1993 DODGE TRUCK Service Repair Manual

2 - 4 FRONT SUSPENSION AND AXLE
•

I
FRONT END
|
|*?£E;
LOOSE
OR WORN
FRONT WHEEL
BEARINGS

LOOSE
C

SHOCKS

MOUNTir
WAR

SHOCK
A )RWORN

JSORBER

nIG
HARD-

E
OR
BSORBER
EXCiSSIVE
PLAY

STEERING

LINKAGE
LOOSE
OR WORN
FRONT WHEEL
BEARINGS

LOOSE
C

STEERINC
SHAFT
C
)RWORN

7
COLUMN
OUPLING
DIFFICULT

STEERING
LOOSE
OR WORN
WHEEL BEARINGS
TIRE/V
OUT OF
f
VHEEL
JA
LANCE
LOW OR UNEVEN
TIRE
AIR
PRESSURE

LO(
WHEEL B
DSE

EARINGS
LOW OR UNEVEN
TIRE AIR
PRESSURE
1vsnciEi

I
1
PULLS
TO I

I
|
ONE SIDE
j
LOOSE,
WORN
OR

GLAZED
P/S PUMP BELT LOW OR UNEVEN
TIRE PRESSURE
WHILE BR
REFE

BRAKES
AKING—

R
TO

SERVICE

LOOSE
STEERING
GEAR-TO-FRAME
RAIL BOLTS
LOOSE
STEERING

GEAR-TO-FRAME
RAIL BOLTS UNEVEN TIRE TREAD
WEAR,
OR
EX­

CESSIVELY
WORN TIRE TREAD
BROKEN
OR WEAK

REAR
SPRING LOW
POWER STEERING
FLUID
LEVEL
BROKEN
OR WEAK

REAR
SPRING
WORN

UPPER
SUSPENSION ARM BUSHINGS WORN TIE-

ROD
END

BALL
STUDS WORN TIE-

ROD
END

BALL
STUDS
SHOCK
ABSORBER

NOT FUNCTIONING
CORRECTLY
LACK
OF ASSIST
FROM POWER

STEERING
PUMP
LOOSE
OR WORN

SUSPENSION
BUSHINGS

WORN LOWER

SUSPENSION
ARM
PIVOT
BUSHINGS INCORRECT

STEERING
GEAR ADJUSTMENT
LOOSE
OR WORN

SUSPENSION
ARM
BUSHINGS
INCORRECT

STEERING
GEAR ADJUSTMENT
BALL
STUDS

REQUIRE

LUBRICATION INCORRECT FRONT
WHEEL ALIGNMENT (EITHER CASTER OR CAMBER)

LOOSE
LOWER

SUSPENSION
ARM
LOOSE
OR WORN

UPPER
SUSPENSION ARM BALL STUDS
LOOSE
OR WORN

SUSPENSION
ARM
BUSHINGS
STEERING
GEAR
LUBRICANT LEVEL LOW
WORN ISOLATOR

PAD
BETWEEN COIL
SPRING
AND

FRAME
BRACKET INCORRECT FRONT-
WHEEL ALIGNMENT (PARTICULARLY
CASTER)
INCORRECT FRONT
WHEEL ALIGNMENT INCORRECT

STEERING
GEAR ADJUSTMENT

STEERING
GEAR

MALFUNCTION
INCORRECT FRONT
WHEEL ALIGNMENT (PARTICULARLY
CASTER)

J9002-97
SUSPENSION AND STEERING
SYSTEM
DIAGNOSIS

•

FRONT
SUSPENSION
AND
AXLE
2 - 5 (4) Front wheels for excessive radial, lateral
runout and unbalance. Refer to Group 22, Wheels and Tires for diagnosis information.
(5) Suspension components for wear and noise. Check
components for correct torque. Refer to Groups 2 and 3, Suspension and Axle for additional information.

WHEEL
ALIGNMENT
MEASUREMENTS/ADJUSTMENTS
The front wheel alignment positions must be set to
the specified limits. This will prevent abnormal tire
tread wear. The equipment manufacturer's recommenda­
tions for use of their
equipment
should always
be followed. All
damaged
front suspension sys­
tem components
should
be replaced. Do not at­ tempt to straighten any
bent
component.

CAMBER AND CASTER-2WD VEHICLES Camber and caster angle adjustments involve repo­
sitioning the upper suspension arm cam adjustment
bolts (Fig. 2). Alignment adjustments are accom­
plished by loosening the nuts and changing the posi­
tion of the cam bolt.
(1) Remove all foreign material from the adjust­
ment bolt threads.
(2) Record the camber and caster measurements
before loosening the adjustment bolt nuts.
(3) The camber angle should be adjusted as near as
possible to the preferred angle. The caster should be
the same at both sides of the vehicle. Refer to the Specifications chart.
CAMBER AND CASTER—4WD VEHICLES For 4WD vehicles, the correct wheel camber (verti­
cal tilt) angle is factory preset at zero degree (0°).
Camber cannot be altered by adjustment.
CAUTION: Do not attempt to
adjust
the
camber
an­
gle by
heating
or bending the axle or any
suspen­

sion
component. If camber angle is
incorrect,
the
component(s)
causing
an
incorrect
angle must be replaced.
(1) It is important that the camber (vertical tilt)
angle be the same for both front wheels.
(2) The camber angle should be measured with ac­
curate wheel alignment equipment. The acceptable
range is -1° to +1°. Refer to the Specifications chart.
Road test the vehicle and observe the steering
wheel return-to-center position. Before road testing,
check
and
correct
the tire
inflation pressures. Inflate
both
of the front tires
with exactly the
same
pressure.
During the road test, make vehicle turns to both
the left and right. If the steering wheel returns to­
ward the center position unassisted, the caster angle is correct. However, if the steering wheel does not re­ turn toward the center position unassisted, an incor­
rect caster angle is probable.
(1) The caster angle is factory preset at positive
two degrees
(
+
2°).
The acceptable range is +1/2° to +
3
1/2°.
(2) The caster angle should be measured with ac­
curate wheel alignment equipment.
(3) Caster angle can be adjusted by installing ta­
pered shims between the front axle pads and the spring brackets. The caster angle should be adjusted
as near as possible to the preferred angle.
(4) Record the caster measurement before remov­
ing the original shims from the spring pads.
(5) The caster should be the same at both sides of
the vehicle. Refer to the Specifications chart.
RN1030

Fig.
2 Caster &
Camber
Adjustment Location—2WD
Vehicles

WHEEL TOE POSITION The wheel toe position adjustment should be the fi­
nal front wheel alignment adjustment. In all in­ stances, follow the equipment manufacturer's
recommended procedure.
(1) Secure the steering wheel with the front wheels
in the straight-ahead position. For vehicles equipped
with power steering, start the engine before straight­ ening the wheels.
With power steering, the engine should be op­
erating during the wheel toe position adjust­
ment.
(2) Loosen the tie rod adjustment sleeve clamp
bolts (Fig. 3).
(3) Adjust the wheel toe position by rotating the
tie rod adjustment sleeve (Fig. 3). Rotate each tie-rod end in the direction of
sleeve rotation during the adjustment (Fig. 3).
This will ensure that both tie-rod ends are at the center of their travel.
(4) If applicable, turn the ignition switch off.

2
- 6
FRONT
SUSPENSION
AND
AXLE

•
(5) Position the adjustment sleeve clamps so the
ends are not located at the sleeve slot. Tighten the
clamp bolt nuts to 26 N*m (225 in. lbs.) torque.
Tighten Model D350 and all 4WD vehicle (heavy
duty tie rods) nuts to 34 N*m (25 ft. lbs.) torque. En­
sure clamp bolts are located at the underside of the
sleeve.
CLAMP
RN1036

Fig.
3 Toe Position Adjustment
(Typical)

ALIGNMENT
SPECIFICATIONS

ALIGNMENT
(4WD)
ASGSPTABLE RANGE
PREFERRED

Camber
-rto+r
0°

"Caster
+
1/2°
to
37*°
+2°

King
Pin
Inclination
8.5° 8.5°

Toe-In
(at
Hub
Height)
-0.05°
to
+0.45° 0.20°

ALIGNMENT
(2WD)
ACCEPTABLE RANGE PREFERRED

Camber
0°to 1°
+1/2°

'Caster
-1°
to
+2°
+1/2°

Toe-in
(at
Hub
Height)
0°
to
0.50° 0.25°

Turning
Angle
(Base
Tire)
Left
and
Right
33°

33°
J9102-64

*lf vehicle
wanders,
caster
should
be increased. If steering
effort
is very
high
(especially when cornering), caster
should
be decreased.
TIE
RODS

•

FRONT
SUSPENSION
AND
AXLE
2 • 7
FRONT SUSPENSION
—2WD
VEHICLES

INDEX

page

Coil Springs
9
Lower Ball Stud
. 10

Lower Suspension
Arm 10

Lower Suspension
Arm
Bushing
11

Lower Suspension
Arm
Strut
8

Service
Information
7

Shock
Absorber
9
page

Stabilizer
Bar 8

Steering Knuckle
13
Upper Ball Stud
11

Upper Suspension
Arm 11

Upper Suspension
Arm
Bushing Replacement
. . . 12

Wheel
Hub and
Bearings
7

SERVICE
INFORMATION
Periodic lubrication of the front suspension (steer­
ing) system components is required. Refer to Group 0, Lubrication And Maintenance for the service in­
terval.
Rubber bushings must never be lubricated.
All front suspension components that are
cushioned by rubber should be tightened with
the suspension system at the normal height.

WHEEL
HUB
AND
BEARINGS

REMOVAL (1) Block the brake pedal in the up (non-depressed)
position.
(2) Raise and support the vehicle.
(3) Remove the wheel.
(4) Remove bolts from the disc brake caliper.
(5) Separate the disc brake caliper from the rotor.
Position and support the caliper away from the im­
mediate work area. Do not allow the caliper to
hang from the brake fluid hose.
(6) Remove the dust cap, cotter pin, and remaining
hub components from the spindle (Fig. 1).

CAUTION:
Use care
to
prevent
the
inner wheel bear­
ing
and
bearing seal from contacting
the
steering
knuckle spindle threads during removal
(Fig. 1).

Otherwise,
the
threads, bearing,
and
seal could
all
be damaged.

(7) Carefully slide the wheel hub/rotor from steer­
ing knuckle spindle (Fig. 1).
(8) For bearing cleaning or replacement, remove
the seal and inner wheel bearing from the wheel
hub/rotor bore (Fig. 1).
CLEANING AND INSPECTION (1) Thoroughly clean both wheel bearings and in­
terior of the hub/rotor (Fig. 1). Remove all of the residual lubricant.
(2) To clean the bearings:
• Soak them in an appropriate cleaning solvent
BRAKE
INNER
Fig.
1 Front
Wheel
Bearings
&
Hub/Rotor

• Strike the flat of each bearing against a hardwood
block several times • Flush bearing between strikes
• Repeat the procedure above until each bearing is
clean
• Dry the bearings with compressed air but do not spin them
(3) After cleaning, apply engine oil to each bear­
ing. (4) Rotate each bearing slowly while applying
downward force. Examine the rollers for pitting and
roughness. Replace worn or otherwise defective bear­
ings.
If a bearing has pitted and/or rough surfaced
rollers, replace both the bearing and bearing cup (Fig. 1).
(5) If reusable, remove the engine oil from each
bearing. Pack each bearing with multi-purpose NLGI, grade 2, EP-type lubricant. Place the bearings
in a clean, safe place.
Ensure that lubricant is forced into all the cav­
ities between the bearing cage and rollers.

2
- 8
FRONT SUSPENSION
AND
AXLE

• INSTALLATION
(1) If a bearing and cup must be replaced, remove
the cup from the wheel hub/rotor bore (Fig. 1). Use a
brass drift or an appropriate removal tool to tap out
the cup.
(2) Install the replacement bearing cup(s) with an
appropriate installation tool. (3) Apply lubricant to surface area of the wheel
hub/rotor bore. Install the inner wheel bearing in the
hub/rotor. Install a replacement bearing seal with an appropriate seal installation tool. (4) Inspect the bearing and seal contact surfaces on
the steering knuckle spindle for burrs and/or rough­ ness (Fig. 1).
(5) Remove all the rough contact surfaces from the
spindle. Apply a coating of multi-purpose NLGI,
grade 2, EP-type lubricant to the spindle surface.
CAUTION: Us© care to prevent the inner
wheel
bear­
ing
and bearing
seal
from contacting the steering

knuckle
spindle
threads during removal (Fig. 1).

Otherwise,
the threads, bearing, and
seal
could
be

damaged.

(6) Carefully slide the wheel hub/rotor onto the
spindle.
Install the outer wheel bearing, the washer and
nut.
(7) Tighten the nut to 41 to 54 Nnn (30 to 40 ft.
lbs.) torque while rotating the wheel hub/rotor. Stop
the hub/rotor and loosen the nut to completely re­
lease the bearing preload torque. Next, tighten the
nut finger-tight, install the nut lock. Install a re­
placement cotter pin.
(8) The wheel bearing adjustment (above) should
have 0.001 to 0.003 inch (0.254 to 0.0762 mm) end
play.
(9) Clean the dust cap. Apply a coating of multi­
purpose NLGI, grade 2, EP-type lubricant to internal surface. Install the cap. Do not fill the dust cap with lubricant. (10) Install the brake caliper, refer to Group 5,
Brakes. (11) Install the wheel and tire, refer to Wheel and
Tire Installation in this section. Lower the vehicle.

LOWER SUSPENSION ARM STRUT

REMOVAL (1) Raise and support the vehicle.
(2) Use a small drift and a hammer to drive the
spring pin from the front of the strut. Remove the
spring pin, nut, retainer and bushing from the end of
the strut (Fig. 2).
(3) Remove the strut rear bolts and jounce bumper
from the bracket. Remove the strut from the vehicle (Fig. 2).
NUT

FRONT
RETAINER
STRUT
J9002-120
Fig. 2 Lower Suspension Arm Strut Removal/ Installation INSTALLATION
(1) Position the rear retainer and rear bushing on
the front end of the strut (Fig. 2).
(2) Carefully slide the strut into position. Install
the rear bolts. Tighten the bolts to 182 Nnn (135 ft. lbs.) torque.
(3) Install the front bushing, front retainer and
nut at the front end of the strut. Tighten the nut
with 70 Nnn (52 ft. lbs.) torque.
(4) Install the spring pin.

STABILIZER
BAR
REMOVAL
(1) Remove the link rod nut at each end of the sta­
bilizer bar (Fig. 3). Fig. 3 Stabilizer Bar

4

FRONT
SHOCK ABSORBER
J9017-29

Fig.
4
Coil Spring Suspension INSTALLATION

(1) Extend shock fully, install retainer on shock
absorber. Install bushing and sleeve, make sure they
are not worn or broken.
(2) Guide shock up through coil spring. Install top
retainer and nut. Tighten nut to 34 Nnn (25 ft. lbs.)
torque.
(3) Align lower end of shock and install mounting

bolts.
Tighten bolts to 23 Nnn (200 in. lbs.) torque.
FRONT SUSPENSION
AND
AXLE
2 - i

Fig.
5
Spring Compressor
&
Ball
Stud Loosening
Tools
Installed (8) Remove the loosening tool. Slowly loosen the
coil spring compressor tool until all tension is re­ lieved from the spring. Remove the spring compres­
sor and spring with the rubber isolation pad.
(2) Remove the outer retainers and rubber bush­
ings from the link rods (Fig. 3).
(3) Remove the bolts or nuts from the U-shaped
stabilizer bar support brackets. Remove the stabilizer
bar from the vehicle (Fig. 3).

INSTALLATION
(1) Position the stabilizer bar ends over the link

rods.
Install the U-shaped support brackets and bolts/ nuts (Fig. 3). Tighten the bolts/nuts to 23 Nnn (200

in.
lbs.) torque. (2) Install the outer retainers and rubber bushings
on the link rods (Fig. 3).
(3) Install the link rod nuts (Fig. 3). Tighten the
nuts to 11 Nnn (100 in. lbs.).

SHOCK ABSORBER
REMOVAL
(1) Raise vehicle on hoist. Position support stands
on frame and lower front hoist.
(2) Remove upper nut and retainer.
(3) Remove two lower mounting bolts, lower shock
from suspension arm (Fig. 4). (4) Remove support stands and lower vehicle to
ground.

COIL
SPRINGS

REMOVAL
(1) Raise vehicle on hoist. Position support stands
on frame and lower front hoist. Remove front tire. (2) Remove brake caliper assembly, refer to Group
5, Brakes. (3) Remove shock absorber.
(4) Remove lower control arm strut.
(5) Install Spring Compressor DD-1278 in the
spring (Fig. 5). Tighten the nut finger-tight, and
then loosen the nut 1/2 of-a-turn.
(6) Remove cotter pins and ball joint nuts.
(7) Install Ball Stud Remover C-3564-A on the
lower ball stud (Fig. 4). Turn the threaded portion of
the tool and lock the tool securely against the lower stud (Fig. 5). Expand the tool enough to place force
on the lower ball stud. Strike the steering knuckle sharply with a hammer to loosen the stud. Do not
attempt to force the stud out of the steering
knuckle with the loosening tool.

2
- 10
FRONT SUSPENSION
AND
AXLE

• INSTALLATION
(1) Position the spring and isolation pad on the
suspension arm. Install the spring compressor tool.
Compress the spring until the lower suspension arm
can be properly positioned in the steering knuckle.
(2) Install the nuts on the ball studs. Tighten the
upper nut to 142 Nnn (105 ft. lbs.) torque. Tighten
the lower nut.
* 11/16-16 bolt, to 183 Nnn (135 ft. lbs.) torque
• 3/4-16 bolt, to 237 Nnn (175 ft. lbs.) torque Install replacement cotter pins.
(3) Install the strut.
(4) Connect the stabilizer bar.
(5) Install the shock absorber.
(6) Install the brake splash shield on the steering
knuckle. Tighten the screws to 23 Nnn (200 in. lbs.)
torque.
(7) Carefully install the hub/rotor and bearings.
(8) Install the brake caliper, refer to Group 5, Brakes.
(9) Install the wheel and tire, refer to Wheel and Tire
Installation within this section. Lower the vehicle. (10) Test the vehicle brakes and the suspension for
proper operation.

LOWER SUSPENSION
ARM
REMOVAL
(1) Follow procedure under Coil Spring Removal.
(2) Remove hex-head mounting bolt from the cross-
member. (3) Remove the lower suspension arm from vehicle.
INSTALLATION (1) Position lower suspension arm on vehicle.
(2) Install mounting bolt, tighten finger-tight.
(3) Follow procedure under Coil Spring Installa­
tion.
(4) Lower the vehicle to the surface with the
wheels/tires supporting the vehicle weight. Tighten
the lower suspension arm mounting bolt to 305 Nnn (225 ft. lbs.) torque.

LOWER
BALL
STUD

INSPECTION
(1) Raise the front of the vehicle. Install safety
floor stands under both lower suspension arms as far outboard as possible. The upper suspension arms
must not contact the rebound bumpers. (2) Install a dial indicator and clamp assembly to
the lower suspension arm. (3) Position indicator plunger against knuckle arm
and zero indicator. (4) Raise and lower the wheel with a pry bar under
the center of the tire. Measure the axial movement of
the knuckle with respect to the suspension arm.
(5) If the travel of the suspension arm is 0.020
inch (0.51 mm) or more, replace the ball joint. REMOVAL
(1) Follow procedure under Coil Spring Removal.
(2) Remove ball joint seal. Use assembled Remov­
er/Installer C-4212 to force the ball stud out of the
lower suspension arm bore (Fig. 6).

Fig.
6
Lower
Bail
Stud
Removal

INSTALLATION (1) Force the replacement ball stud into the lower
suspension arm bore with assembled Remover/In­
staller C-4212 (Fig. 7).
Fig.
7
Lower
Ball
Stud
Installation

•

FRONT
SUSPENSION
AND
AXLE
2 - 11 (2) Position the seal over the ball stud (if neces­
sary, use a replacement seal). Force portion of the
seal downward on the ball stud housing with an ap­
propriate size socket wrench until it is securely locked in place.
(3) Install lower suspension arm using procedure
under Lower Suspension Arm Installation.

LOWER SUSPENSION
ARM
BUSHING

REMOVAL (1) Follow procedure under Coil Spring and Lower
Suspension Arm Removal.
(2) Use an arbor press and an appropriate size
sleeve to force the original bushing from the lower
suspension arm bore.
INSTALLATION (1) Use an arbor press and an appropriate size
sleeve to force the replacement bushing into the
lower suspension arm bore. Ensure that it is com­
pletely seated in the bore.
(2) Install the lower suspension arm according to in­
structions provided within the installation procedure.

UPPER SUSPENSION
ARM REMOVAL (1) Raise the vehicle. Position support stands un­
der the frame rail and lower the front of the hoist.
Remove the wheel/tire.
(2) Remove shock absorber, refer to above proce­

dures.

(3) Install Spring Compressor DD-1278 (Fig. 5).
Tighten the nut finger-tight and then loosen it 1/2 of- a-turn.
(4) Remove the cotter pins and the ball stud nuts.
(5) Install Ball Stud Remover C^3564-A (Fig. 8).
Turn the threaded portion of the tool to lock it se­ curely against the upper ball stud (Fig. 8). Spread
the tool enough to apply force against the upper ball stud. Strike the steering knuckle sharply with a
hammer to loosen the upper ball stud. Do not at­
tempt to force the ball stud out of the steering knuckle bore with the loosening tool.
(6) Remove the loosening tool. Remove the nuts,
eccentric (cam) bolts and suspension arm from the
vehicle (Fig. 9).
INSTALLATION (1) Position the suspension arm and install the ec­
centric (cam) bolts (Fig. 9). and nuts finger-tight.
(2) Install upper ball stud into steering knuckle.
Install nuts on the ball studs. Tighten to 142 N« (105
ft. lbs.) torque. Install replacement cotter pins.
(3) Remove the spring compressor tool (Fig. 5).
Fig.
8
Ball
Stud
Loosening
Tool Installed
(4) Install the shock absorber. Tighten nut to 34
N*m (25 ft. lbs.) torque and lower bolts to 23 N*m (200 in. lbs.) torque.
(5) Install the wheel/tire. Raise the vehicle, remove
the support stands and lower the vehicle to the surface.
(6) Adjust the caster and camber angles. Tighten
the eccentric (cam) nuts to 95 N*m (70 ft. lbs.)
torque.

UPPER BALL STUD
INSPECTION (1) Position a floor jack under the lower suspension
arm. Raise the wheel and allow the tire to lightly
contact the floor (vehicle weight relieved from the

tire).

(2) Grasp the top of the tire and apply force in and
out. Look for any movement at the ball joints be­
tween the upper suspension arm and steering knuckle.
(3) If any lateral movement is evident, replace the
ball joint.
REMOVAL (1) Position a support under the outer end of the
lower suspension arm. Lower the vehicle so that the
support compresses the coil spring.
(2) Remove the wheel/tire.
(3) Remove the ball stud nuts. Use Ball Stud Re­
mover C-3564-A to loosen the upper ball stud (Fig.

8).
(4) Use Wrench C-3561 to un-thread the upper ball
stud from the upper suspension arm.