Home ReviewsRefund
Home/Chevrolet/Silverado 2500/Chevrolet Silverado 2500 (2000-2004)/Repair manual/Suspension Front/Front Suspension System: Removal & Installation
Contents Wiring diagrams Section: Suspension Front All sections

Front Suspension System: Removal & Installation Chevrolet Silverado 2500

Suspension Front 22 illustrations ~4350 words

Removal Procedure

  1. Raise and support the vehicle.
  2. Remove the tire and wheel assembly. Refer to «TIRE & WHEEL REMOVAL & INSTALLATION»(ref-175630-S02498601802005042500000) .
  3. Remove the stabilizer links. Refer to «Stabilizer Shaft Link Replacement»(ref-175628-S40922206812005042500000) .
  4. Remove the oil pan skid plate, if equipped.
  5. Remove the stabilizer shaft insulator bracket bolts (3).
  6. Remove the stabilizer shaft bracket (2).
  7. Remove the stabilizer shaft (4).
  8. Remove the stabilizer shaft insulators (1).
  9. Inspect all of the parts for wear and damage.

Installation Procedure

Important: Place the insulators on the stabilizer shaft with the slits facing toward the front of the vehicle.

  1. Install the insulators (1) to the stabilizer shaft (4).
  2. Install the stabilizer shaft (4).
  3. Install the brackets (2) over the insulators and the stabilizer shaft.
  4. Install insulator bracket bolts (3). 4.1. Tighten the bolts to 33 N.m (24 ft lbs), 15 series. 4.2. Tighten the bolts to 50 N.m (39 ft lbs), 25/35 series.
  5. Install the stabilizer links. Refer to «Stabilizer Shaft Link Replacement»(ref-175628-S40922206812005042500000) .
  6. Install the oil pan skid plate, if equipped. Tighten the oil pan skid plate retaining bolts to 20 N.m (15 ft lbs).
  7. Install the tire and wheel assembly. Refer to «TIRE & WHEEL REMOVAL & INSTALLATION»(ref-175630-S02498601802005042500000) .
  8. Remove the safety stands
  9. Lower the vehicle.
  1. Raise and support the vehicle.
  2. Remove the stabilizer shaft nut (1) from the link bolt.
  3. Remove the stabilizer shaft link bolt (3).
  4. Remove the stabilizer shaft link insulators and spacers (2).
  5. Inspect all of the parts for wear and damage.
  1. Install the stabilizer shaft link insulators and spacers (2).
  2. Perform the following procedure before installing the stabilizer link bolts. Remove all traces of the original adhesive patch. Apply Threadlocker GM P/N 12345382 (Canadian P/N 10953489) BLUE LOCTITE # 242 on the threads of the bolts.
  3. Install the stabilizer shaft link bolts (3).
  4. Install the stabilizer shaft nut (1) to the link bolt. Tighten the nut to 10 N.m (81 in lbs).
  5. Remove the safety stands
  6. Lower the vehicle.
  1. Raise and support the vehicle.
  2. Remove the tire and wheel assembly. Refer to «TIRE & WHEEL REMOVAL & INSTALLATION»(ref-175630-S02498601802005042500000) .
  3. Remove the lower control arm. Refer to «Lower Control Arm Replacement (4WD)»(ref-175628-S42132680922005042500000) or «Lower Control Arm Replacement (RWD)»(ref-175628-S28807815732005042500000) .
  4. Secure the lower control arm in a bench vice or equivalent.
  5. Center punch the rivet heads.
  6. Drill lout the rivets.
  7. Remove the lower ball joint.
  1. Install the ball joint to the lower control arm.
  2. Install the replacement bolts to the lower control arm.
  3. Install the nuts to the bolts. Tighten the nuts to 70 N.m (52 ft lbs).
  4. Remove the lower control arm from the bench vice.
  5. Install the lower control arm. Refer to «Lower Control Arm Replacement (4WD)»(ref-175628-S42132680922005042500000) or «Lower Control Arm Replacement (RWD)»(ref-175628-S28807815732005042500000) .
  6. Install the tire and wheel tire assembly. Refer to «TIRE & WHEEL REMOVAL & INSTALLATION»(ref-175630-S02498601802005042500000) .
  7. Remove the safety stands.
  8. Lower the vehicle.
  9. Verify the wheel alignment. Refer to «MEASURING WHEEL ALIGNMENT (WITH REAR WHEEL STEERING)»(ref-175627-S27455748472005042500000) or «MEASURING WHEEL ALIGNMENT (WITHOUT REAR WHEEL STEERING)»(ref-175627-S22497817522005042500000) .
  1. Raise and support the vehicle.
  2. Remove the tire and wheel assembly. Refer to «TIRE & WHEEL REMOVAL & INSTALLATION»(ref-175630-S02498601802005042500000) .
  3. Remove the lower control arm. Refer to «Lower Control Arm Replacement (4WD)»(ref-175628-S42132680922005042500000) or «Lower Control Arm Replacement (RWD)»(ref-175628-S28807815732005042500000) .
  4. Place the lower control arm in a bench vice.
  5. Using a chisel, remove the 4 securing crimps from the ball joint body, the 15 series only.
  6. Using a press, remove the ball joint from the lower control arm.

Important: Use the outer flange of the ball joint in order to press the ball joint into place.

  1. Install the new ball joint using a press.
  2. Place the lower control arm in a bench vice.
  3. Using a punch, install 4 crimps to the ball joint. Use the replaced ball joint as a reference, the 15-series only.
  4. Install the lower control arm. Refer to «Lower Control Arm Replacement (4WD)»(ref-175628-S42132680922005042500000) or «Lower Control Arm Replacement (RWD)»(ref-175628-S28807815732005042500000) .
  5. Install the tire and wheel assembly. Refer to «TIRE & WHEEL REMOVAL & INSTALLATION»(ref-175630-S02498601802005042500000) .
  6. Remove the safety stands.
  7. Lower the vehicle.
  8. Verify the wheel alignment. Refer to «MEASURING WHEEL ALIGNMENT (WITH REAR WHEEL STEERING)»(ref-175627-S27455748472005042500000) or «MEASURING WHEEL ALIGNMENT (WITHOUT REAR WHEEL STEERING)»(ref-175627-S22497817522005042500000) .

Scheme 3

Scheme 3: Tools Required
Scheme 3: Tools Required
  1. J 43631 Ball Joint Remover
  2. J 45851 Ball Joint Separator Protector Adapters

Scheme 4

Scheme 4: Removal Procedure
Scheme 4: Removal Procedure

Scheme 5

Scheme 5
Scheme 5
  1. Raise and support the vehicle.
  2. Remove the tire and wheel. Refer to «TIRE & WHEEL REMOVAL & INSTALLATION»(ref-175630-S02498601802005042500000) .
  3. Remove the wheel hub and bearing. Refer to «Wheel Hub, Bearing & Seal Replacement (RWD)»(ref-175628-S16256654882005042500000) or «Wheel Hub, Bearing & Seal Replacement (4WD)»(ref-175628-S00312220802005042500000) .
  4. Support the lower control arm with a suitable jack.
  5. Disconnect the outer tie rod from the knuckle. Refer to «TIE ROD END REPLACEMENT - OUTER»(ref-175031-S18818581722005041400000) or «TIE ROD REPLACEMENT»(ref-175034-S42152892872005041500000) .
  6. Remove the brake hose bracket retaining bolt from the knuckle.
  7. Remove the retaining nut and separate the upper ball joint from the steering knuckle using the J 43631 and J 45851 .
  8. Remove the retaining nut and separate the lower ball joint from the steering knuckle using the J 43631 and J 45851 .
  9. Remove the steering knuckle.
  1. Clean all grease and contaminants from the tapered section and the threads of the upper ball joint, the lower ball joint, and the tie rod end.
  2. Clean and inspect the taper holes and the mounting surfaces of the steering knuckle. If any of the tapered holes are elongated, out of round, or damaged, the replace the steering knuckle.
  3. Install the steering knuckle.
  4. Connect the lower ball joint to the steering knuckle and install the retaining nut. Tighten the retaining nut to 100 N.m (74 ft lbs).
  5. Connect the upper ball joint to the steering knuckle and install the retaining nut. Tighten the retaining nut to 50 N.m (37 ft lbs).
  6. Install the brake hose bracket retaining bolt to the knuckle. Tighten the bolt to 9 N.m (80 in lbs).
  7. Connect the outer tie rod to the steering knuckle. Refer to «TIE ROD END REPLACEMENT - OUTER»(ref-175031-S18818581722005041400000) or «TIE ROD REPLACEMENT»(ref-175034-S42152892872005041500000) .
  8. Install the wheel hub and bearing. Refer to «Wheel Hub, Bearing & Seal Replacement (RWD)»(ref-175628-S16256654882005042500000) or «Wheel Hub, Bearing & Seal Replacement (4WD)»(ref-175628-S00312220802005042500000) .
  9. Install the tire and wheel. Refer to «TIRE & WHEEL REMOVAL & INSTALLATION»(ref-175630-S02498601802005042500000) .
  10. Remove the safety stands.
  11. Lower the vehicle.
  1. Clean all grease and contaminants from the tapered section and the threads of the upper ball joint, the lower ball joint, and the tie rod end.
  2. Clean and inspect the taper holes and the mounting surfaces of the steering knuckle. If any of the tapered holes are elongated, out of round, or damaged, replace the steering knuckle.
  3. Install the steering knuckle.
  4. Connect the lower ball joint to the steering knuckle and install the retaining nut. Tighten the lower control arm retaining nut to 100 N.m (74 ft lbs).
  5. Connect the upper ball joint to the steering knuckle and install the retaining nut. Tighten the upper control arm retaining nut to 50 N.m (37 ft lbs).
  6. Install the brake hose and the bracket retaining bolt to the steering knuckle. Tighten the bolt to 9 N.m (80 in lbs).
  7. Connect the outer tie rod to the steering knuckle. Refer to «TIE ROD REPLACEMENT»(ref-175034-S42152892872005041500000) .
  8. Install the wheel hub and bearing assembly. Refer to «Wheel Hub, Bearing & Seal Replacement (RWD)»(ref-175628-S16256654882005042500000) or «Wheel Hub, Bearing & Seal Replacement (4WD)»(ref-175628-S00312220802005042500000) .
  9. Install the tire and wheel. Refer to «TIRE & WHEEL REMOVAL & INSTALLATION»(ref-175630-S02498601802005042500000) .
  10. Load the torsion bars. Refer to «Torsion Bar Replacement»(ref-175628-S41977960152005042500000) .
  11. Align the vehicle. Refer to «MEASURING WHEEL ALIGNMENT (WITH REAR WHEEL STEERING)»(ref-175627-S27455748472005042500000) or «MEASURING WHEEL ALIGNMENT (WITHOUT REAR WHEEL STEERING)»(ref-175627-S22497817522005042500000) .
  12. Lower the vehicle.
  1. Install the upper control arm.
  2. Install the upper control arm bolts (4), the 25/35 series for the 4WD.
  3. Install the upper control arm nuts and the adjustment cams (2), the 25/35 series for the 4WD. Tighten the nuts to 190 N.m (140 ft lbs).
  4. Install the upper control arm bolts (4). Use the 15-series 2WD, the 15-series 4WD, and the 25/35-series 2WD where applicable.
  5. Install the upper control arm nuts and the adjustment cams (2). Use the 15-series 2WD, the 15-series 4WD, and the 25/35-series 2WD where applicable. Tighten the nuts to 190 N.m (140 ft lbs).
  6. Connect the upper control arm to the steering knuckle.
  7. Install the wheel drive shaft.
  8. Install the new nut to the upper ball joint stud. Tighten the nut to 50 N.m (37 ft lbs).
  9. Install the retaining bolts for the brake hose and wheel speed sensor brackets. Tighten the bolts to 9 N.m (80 in lbs).
  10. Install the tire and wheel. Refer to «TIRE & WHEEL REMOVAL & INSTALLATION»(ref-175630-S02498601802005042500000) .
  11. Remove the safety stands.
  12. Lower the vehicle.
  13. Verify the wheel alignment. Refer to «MEASURING WHEEL ALIGNMENT (WITH REAR WHEEL STEERING)»(ref-175627-S27455748472005042500000) or «MEASURING WHEEL ALIGNMENT (WITHOUT REAR WHEEL STEERING)»(ref-175627-S22497817522005042500000) .
  1. Install the lower control arm.
  2. Connect the ball joint stud to the steering knuckle.
  3. Install the lower ball joint retaining nut. Tighten the nut to 100 N.m (74 ft lbs).
  4. For vehicles with rack and pinion steering, install the front coil spring. Refer to «Front Coil Springs Replacement»(ref-175628-S20835579802005042500000) .
  5. Install the lower control arm 15-series bolts.
  6. Install the lower control arm nuts and the 15-series washers. Tighten the nuts to 145 N.m (107 ft lbs).
  7. Install the lower control arm 25/35-series bolts.
  8. Install the lower control arm nuts and the 25/35-series washers. Tighten the nuts to 150 N.m (110 ft lbs).
  9. For vehicles with recirculating ball steering, install the torsion bar. Refer to «Torsion Bar Replacement»(ref-175628-S41977960152005042500000) .
  10. Install the front stabilizer shaft link. Refer to «Stabilizer Shaft Replacement»(ref-175628-S33407365782005042500000) .
  11. Install the shock absorber. Refer to «Shock Absorber Replacement (RWD)»(ref-175628-S24370608712005042500000) or «Shock Absorber Replacement (4WD)»(ref-175628-S38670389612005042500000) .
  12. Install the tire and wheel. Refer to «TIRE & WHEEL REMOVAL & INSTALLATION»(ref-175630-S02498601802005042500000) .
  13. Remove the safety stands.
  14. Lower the vehicle.
  15. Verify the wheel alignment. Refer to «MEASURING WHEEL ALIGNMENT (WITH REAR WHEEL STEERING)»(ref-175627-S27455748472005042500000) or «MEASURING WHEEL ALIGNMENT (WITHOUT REAR WHEEL STEERING)»(ref-175627-S22497817522005042500000) .
  1. Install the lower control arm.
  2. Install the lower control arm 15-series bolts.
  3. Install the lower control arm 25/35-series bolts.
  4. Install the washers with the shoulder facing the arm.
  5. Install the lower control arm retaining nuts. Tighten the nuts to 150 N.m (110 ft lbs).
  6. Install the wheel drive shaft.
  7. Connect lower ball joint stud to the steering knuckle.
  8. Install the retaining nut to the lower ball joint stud. Tighten the nut to 100 N.m (74 ft lbs).
  9. Install the torsion bars. Refer to «Torsion Bar Replacement»(ref-175628-S41977960152005042500000) .
  10. Install the shock absorber lower nut and bolt. Refer to «Shock Absorber Replacement (RWD)»(ref-175628-S24370608712005042500000) or «Shock Absorber Replacement (4WD)»(ref-175628-S38670389612005042500000) .
  11. Install the stabilizer shaft links to the lower control arm. Refer to «Stabilizer Shaft Replacement»(ref-175628-S33407365782005042500000) .
  12. Install the tire and wheel. Refer to «TIRE & WHEEL REMOVAL & INSTALLATION»(ref-175630-S02498601802005042500000) .
  13. Remove the safety stands.
  14. Lower the vehicle.
  15. Align the vehicle. Refer to «MEASURING WHEEL ALIGNMENT (WITH REAR WHEEL STEERING)»(ref-175627-S27455748472005042500000) or «MEASURING WHEEL ALIGNMENT (WITHOUT REAR WHEEL STEERING)»(ref-175627-S22497817522005042500000) .

Scheme 6

Scheme 6: Removal Procedure
Scheme 6: Removal Procedure

Scheme 7

Scheme 7
Scheme 7
  1. Raise and support the vehicle.
  2. Unsnap the jounce bumper from the mounting cup. Use the 4WD 15-series and, the 2WD 25/35-series supplies.
  3. Remove the nut from the jounce bumper stud. Use the 4WD 15-series and, the 2WD 25/35-series supplies.
  4. Remove the jounce bumper.
  1. Snap the jounce bumper to the mounting cup. Use the 4WD 15-series and, the 2WD 25/35-series supplies.
  2. Install the jounce bumper. Use the 4WD 15-series and, the 2WD 25/35-series supplies.
  3. Install the nut to the jounce bumper stud. Tighten the nut to 30 N.m (22 ft lbs).
  4. Remove the safety stands.
  5. Lower the vehicle.
  1. Install the coil spring and the insulator to the lower control arm.
  2. Raise the transmission jack in order to compress the front coil spring. It may be necessary to use a pry bar in order to guide the lower control arm into position.
  3. Install the front pivot bolt.
  4. Install the rear pivot bolt.
  5. Install the lower control arm pivot nuts. Tighten the pivot bolt nuts to 145 N.m (107 ft lbs).
  6. Lower the jack. Remove the J 23028-15 from the control arm.
  7. Install the front stabilizer shaft link. Refer to «Stabilizer Shaft Replacement»(ref-175628-S33407365782005042500000) .
  8. Install the shock absorber. Refer to «Shock Absorber Replacement (RWD)»(ref-175628-S24370608712005042500000) or «Shock Absorber Replacement (4WD)»(ref-175628-S38670389612005042500000) .
  9. Install the tire and wheel assembly. Refer to «TIRE & WHEEL REMOVAL & INSTALLATION»(ref-175630-S02498601802005042500000) .
  10. Install the engine protection shield, if equipped.
  11. Lower the vehicle.
  1. Raise and support the vehicle.
  2. Remove the tire and wheel. Refer to «TIRE & WHEEL REMOVAL & INSTALLATION»(ref-175630-S02498601802005042500000) .
  3. Remove the brake rotor. Refer to «BRAKE ROTOR»(ref-129604-S05458896122004080600000) .
  4. Remove the wheel stud from the hub flange using the J 43631 .
  5. Remove the wheel stud from the hub flange.
  1. Install the new stud into the hub flange hole using firm hand pressure.
  2. Install 4 washers to the new wheel stud.
  3. Thread a wheel nut onto the new stud with the flat side facing the front hub flange.
  4. Tighten the lug nut until the stud contacts the back of the hub flange.
  5. Remove the wheel nut.
  6. Remove the washers.
  7. Install the brake rotor.
  8. Install the tire and wheel. Refer to «TIRE & WHEEL REMOVAL & INSTALLATION»(ref-175630-S02498601802005042500000) .
  9. Remove the safety stands.
  10. Lower the vehicle.

Wheel Hub, Bearing & Seal Replacement (RWD)

Note. Never place vehicle on the ground with the halfshaft removed or the halfshaft nut torqued improperly. Otherwise, bearing seals may become dislodged causing premature wear and/or damage to the hub and bearing assembly.

  1. Raise and support the vehicle.
  2. Remove the tire and wheel. Refer to «TIRE & WHEEL REMOVAL & INSTALLATION»(ref-175630-S02498601802005042500000) .
  3. Remove the rotor. Refer to «BRAKE ROTOR»(ref-129604-S05458896122004080600000) .
  4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle.
  5. Remove the wheel hub and bearing (4) 15-series mounting bolts.
  6. Remove the wheel hub and bearing mounting bolts (4), the 25/35 series.
  7. Remove the wheel hub and bearing and splash shield from the vehicle.
  8. Remove the O-ring seal from the steering knuckle bore, the 25/35 series.
  9. Remove the wheel speed sensor mounting bolt (5).
  10. Clean and inspect the O-ring seal, the 25/35 series.
  11. Replace the seal if the following conditions exist: Nicks Cuts Dry or brittle Compression set
  1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing.
  2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent.
  3. Install the O-ring (7) to the steering knuckle, 25/35 series.
  4. Install the wheel sped sensor mounting bolt. Tighten the bolt to 18 N.m (13 ft lbs).
  5. Install the wheel hub and bearing and splash shield to the vehicle, 25/35 series.
  6. Install the wheel hub and bearing (4) and splash shield to the 15-series steering knuckle.
  7. Install the wheel hub and the 15-series bearing mounting bolts. Install the wheel hub and bearing mounting bolts, the 25/35 series. Tighten the bolts to 180 N.m (133 ft lbs).
  8. Install the wheel speed sensor and brake hose mounting bracket bolt to the steering knuckle. Tighten the bolt to 12 N.m (106 in lbs).
  9. Install the rotor. Refer to «BRAKE ROTOR»(ref-129604-S05458896122004080600000) .
  10. Install the tire and wheel. Refer to «TIRE & WHEEL REMOVAL & INSTALLATION»(ref-175630-S02498601802005042500000) .
  11. Lower the vehicle.

Note. Never Place vehicle on the ground with the halfshaft removed or the halfshaft nut torqued improperly. Otherwise, bearing seals may become dislodged causing premature wear and/or damage to the hub and bearing assembly.

Scheme 8

Scheme 8: Removal Procedure
Scheme 8: Removal Procedure

Scheme 9

Scheme 9
Scheme 9

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11
Scheme 11
  1. Raise and support the vehicle.
  2. Remove the tire and wheel. Refer to «TIRE & WHEEL REMOVAL & INSTALLATION»(ref-175630-S02498601802005042500000) .
  3. Remove the rotor. Refer to «BRAKE ROTOR»(ref-129604-S05458896122004080600000) .
  4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle.
  5. Remove the wheel drive shaft nut retaining cover.
  6. Remove the wheel driveshaft assembly retaining nut (2) and washer (3) from the wheel driveshaft. Do nut reuse the nut. A new nut must be used when installing the wheel drive shaft.
  7. Disengage the wheel drive shaft from the wheel hub and bearing using J 45859 or equivalent.
  8. Remove the wheel hub and the 15-series bearing mounting bolts (4).
  9. Remove the wheel hub and bearing (4) mounting bolts, 25/35 series.
  10. Remove the wheel hub and bearing and splash shield from the vehicle.
  11. Remove the O-ring seal form the steering knuckle bore, 25/35 series.
  12. Remove the wheel speed sensor mounting bolt (5).
  13. Clean and inspect the O-ring seal, 25/35 series.
  14. Replace the seal if the following conditions exist: Nicks Cuts Dry or brittle Compression set
  1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing assembly.
  2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent.
  3. Install the O-ring (7) to the steering knuckle, the 25/35 series.
  4. Install the wheel speed sensor mounting bolt to the wheel hub and bearing. Tighten the sensor mounting bolt to 18 N.m (13 ft lbs).
  5. Install the wheel hub and bearing and splash shield to the vehicle, 25/35 series.
  6. Install the wheel hub and bearing (5) and splash shield (6) to the vehicle, 15 series.
  7. Install the wheel hub and bearing mounting bolts, the 15 series. Install the wheel hub and bearing mounting bolts, 25/35 series. Tighten the wheel hub to knuckle bolts to 180 N.m (133 ft lbs).
  8. Install the nut (2) and washer (3) retaining the wheel drive shaft assembly to the wheel hub and bearing. Tighten the nut to 240 N.m (177 ft lbs).
  9. Install the wheel speed sensor and brake hose mounting bracket bolt to the steering knuckle. Tighten the bolt to 12 N.m (106 in lbs).
  10. Install the rotor.
  11. Install the tire and wheel. Refer to «TIRE & WHEEL REMOVAL & INSTALLATION»(ref-175630-S02498601802005042500000) .
  12. Lower the vehicle.

Note. Use care when handling the torsion bars in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the torsion bars.

Scheme 12

Scheme 12: Removal Procedure
Scheme 12: Removal Procedure

Scheme 13

Scheme 13
Scheme 13

Scheme 14

Scheme 14
Scheme 14

Scheme 15

Scheme 15
Scheme 15

Scheme 16

Scheme 16
Scheme 16
  1. Raise and support the vehicle.
  2. Install the J 36202 to the adjustment arm and the crossmember.
  3. Increase the tension on the adjustment arm until the load is removed from the adjustment bolt and the adjuster nut. Important: Mark the adjustment bolt and count the number of times that is required to remove the adjustment bolt.
  4. Remove the adjustment bolt (3) and the adjuster nut (4).
  5. Remove the adjustment bolt (3) and the adjuster nut (4), for vehicles with MN8, MT1 AND MW3.
  6. Remove the J 36202 , allowing the torsion bar to unload.
  7. Remove the adjustment arm by sliding the torsion bar forward until the torsion bar clears the adjustment arm. Use your hand to support the adjustment arm as the adjustment arm releases from the torsion bar.
  8. Remove the torsion bar crossmember bolts (4) from the weld nuts (10>
  9. Remove the upper link mounting nuts (1) and the bolts (2).
  10. Remove the torsion bar crossmember. Important: Note the position of the torsion bars as the left and right bars are different.
  11. Remove the torsion bars from the vehicle.
  1. Install the torsion bars to the lower control arm.
  2. Install the torsion bar crossmember.
  3. Install the torsion bar crossmember bolts (1) to the weld nuts (4). Tighten the bolt to 95 N.m (70 ft lbs).
  4. Install the upper link mounting nuts and the bolts (3). Tighten the nut to 95 N.m (70 ft lbs).
  5. While supporting the adjustment arm, slide the torsion bar rearward until the torsion bar fully engages the adjustment arm.
  6. Install the J 36202 to the adjustment arm and the crossmember.
  7. Increase the tension on the adjustment arm in order to load the torsion bar. Important: Install the adjustment bolt the same amount of turns that were required to remove the bolt during removal.
  8. Install the adjustment bolt (3) and the adjuster nut (4).
  9. Install the adjustment bolt (3) and the adjuster nut (4), for vehicles with MN8, MT1 AND MW3.
  10. Remove the J 36202 releasing the tension on the torsion bar until the load is taken up by the adjustment bolt.
  11. Remove the safety stands.
  12. Lower the vehicle.
  13. Measure the Z height. Refer to «TRIM HEIGHT INSPECTION PROCEDURE»(ref-175636-S21676013112005042500000) .
  14. Turn the adjustment bolt (2) clockwise to increase the Z height and counterclockwise to decrease the Z height.

Important: This procedure requires the removal of both torsion bars.

  1. Raise and support the vehicle.
  2. Remove the torsion bars. Refer to «Torsion Bar Replacement»(ref-175628-S41977960152005042500000) .
  3. Remove the bushing from the bracket utilizing a bushing driver or the equivalent.
  1. Install the bushing to the bracket utilizing a bushing driver or the equivalent.
  2. Install the torsion bars. Refer to «Torsion Bar Replacement»(ref-175628-S41977960152005042500000) .
  3. Remove the safety stands.
  4. Lower the vehicle.
  5. Measure the Z height. Refer to «TRIM HEIGHT INSPECTION PROCEDURE»(ref-175636-S21676013112005042500000) .
  6. Turn the adjustment bolt clockwise to increase the Z height and counterclockwise to lower the Z height.

Note. The front shock absorbers of the vehicle are multi-functional. In addition to contributing to a smooth ride they also provide the only stop to the front suspension when fully extended. Therefore, when servicing the shock absorber, service replacement shock absorbers must be equivalent to original shock absorbers in both extended length and strength. Use of shocks not complying to original equipment or strength could result in suspension over-travel or shock breakage. Suspension over-travel may result in suspension component breakage.

Scheme 17

Scheme 17: Removal Procedure
Scheme 17: Removal Procedure

Scheme 18

Scheme 18
Scheme 18

Scheme 19

Scheme 19
Scheme 19

Scheme 20

Scheme 20
Scheme 20
  1. Raise and support the vehicle.
  2. Support the lower control arm with a jack stand.
  3. If equipped with selectable ride, disconnect the electrical connector using the following procedure: 3.1. Grasp the connector lock tabs (1,2). Rotate the connector tabs counterclockwise until the connector is unlocked. 3.2. Disengage the connector from the tennon by firmly pulling the connector up. 3.3. Hold the tennon end with a wrench while removing the nut. 3.4. Remove the nut. Important: Do not discard the plastic pilot ring (2).
  4. Remove the upper insulator (1).
  5. Remove the shock absorber mounting bolts at the lower control arm.
  6. Remove the shock absorber through the lower control arm from below.
  1. Install the shock absorber through the lower control arm from below. Insert the tennon through the mounting hole in the upper spring pocket.
  2. Align the shock absorber with the mounting holes in the lower control arm.
  3. Install the shock absorber mounting bolts to the lower control arm. Tighten the bolts to 25 N.m (18 ft lbs). Important: The upper insulators are substantially larger that the lower insulators. The upper insulator (1) must be installed above the shock mounting bracket on the frame. The plastic pilot ring (2) will assist the alignment of the isolators.
  4. Install the upper insulator to the shock absorber.
  5. Install the nut to the tennon end. Do not tighten the nut.
  6. Remove the safety stands.
  7. Lower the vehicle.
  8. Hold the tennon end with a wrench while torquing the nut. Tighten the nut to 20 N.m (15 ft lbs).
  9. If equipped with selectable ride, connect the electrical connector using the following procedure: 9.1. Verify that the connector is unlocked. 9.2. Align the connector so that the tabs (1) are perpendicular to the wrench flats on the tennon end. 9.3. Engage the connector to the tennon by firmly pushing the connector down. 9.4. Grasp the connector lock tabs (1,). Rotate the connector counterclockwise.
  10. The connector is locked into place when you hear an audible snap and the tabs (1,2) are aligned.
  11. Dispose of the shock absorber. Refer to «Shock Absorber Disposal»(ref-175628-S15781494022005042500000) .

Shock Absorber Replacement (4WD)

Note. The front shock absorbers of the vehicle are multi-functional. In addition to contributing to a smooth ride they also provide the only stop to the front suspension when fully extended. Therefore, when servicing the shock absorber, service replacement shock absorbers must be equivalent to original shock absorbers in both extended length and strength. Use of shocks not complying to original equipment or strength could result in suspension over-travel or shock breakage. Suspension over-travel may result in suspension component breakage.

Scheme 21

Scheme 21: Removal Procedure
Scheme 21: Removal Procedure

Scheme 22

Scheme 22
Scheme 22

Scheme 23

Scheme 23
Scheme 23

Scheme 24

Scheme 24
Scheme 24
  1. Raise and support the vehicle.
  2. Support the lower control arm with a jack stand.
  3. If equipped with selectable ride, disconnect the electrical connector, with the following procedure: 3.1. Grasp the connector lock tabs (1,2). Rotate the connector tabs counterclockwise until the connector is unlocked. 3.2. Disengage the connector from the tennon by firmly pulling the connector up. 3.3. Hold the tennon end with a wrench while removing the nut. 3.4. Remove the nut.
  4. Remove the upper insulator (1). Do not discard the plastic pilot ring (2).
  5. Remove the shock absorber mounting bolt at the lower control arm, the 15 series.
  6. The lower shock mounting bushing is serviceable by driving the bushing out with the appropriate tool.
  7. Remove the shock absorber mounting bolt (2) at the lower control arm, the 25 series.
  8. Remove the shock absorber.
  1. Install the shock absorber. Insert the stem through the hole in the shock bracket on the frame.
  2. Align the shock absorber with the mounting holes in the lower control arm, the 15 series.
  3. Align the shock absorber with the mounting holes in the lower control arm, the 25 series.
  4. Install the shock absorber through the bolt (2) to the lower control arm.
  5. Install the shock absorber through the bolt nut (3). Tighten the nut to 80 N.m (59 ft lbs). Important: The upper insulators are substantially larger that the lower insulators. The upper insulator (1) must be installed above the shock mounting bracket on the frame. The plastic pilot ring (2) will assist the alignment of the isolators.
  6. Install the upper insulator to the shock absorber.
  7. Install the nut to the tennon end. Do not tighten the nut.
  8. Remove the safety stands.
  9. Lower the vehicle.
  10. Hold the tennon end with a wrench while torquing the nut. Tighten the nut to 20 N.m (15 ft lbs).
  11. If equipped with selectable ride, connect the electrical connector using the following procedure: 11.1. Verify that the connector is unlocked. 11.2. Align the connector so that the tabs (1) are perpendicular to the wrench flats on the tennon end. 11.3. Engage the connector to the tennon by firmly pushing the connector down. 11.4. Grasp the connector lock tabs (1, 2). Rotate the connector counterclockwise.
  12. The connector is locked into place when you hear an audible snap and the tabs (1, 2) are aligned.
  13. Dispose of the shock absorber. Refer to «Shock Absorber Disposal»(ref-175628-S15781494022005042500000) .

More articles — Front Suspension System