVESHAFTS Ä

REAR SUSPENSION INDEX
page page
Coil Springs and Jounce Bumper ............ 51
General Information ....................... 50
Pivot Bushing AC AG AJ AP Body ........... 55
Pivot Bushing AC and AY Body ............. 52 Rear Axle Assembly
...................... 57
Shock Absorbers ......................... 51
Track Bar-Brace-Bracket ................... 52
GENERAL INFORMATION
All front wheel drive passenger cars. Utilize a
Trailing Arm Twist Beam type rear axle in conjunc-
tion with coil (or air) springs (Fig. 1). The blade type
Trailing Arms, attached to body mounted pivots, pro- vide fore and aft location of the suspension while a
Track Bar provides lateral location. Located in line with the spindles. An open channel
section beam axle assures that the rear tires remain
parallel to each other, and essentially perpendicular
Fig. 1 Trailing Arm Rear Suspension
2 - 50 SUSPENSION AND DRIVESHAFTS Ä

to the road surface. While being able to twist as one
wheel moves vertically with respect to the other.Roll resistance is provided partly by the axle's re-
sistance to twist. But primarily by a torque tube or
rod (depending on the suspension option called for)
running through the channel and attached rigidly to
its end plates by welding. Because the torque tube/
rod is an integral part of the axle assembly, it cannot
be individually replaced. The spindles are bolted to the axle end (spindle
mounting) plates and can be individually replaced if
required. Rear wheel alignment changes require the
use of shims between the spindle and axle end plates.
SHOCK ABSORBERS
REMOVAL
(1) Raise vehicle, see Hoisting, Group 0.
(2) Support axle and remove wheel and tire assem-
bly. (3) If equipped with air shocks, disconnect air
lines. (4) Remove upper and lower shock absorber fasten-
ers, remove shock absorbers (Fig. 2).
INSPECTION
Inspect for evidence of fluid leakage from upper
end of reservoir. (Actual leakage will be a stream of
fluid running down and leaking off lower end). Slight
seepage is not unusual and will not effect perfor-
mance.
INSTALLATION
(1) Position shock absorber on car. Install upper
and lower fasteners loosely to hold shock absorber in
place. (2) Tighten upper fastener to 61 N Im (45 ft. lbs.)
torque. Connect air line, if so equipped. (3) Install wheel and tire assembly, tighten wheel
stud nuts to 129 N Im (95 ft. lbs.) torque. Lower vehi-
cle to ground. (4) With suspension supporting the weight of the
vehicle. Tighten lower shock absorber fastener to 54
N Im (40 ft. lbs.) torque.
COIL SPRINGS AND JOUNCE BUMPER
REMOVAL
(1) Lift vehicle see hoisting Group 0.
(2) Support axle assembly and remove both lower
shock absorber attaching bolts. (3) Lower axle assembly until spring and spring
upper isolator can be removed (Fig. 3). Do not
stretch brake hose. (4) Remove two screws holding cup to rail (Fig. 1).
Remove assembly.
INSTALLATION
(1) Position cup to rail. Install and tighten attach-
ing bolts to 8 N Im (70 in. lbs.) torque.
(2) Install isolator over jounce bumper and install
spring. (3) Raise axle and loosely assemble both shock ab-
sorber to axle mounting bolts. Remove axle support
and lower vehicle. (4) With suspension supporting the weight of the
vehicle. Tighten both shock absorber attaching bolts
to 61 N Im (45 ft. lbs.) torque.
Fig. 2 Remove/Install Shock Absorber Fasteners
Fig. 3 Coil Spring & Jounce Bumper
Ä SUSPENSION AND DRIVESHAFTS 2 - 51

WARNING: WHEN REMOVING THE REAR AXLE
PIVOT BUSHING ON VEHICLES EQUIPPED WITH EI-
THER REAR COIL SPRINGS OR AIR SUSPENSION.
THE REAR AXLE MUST BE SUPPORTED BY THE
AXLE AND TRAILING ARM TO ENSURE ADEQUATE
SUPPORT OF REAR AXLE.
(3) Support the rear axle assembly at both the axle
channel and the trailing arm (Fig. 6). Then remove
lower shock absorber to rear axle mounting bolt (Fig.
6).
(4) Remove hanger bracket to frame rail bolts (Fig.
7).
(5) Lower axle assembly down enough to remove
pivot bolt and hanger bracket (Fig. 7). Right side
trailing arm shown.
PIVOT BUSHING REMOVAL FROM AXLE AS- SEMBLY
Remove bushing with Remover/Installer Spe-
cial Tool C-4212-L (Press) and 3 piece set, Spe- cial Tool 6122 (Receiver Support Bridge, Bushing
Remover/Installer and Bushing Remover). (1) Install receiver (support) bridge into base of
press C-4212-L and bushing Remover/Installer disc
onto screw. (2) Position assembly with receiver bridge support-
ing trailing arm while turning screw to begin bushing
removal. (3) After bushing has begun to move replace bushing
remover/installer (round disc) with bushing remover
(oval shaped disc). Use this assembly to finish pressing
bushing out of trailing arm (Fig. 8).
PIVOT BUSHING INSTALLATION
(1) Align the bushing with the bushing mounting
hole in the trailing arm bracket (Fig. 9). Tap bushing in
slightly to hold position. (2) Assemble bushing installer Tool onto press screw
and support bridge into press base. Position assem-
bly as shown in (Fig. 10) and press bushing into
arm to depth shown in (Fig. 9). (3) Position hanger bracket on pivot bushing, and
install through bolt, loose assemble nut (Fig. 11). Right
side trailing arm shown. (4) Position hanger to frame rail (a suitable drift will
aid in guiding hanger bracket into position). Install
and tighten screws to 75 N Im (55 ft. lbs.) torque (Fig.
12). Install lower shock absorber mounting bolt, but
do not tighten. (5) Position brake hose mounting bracket to trailing
arm, install and tighten retaining screw to 11 N Im (95
in. lbs.) torque (Fig. 13). (6) Attach park brake cable housing to hanger
bracket and cable to connector.
Fig. 8 Tools Installed To Remove Bushing
Fig. 6 Remove Pivot Bushing Hanger Bracket Bolts
Fig. 7 Remove Hanger Bracket
Ä SUSPENSION AND DRIVESHAFTS 2 - 53