Page 73 of 2490
f
ollowing procedure as this will
damage the ball joint gaiter.
Release wishbone ball joint from vertical link.
1. Install special tool 204-192 on upper wishbone ball joint.
2. Tighten bolt of special tool to release ball joint
taper from vertical link.
12. Remove special tool from ball joint.
13
.
Lift upper wishbone to withdraw ball joint from vertical link.
14
.
To prevent damage to lower ball joint, secure vertical link to
road spring using strong wire.
15
.
Remove upper wishbone fulcrum nut and bolt and withdraw
wishbone from vehicle.
16. Secure upper wishbone in a vise.
17. Using a hacksaw, partially cut through two diametrically
opposite segments of ball joint flange.
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18. Carefull
y chisel thro
ugh and remove the two ball joint flange
segments to permit installati on between press bed plates.
19. Remove wishbone from vise and thoroughly clean to remove
swarf and road deposits.
20. F
or warranty purposes, paint positi
ons of spring clip ends on
ball joint housing and rubber gaiter.
21 . NOTE
: Any gaiter damage incurred during removal must be
recorded for warranty purposes.
Remove retaining clips and gaiter.
Exerci si
ng care to avoid spli
tting or otherwise damaging
gaiter, remove retaining clips.
Remove gaiter and retain for warranty purposes.
22
.
Invert wishbone and position on press with ball joint flange
between press bed plates.
Page 75 of 2490

I
nstallation
23
.
Install special tool 204-200 on ball joint and operate press to
release joint from wishbone.
24. Remove special tool from ball joint.
25. Remove ball joint and wishbone from press.
26. Ensuring that their relative positions are clearly marked,
place ball joint, rubber gaiter and retaining clip in a clean
plastic bag and return for warranty purposes.
27. Thoroughly clean wishbone paying particular attention to ball
joint and pivot bolt locations.
1. Inst
all ball joint in wishbone.
Pos
ition support of special tool 204-199 on press bed and
place wishbone on tool.
U
sing ball joint plastic cover to align, position mandrel of
special tool 204-199 on ball joint
Ali
gn assembly with press ram and operate press to fully
seat ball joint in wishbone.
2. Remove tool mandrel 204-199 from ball joint.
3. Remove wishbone and support tool 204-199 from press.
4. Position wishbone on suspensi on beam, install fulcrum shaft
thread rearward, install nu t and tighten to 60-80Nm.
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5. Re
move wire temporarily securing
vertical link to road spring.
6. Remove and discard plasti c cover from ball joint.
7. Position wishb
o
ne to engage ball joint taper in vertical link.
8. In
stall nut securing ball joint to vertical link and tighten nut to
60-80Nm.
9. Reposition wheel speed sensor harness on wishbone and
secure with two tiestraps.
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10
.
Install road wheel. Re fer to Section 100-02
11. Raise vehicle, remove stands and fully lower vehicle.
12
.
Fully slacken nut on special tool 204-114.
13
.
Release dowel of special tool from suspension turret slot.
14. Raise vehicle for access an d remove special tool from
suspension.
15. Fully lower vehicle.
16. Carry out steering geometry an d wheel alignment checks and
if necessary adjust. Refer to 57.65.01.
Page 78 of 2490
Front Suspension - Rear Lower Arm
Remo
val and Installation
Remov
a
l
CAUTI
O
N: Replacement of
nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the
vehicle. These devices restrict the number of times a nut or bolt can be used. Refer to Section 100-00 for further
information.
S p
ecial Tool(s)
R
o
ad spring compressor
204-111 (JD115)
Taper separator
2
11-098 (JD 100)
Ball
Jo
int Taper Separator
204-192 (JD 219)
Bal l
joint splitter
204-293
1. Ra
ise front of vehicle and support on stands. Refer to Section
100-02.
2. Remove appropriate road wheel. Refer to Section 100-02.
3. CAUTIO
N: Do not suspend caliper from brake hose as
this will damage the hose.
Remove brake calipers from carriers. 1. Remove caliper spring clip.
2. Remove guide pin dust caps.
3. Slacken and withdraw guide pins.
4. Remove caliper from carrier and tie to suspension mounting bracket.
4. Ra
ise vehicle further to provid
e access for Special Tool 204-
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1
11 and support on stands. Refer to Section 100-02.
5. Ins
tall Special Tool 204-111 in road spring.
Sl
acken tool adjuster to suit spring length.
Install adaptor
and thrust collar.
Posit
ion stem of tool in center of spring passing dowel
through slot in su spension turret.
6. R
otate stem of Special Tool to
position dowel across slot.
7. W
ARNING: WHEN TURNING TOOL ADJUSTER, ENSURE
THAT TOOL STEM DOES NOT ROTATE AND DISTURB POSITION
OF DOWEL IN SUSPENSION TURRET.
Rotate adjuster of Special Tool to tension spring.
8. R
emove spring pan to lower
wishbone securing bolts.
9. Rotate adjuster of Special Tool to release tension from spring.
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10. NOTE
: It is not necessary to re
move Special Tool from spring
at this stage.
Remove spring assembly and Special Tool 204-111 from
suspension turret.
11. Lower vehicle to working heig ht and support on stands.
12 . Remove an
d discard tiestraps
securing wheel speed sensor
harness to upper wishbone.
13 . R
emove wheel speed sensor se
curing screw and withdraw
sensor from vertical link.
14 . R
emove nut securing tie rod oute
r ball joint to steering arm.
15. Release tie rod ball joint from vertical link.