Rear Toe Adjustment (57.65. 08)
Whee
l
Bearing Circlip Inspection
Wheel Bearing Inspection
204‐01: Front Suspension
Specification
Description and Operation
Front Suspension
Removal and Installation
Ball Joint (60.15.02)
Rear Lower Arm (60.35.54)
Rear Lower Arm Bushing (60.35.56)
Front Shock Absorber (60.30.04)
Spring
Spring Seat (60.20.03)
Front Sta
bilizer Bar (60.10.01)
Front Stabilizer Bar Bushing (60.10.04)
Front Stabilizer Bar Link (60.10.02)
Upper Arm Bushing
Front Wheel Bearing (60.25.40)
Wheel Hub
Wheel Knuckle (60.25.23)
Wheel Knuckle and Wheel Hub Assembly (60.25.38.90)
Wheel Knuckle and Wheel Hub Assembly Conversion (60.25.43)
204‐02: Rear Suspension
Specif
ication
Description and Operation
Rear Suspension
Removal and Installation
Axle Bump Stop (64.30.15)
Rear Suspension and Axle Assembly (64.25.01)
Rear Shock Absorber (64.30.02)
Shock Absorber Lower Bushing (64.30.39)
Spring (64.20.01)
Rear Stabilizer Bar (64.35.08) ‐ 4.0L SC V8 ‐ AJ26
Rear Stabilizer Bar Bushing (64.35.18) ‐ 4.0L SC V8 ‐ AJ26
Upper
Wishbones
Each
upper wi
shbone assembly is a on
e-piece steel forging incorporating:
A pres
s-fit ball joint.
Press-fi
t bushes for location of the upper fulcrum bolt.
Lower Wishbones
Each l
o
wer wishbone comprising
forged steel front and rear arms bolted together, incorporates:
A p
ress-fit ball joint in the outer extremity of the rear arm.
Press-f
i
t bushes for location of the lower fulcrum bolts
Locati
on for the shock absor
b
er lower mounting plates.
Vertica l Links
The vertical
links are of forged steel
wi
th integral steering arms. Each is suppo rted between the upper and lower wishbones
by two ball joints and carries:
Front hub
Brake ca
liper and disc shield assembly
ABS se
nsor
.
Front Hub
s
Each f
o
rged steel front hub accommodates sealed for life cartridge
type wheel bearings, and carries:
The brake rotor assembl
y.
A
h
ub nut with toothed, integral ABS rotor.
Su
s
pension spring pi
n locking device.
Front Road
Springs
The road spri
ng
s are of coil type with their
rating dependent upon vehicle specification
Ea
ch spring is installed between the suspension crossbeam location and the lower wishbone spring pan.
Ru
bber seats ar
e installed betw
een the spring and the crossb eam and the spring pan.
Front Shock A
bsorbers
Th
e
shock absorbers are telescopic hydrau
lically operated units. Optional adaptive damping units incorporate a solenoid-
operated control valve at their upper extremity.
Each shoc
k absorber is installed between the lowe
r wishbone rear arm and a recess in the body.
The l
o
wer end of the shock absorber is se
cured to plates on the wishbone by a bolt that also serves as a pivot.
The u
pper en
d of each shock absorber is secured to the body location by a single nut.
Front Sta
b
ilizer Bar
A
front stabil
izer bar installed on all vehicles
is rated according to suspension specification.
Opera
tion
As each road wheel r
i
ses, move
ment is transmitted through the vertical link assembly to the lower wishbone. The resulting
rise of the wishbone compresses the road spring and partially telescopes the shock absorber. During this action, the spring
absorbs associated shocks and the shock absorber minimizes sprin
g os c
illation.
Du
ring cornering, vehicle weight
is transferred to the outer road wheel with a resulting tendency for the inner wheel to lift.
The stabilizer bar assists in minimizing this tendency by transf erring a proportion of potential lift of the inner wheel to the
outer wheel. This result s in enhanced body stability with improved corner ing capabilities.
Front Suspension - Front Wheel Bearing
Re
moval and Installation
S
pecial Tool(s)
Hub Remover
204-193 (JD 224)
Hub Removal Collets
2
04-194 (JD 225)
Hub Holdin
g Tool
204-195 (JD 227)
Hub Replacer
2
04-196 (JD 236)
Wh
eel Bearing Remover
204-197 (JD 237)
Wh
eel Bearing Replacer
204-198 (JD 238)
ABS Rotor Nut Socket
20
6-066A
Ci
rclip Pliers
Front Susp
ension - Wheel Hub
Re
moval and Installation
S
pecial Tool(s)
Hub Remover
204-193 (JD 224)
Hub Removal Collets
2
04-194 (JD 225)
Hub Holdin
g Tool
204-195 (JD 227)
Hub Replacer
2
04-196 (JD 236)
Wh
eel Bearing Remover
204-197 (JD 237)
Wh
eel Bearing Replacer
204-198 (JD 238)
ABS Rotor Nut Socket
20
6-066A
Ci
rclip Pliers
Front Suspension - Wheel Knuckle
Re
moval and Installation
S
pecial Tool(s)
Hub Remover
204-193 (JD 224)
Hub Removal Collets
2
04-194 (JD 225)
Hub Holdin
g Tool
204-195 (JD 227)
Hub Replacer
2
04-196 (JD 236)
Wh
eel Bearing Remover
204-197 (JD 237)
Wh
eel Bearing Replacer
204-198 (JD 238)
ABS Rotor Nut Socket
20
6-066A
Ci
rclip Pliers
Do t
he disc brake caliper pistons
and pins bind, leak or stick?
Yes INSTALL new calipers as necessary. TE ST the system for normal operation.
No GO to C4
.
C4: INSPECT BR
AKE DISCS
Check the brake discs fo
r excess
ive damage, thickness variatio n or runout. For additional
information, refer to General Procedures in this section.
1
D
oes excessive damage or runout exist?
Yes INSTALL new brake discs and brak e pads as necessary. TEST the system for normal operation.
No GO to C5
.
C5: INSPECT THE FRONT HU
B AND WHEEL BEARING ASSEMBLY
Check the fr
ont hub and wheel bearing assembly.
For additional information, refer toSection 204
-00
Su
spension System
- General
Information
. 1
Are th
e wheel bearings OK?
Yes GO to C6
.
No
INSTALL new wheel bearings. For additional inform ation, refer toSection 204
-01
Front Suspension
.
TEST the system
for normal operation.
C
6: CHECK SUSPENSION BUSHES AND BALL JOINTS.
Chec
k all suspension bu
shes and ball joints.
1
Are th
e suspension bushes and ball joints OK?
Yes Vehicle is OK.
No INSTALL new front suspension bushes and ball joints as required. For additional information, refer
toSection 204
-01
Front Suspension
. INSTALL n
ew rear suspension bush
es and ball joints as required.
For additional informat ion, refer toSection 204
-0
2 Rear Suspension
.
P
INPOINT TEST D : THE PEDAL FEELS SPONGY
TE
ST
CONDITIONS
D
ETAILS/RESULTS/ACTIONS
D
1: CHECK FOR SPONGY PEDAL (ENGINE OFF)
Check f
or a firm brake pedal.
1
Is th
e brake pedal effort an
d brake pedal travel normal?
Yes Vehicle is OK.
No GO to D2
.
D2:
CHECK BRAKE PEDAL RESERVE (ENGINE OFF)
Pump th
e brake pedal 10 times and
hold on the final application.
1
Does th
e brake pedal feel fi
rm on final application?
Yes GO to D3
.
No
BLEED the brake system. For additional information, re fer to General Procedures in this section. TEST
the system for normal operation.
D3:
CHECK BRAKE PEDAL RESERVE (ENGINE ON)
Engine is
idle.
1
Apply the brake pedal ligh
tl
y three or four times.
2
W
ait 15 seconds for the vacuum to recover.
3
Push down on
the brake pedal until it stops moving
downward or an increased resistance to the brake
pedal travel occurs.
4
Hol
d the brake pedal in the applied position while increasing the engine speed to 2000 revs/min.
5
Re
lease the accelerator pedal.
6
Does th
e brake pedal move downward as
the engine speed returns to idle?
Yes GO to D4
.
No
CHECK the vacuum to brake booster. For additional information, refer toSection 206
-0
7 Power Brake
Actuation.
Yes
Vehicle is OK.
No GO to J2
.
J
2: CHECK BRAKE FLUID LEVEL
Check the brake master cyli
nder reservoir fluid level.
1
Is the fl
uid level OK?
Yes GO to J3
.
No
CHECK brake master cylinder reservoir sealing points. For additional information, refer to Brake
Master Cylinder in this section. ADD brake fl uid and BLEED the brake system. For additional
information, refer to General Proc edures in this section. TEST the system for normal operation.
REPEAT road test if necessary.
J
3: CHECK BRAKE PEDAL RESERVE
Engine is
idle.
1
Apply the brake pedal ligh
tl
y three or four times.
2
W
ait 15 seconds for the vacuum to replenish.
3
Push down on
the brake pedal until it stops moving
downward or an increased resistance to the brake
pedal travel occurs.
4
Hol
d the brake pedal in the applied position while increasing the engine speed to 2000 revs/min.
5
Re
lease the accelerator pedal.
6
Does th
e brake pedal move downward as
the engine speed returns to idle?
Yes GO to J4
.
No
CHECK the vacuum to the brake booster. Fo r additional information, refer toSection 206
-0
7 Power
Brake Ac
tuation
.
J
4: CHECK THE FRONT HUB AND BEARING ASSEMBLY
Check the fr
ont hub and bearing assembly. Fo
r additional information, refer toSection 204
-01
Front
Suspe
nsion
. 1
Are th
e front wheel bearings loose?
Yes INSTALL a new front wheel bearin g if damaged. For additional information, refer toSection 204
-01
F
ront Suspension
. TEST
the system for normal operation.
No CHECK the front brake discs for thickness variances. For additional information, refer to General
Procedures in this section.
PINPO
INT TEST K : SLOW OR INCOMPLETE BRAKE PEDAL RETURN
TE
ST
CONDITIONS
D
ETAILS/RESULTS/ACTIONS
K1: C
HECK FOR BRAKE PEDAL RETURN
Ru
n the engine at fast idle while
making several brake applications.
1
Pull the
brake pedal rearward with approximately 44.5 N (10lb) force.
2
Relea
se the brake pedal and measure
the distance to the toe board.
3
Make a hard brake
application.
4
Relea
se the brake pedal and measure the brake
pedal to toe board distance. The brake pedal
should return to its original position.
5
Does th
e brake pedal return
to its original position?
Yes Vehicle is OK.
No GO to K2
.
K
2: CHECK FOR BRAKE PEDAL BINDING
Check the brake pedal to make
s
ure it is operating freely.
1
Is th
e brake pedal operating freely?
Yes INSTALL a new brake booster. For addi tional information, refer toSection 206
-0
7 Power Brake
Actuation. TEST
the system for normal operation.
No REPAIR or INSTALL new brake pedal. TE ST the system for normal operation.
Brake System - Gener
al Information - Front Brake Disc Runout
CheckVehicles With: Standard Brakes
Gen e
ral Procedures
S
p
ecial Tool(s)
Dial Test Indicator
G
auge and Stand.
1. Raise front of vehicle and support on stands. Refer to section
100-02.
2. Remove wheel.
3. CAUT
ION: Tie caliper housing aside. Do not allow the
caliper housing to hang on the hydraulic hose, as this will damage
the hose.
Remove caliper housing from caliper carrier.
1. Remove anti-rattle spring.
2. Remove dust covers.
3. Remove guide pins.
Remove an
d tie caliper housing aside.
4.
Make sure that wheel
bearing en
d-float is correct. Refer to
specification section 204-01.
5. Measure brake d
isc run-out.
Inst
al
l brake disc to hub and secure with all wheel nuts,
tighten wheel nuts to 20 Nm in a diagonal sequence.
Posi
tion the gauge so that the pointer contacts the disc,
10 mm from its outer edge.
Slo w
ly rotate the disc one revolution, the disc run-out
must not exceed the specification. Refer to Specification
Section 206-03.
6. If the brake disc run-out exceeds specification, reposition the
brake disc on the hub and re peat the above procedure.
Continue repositioning the brake di sc until the run-out is within
specification.
7. If the brake disc run-out still exceeds specification, check the
hub face run-out.
8. Remove brake disc. Refer to procedure 70.10.12.
9. Measure hub face run-out.
Posi
tion the gauge so that the pointer contacts the hub
face.
Slo w
ly rotate the hub one revolution, the hub run-out