Front Suspension System: Removal & Installation Chevrolet SSR I

Removal Procedure

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Remove the stabilizer shaft links to the stabilizer shaft retaining nuts. Refer to «Stabilizer Shaft Link Replacement»(ref-187849-S40895343462005090100000) .
3. Remove the stabilizer shaft insulator clamp mounting bolts.
4. Remove the stabilizer shaft insulator clamp from the stabilizer shaft insulator.
5. Remove the stabilizer shaft insulators from the stabilizer shaft.
6. Remove the stabilizer shaft from the vehicle.

Installation Procedure

1. Install the stabilizer shaft to the vehicle.
2. Install the stabilizer shaft insulators to the stabilizer shaft.
3. Install the stabilizer shaft insulator clamp to the stabilizer shaft insulator.
4. Install the stabilizer shaft insulator clamp mounting bolts. Tighten: Tighten the stabilizer shaft insulator clamp mounting bolts to 55 N.m (41 lb ft).
5. Install the stabilizer shaft links to the stabilizer shaft. Refer to «Stabilizer Shaft Link Replacement»(ref-187849-S40895343462005090100000) .
6. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Remove the stabilizer shaft link to lower control arm retaining nut.
3. Remove the stabilizer shaft link to stabilizer shaft retaining nut.
4. Remove the stabilizer shaft link.

1. Install the stabilizer shaft link to the lower control arm.
2. Install the stabilizer shaft link to the stabilizer shaft.
3. Install the stabilizer shaft link to lower control arm retaining nut.
4. Install the stabilizer shaft link to stabilizer shaft retaining nut. Tighten: Tighten the stabilizer shaft link retaining nuts to 100 N.m (74 lb ft).
5. Lower the vehicle.

1. Raise the and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Remove the stabilizer shaft insulator clamp mounting bolts.
3. Remove the stabilizer shaft insulator clamp from the stabilizer shaft insulator.
4. Lower the stabilizer shaft and remove the stabilizer shaft insulator.

1. Install the stabilizer shaft insulator to stabilizer shaft with slit facing the front of the vehicle.
2. Install the stabilizer shaft insulator clamp to the stabilizer shaft insulator.
3. Install the stabilizer shaft insulator clamp mounting bolts. Tighten: Tighten the stabilizer shaft insulator clamp mounting bolts to 55 N.m (41 lb ft).
4. Lower the vehicle.

Upper Ball Joint Replacement

Tools Required

1. J 9519-E Lower Ball Joint Remover and Installer
2. J 21474-01 Control Arm Bushing Set. See «Special Tools and Equipment»(ref-187849-S14260925762005090100000) .
3. J 45117 Ball Joint Installation Spacer. See «Special Tools and Equipment»(ref-187849-S14260925762005090100000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-187818-S18654946232005090100000) in Tires and Wheels.
3. Remove the steering knuckle with wheel hub attached. Refer to «Steering Knuckle Replacement»(ref-187849-S36965628442005090100000) .
4. Remove the upper ball joint retaining clip.
5. Remove the upper ball joint boot.
6. Remove the upper ball joint from the steering knuckle using J 9519-E .

1. Install the upper ball joint to steering knuckle using J 9519-E , J 21474-01 , and J 45117 . See «Special Tools and Equipment»(ref-187849-S14260925762005090100000) .
2. Install the upper ball joint retaining clip.
3. Install the steering knuckle with wheel hub attached. Refer to «Steering Knuckle Replacement»(ref-187849-S36965628442005090100000) .
4. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-187818-S18654946232005090100000) in Tires and Wheels.
5. Lower the vehicle.
6. Check the front wheel alignment. Refer to «Wheel Alignment Specifications»(ref-187868-S41273696392005090100000) in Wheel Alignment.

Lower Ball Joint Replacement

Tools Required

1. J 9519-E Ball Joint Remover and Installer Set
2. J 34874 Booster Seal Remover/Installer. See «Special Tools and Equipment»(ref-187849-S14260925762005090100000) .
3. J 41435 Ball Joint Installer. See «Special Tools and Equipment»(ref-187849-S14260925762005090100000) .
4. J 45105-1 Ball Joint Flaring Adapter. See «Special Tools and Equipment»(ref-187849-S14260925762005090100000) .
5. J 45105-2 Receiver. See «Special Tools and Equipment»(ref-187849-S14260925762005090100000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-187818-S18654946232005090100000) in Tires and Wheels.
3. Remove the steering knuckle with wheel hub and bearing attached. Refer to «Steering Knuckle Replacement»(ref-187849-S36965628442005090100000) .
4. Remove the lower ball joint flange with a chisel.
5. Install J 9519-E and J 34874 to the lower ball joint. See «Special Tools and Equipment»(ref-187849-S14260925762005090100000) .
6. Remove the lower ball joint from the lower control arm.

1. Install the lower ball joint to the lower control arm using J 9519-E , J 41435 , and J 45105-2 . See «Special Tools and Equipment»(ref-187849-S14260925762005090100000) .
2. Remove J 9519-E , J 41435 , and J 45105-2 from the lower control arm. See «Special Tools and Equipment»(ref-187849-S14260925762005090100000) .
3. Install the J 9519-E and the J 45105-1 to the lower ball joint. See «Special Tools and Equipment»(ref-187849-S14260925762005090100000) .
4. Flare the lower ball joint flange.
5. Remove J 9519-E and J 45105-1 from the lower ball joint. See «Special Tools and Equipment»(ref-187849-S14260925762005090100000) .
6. Install the steering knuckle with wheel hub and bearing attached. Refer to «Steering Knuckle Replacement»(ref-187849-S36965628442005090100000) .
7. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-187818-S18654946232005090100000) in Tires and Wheels.
8. Lower the vehicle.
9. Check the front wheel alignment. Refer to «Wheel Alignment Specifications»(ref-187868-S41273696392005090100000) in Wheel Alignment.

Steering Knuckle Replacement

Tools Required

1. J 24319-B Steering Linkage and Tie Rod Puller
2. J 43631 Ball Joint Remover. See «Special Tools and Equipment»(ref-187849-S14260925762005090100000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-187818-S18654946232005090100000) in Tires and Wheels.
3. Remove the wheel hub and bearing. Refer to «Wheel Hub, Bearing, and Seal Replacement»(ref-187849-S30836122402005090100000) .
4. Remove the outer tie rod retaining nut. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(ref-187845-S12935601222005090100000) in Power Steering System.
5. Remove the brake hose bracket retaining bolts.
6. Remove the brake hose bracket from the steering knuckle.
7. Disconnect the antilock brake system (ABS) wheel speed sensor wiring harness bracket from the steering knuckle.
8. Remove the upper control arm to the steering knuckle pinch bolt and nut.
9. Disconnect the upper control arm from the steering knuckle.
10. Remove the lower ball joint retaining nut.
11. Disconnect the steering knuckle from the lower control arm using J 43631 . See «Special Tools and Equipment»(ref-187849-S14260925762005090100000) .
12. Remove the steering knuckle from the vehicle.

1. Install the steering knuckle to the lower control arm.
2. Install the lower ball joint retaining nut. Tighten: Tighten the lower ball joint retaining nut to 110 N.m (81 lb ft).
3. Connect the upper control arm to the steering knuckle.
4. Install upper control arm pinch bolt and nut. Tighten: Tighten the upper control arm pinch bolt to 40 N.m (30 lb ft).
5. Connect the ABS wheel speed sensor wiring harness bracket to the steering knuckle.
6. Install the brake hose bracket to the steering knuckle.
7. Install the brake hose bracket retaining bolts. Tighten: Tighten the brake hose bracket retaining bolts to 10 N.m (89 lb in).
8. Install the new outer tie rod retaining nut. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(ref-187845-S12935601222005090100000) in Power Steering System.
9. Install the wheel hub and bearing. Refer to «Wheel Hub, Bearing, and Seal Replacement»(ref-187849-S30836122402005090100000) .
10. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-187818-S18654946232005090100000) in Tires and Wheels.
11. Lower the vehicle.
12. Adjust the front toe. Refer to «Front Toe Adjustment»(ref-187868-S30154689602005090100000) in Wheel Alignment.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-187818-S18654946232005090100000) in Tires and Wheels.
3. Remove the upper ball joint to upper control arm pinch bolt and nut.
4. Disconnect the upper control arm from the steering knuckle.
5. Disconnect the antilock brake system (ABS) wheel speed sensor wiring harness from the upper control arm.
6. Remove the upper control arm mounting bolts.
7. Remove the upper control arm.

1. Install the upper control arm.
2. Install the upper control arm mounting bolts. Tighten: Tighten the upper control arm mounting bolts to 150 N.m (111 lb ft).
3. Connect the ABS wheel speed sensor wiring harness to the upper control arm.
4. Connect the upper control arm to the steering knuckle.
5. Install the upper ball joint to upper control arm pinch bolt and nut. Tighten: Tighten the upper ball joint to upper control arm pinch bolt to 40 N.m (30 lb ft).
6. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-187818-S18654946232005090100000) in Tires and Wheels
7. Lower the vehicle.
8. Check the front wheel alignment. Refer to «Wheel Alignment Specifications»(ref-187868-S41273696392005090100000) in Wheel Alignment.

Lower Control Arm Replacement

Tools Required

1. J 24319-B Steering Linkage and Tie Rod Puller
2. J 43631 Ball Joint Remover. See «Special Tools and Equipment»(ref-187849-S14260925762005090100000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-187818-S18654946232005090100000) in Tires and Wheels.
3. Remove the outer tie rod retaining nut.
4. Disconnect the outer tie rod from the steering knuckle using J 24319-B .
5. Remove the stabilizer shaft link lower retaining nut.
6. Disconnect the stabilizer shaft link and washer from the lower control arm.
7. Remove the shock module yoke lower mounting nut.
8. Disconnect the shock module yoke from the lower control arm using J 24319-B .
9. Remove the lower control arm to lower control arm bracket mounting nuts.
10. Remove the lower control arm to lower control arm bracket mounting bolts.
11. Remove lower ball joint retaining nut.
12. Disconnect lower ball joint from steering knuckle using J 43631 . See «Special Tools and Equipment»(ref-187849-S14260925762005090100000) .
13. Pivot the lower control arm outward and downward in order to disconnect the lower control arm from the lower control arm bracket.
14. Remove the lower control arm from the steering knuckle.

1. Install the lower control arm to the steering knuckle.
2. Pivot the lower control arm outward and upward in order to connect the lower control arm to the lower control arm bracket.
3. Install the lower control arm to the lower control arm bracket.
4. Install the lower control arm to lower control arm bracket mounting bolts.
5. Install the lower control arm to lower control arm bracket mounting nuts. Tighten: Tighten the nuts to 110 N.m (81 lb ft).
6. Connect the shock module yoke to the lower control arm.
7. Install the shock module yoke lower mounting nut.
8. Install the stabilizer shaft link and washer to the lower control arm.
9. Install the stabilizer shaft link retaining nut. Tighten: Tighten the nut to 145 N.m (107 lb ft).
10. Install the outer tie rod to the steering knuckle.
11. Install the outer tie rod retaining nut. Tighten: Tighten the nuts to 60 N.m (44 lb ft).
12. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-187818-S18654946232005090100000) in Tires and Wheels.
13. Lower the vehicle.
14. Check the front wheel alignment. Refer to «Wheel Alignment Specifications»(ref-187868-S41273696392005090100000) in Wheel Alignment.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-187818-S18654946232005090100000) in Tires and Wheels.
3. Remove the stabilizer shaft link lower retaining nut.
4. Disconnect the stabilizer shaft link and washer from the lower control arm.
5. Remove the lower control arm to lower control arm bracket mounting nuts.
6. Remove the lower control arm to lower control arm bracket mounting bolts.
7. Pivot the lower control arm outward and downward for access to the lower control arm bracket.
8. Remove the lower control arm bracket mounting bolts from the frame.
9. Remove the lower control arm bracket from the vehicle.

1. Install the lower control arm bracket to the vehicle.
2. Install the lower control arm bracket mounting bolts to the frame. Tighten: Tighten the front lower control arm bracket mounting bolt to 260 N.m (192 lb ft). Tighten the rear lower control arm bracket mounting bolts to 240 N.m (177 lb ft).
3. Install the lower control arm to the lower control arm bracket.
4. Install the lower control arm to lower control arm bracket mounting bolts.
5. Install the lower control arm to lower control arm bracket mounting nuts. Tighten: Tighten the nuts to 110 N.m (81 lb ft).
6. Install the stabilizer shaft link and washer to the lower control arm.
7. Install the stabilizer shaft link retaining nut. Tighten: Tighten the nut to 145 N.m (107 lb ft).
8. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-187818-S18654946232005090100000) in Tires and Wheels.
9. Lower the vehicle.
10. Check the front wheel alignment. Refer to «Wheel Alignment Specifications»(ref-187868-S41273696392005090100000) in Wheel alignment.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Remove the tire and the wheel. Refer to «Tire and Wheel Removal and Installation»(ref-187818-S18654946232005090100000) in Tires and Wheels.
3. Remove the rotor. Refer to «Brake Rotor Replacement - Front»(ref-187846-S28111684432005090100000) in Disc Brakes.
4. Remove the wheel stud bolt using J 43631 . See «Special Tools and Equipment»(ref-187849-S14260925762005090100000) .

1. Install the wheel stud to the wheel hub and bearing.
2. Install 4 washers and the nut to the wheel stud. Tighten: Tighten the wheel stud nut to 130 N.m (95 lb ft), drawing in the wheel stud.
3. Remove the nut and the washers.
4. Install the rotor. Refer to «Brake Rotor Replacement - Front»(ref-187846-S28111684432005090100000) in Disc Brakes.
5. Install the tire and the wheel. Refer to «Tire and Wheel Removal and Installation»(ref-187818-S18654946232005090100000) in Tires and Wheels.
6. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-187818-S18654946232005090100000) in Tires and Wheels.
3. Remove the brake rotor. Refer to «Brake Rotor Replacement - Front»(ref-187846-S28111684432005090100000) in Disc Brakes.
4. Remove the antilock brake system (ABS) sensor mounting bolt from the wheel hub and bearing.
5. Remove the ABS sensor from the wheel hub and bearing.
6. Remove the wheel hub and bearing to the steering knuckle mounting bolts.
7. Remove the wheel hub and bearing from the steering knuckle.
8. Remove the splash shield from the steering knuckle.

1. Install the splash shield to the steering knuckle. Align the splash shield to the steering knuckle threaded holes.
2. Install the wheel hub and bearing to the steering knuckle. Align the threaded holes.
3. Install the wheel hub and bearing to the steering knuckle mounting bolts. Tighten: Tighten the wheel hub and bearing mounting bolts to 105 N.m (77 lb ft).
4. Install the ABS sensor to the wheel hub and bearing.
5. Install the ABS sensor mounting bolt to the wheel hub and bearing. Tighten: Tighten the ABS sensor to the wheel hub and bearing mounting bolt to 18 N.m (13 lb ft).
6. Install the brake rotor. Refer to «Brake Rotor Replacement - Front»(ref-187846-S28111684432005090100000) in Disc Brakes.
7. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-187818-S18654946232005090100000) in Tires and Wheels.
8. Lower the Vehicle.

1. Remove the shock module upper retaining nuts.
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
3. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-187818-S18654946232005090100000) in Tire and Wheels.
4. Remove the shock module yoke to lower control arm retaining nut.
5. Remove the shock module yoke from the lower control arm using J 24319-B .
6. Remove the shock module from the shock tower and lower control arm.

1. Install the shock module to the shock tower.
2. Install the shock module yoke to the lower control arm.
3. Install the shock module upper retaining nuts. Tighten: Tighten the shock module upper retaining nuts to 45 N.m (33 lb ft).
4. Install the shock module yoke to lower control arm retaining nut. Tighten: Tighten the shock module yoke to lower control arm retaining nut to 110 N.m (81 lb ft).
5. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-187818-S18654946232005090100000) in Tire and Wheels.
6. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-187818-S18654946232005090100000) in Tires and Wheels.
3. Remove the shock module from the vehicle. Refer to «Shock Module Replacement»(ref-187849-S18949130892005090100000) .
4. Remove the shock module yoke to shock absorber pinch bolt and nut.
5. Spread the shock module yoke at the pinch bolt using a flat-bladed tool.
6. Remove the shock module yoke from the shock absorber.
7. Install pieces of heater hose to the shock module spring where J 45400 contacts lower part of spring. See «Special Tools and Equipment»(ref-187849-S14260925762005090100000) .
8. Install the shock module (2) into the J 45400 (1). See «Special Tools and Equipment»(ref-187849-S14260925762005090100000) .
9. Turn the spring compressor forcing screw (1) until the coil spring (2) is compressed.
10. Remove the shock absorber upper retaining nut.
11. Remove the shock absorber from the shock module.
12. Loosen the compressor forcing screw until the upper mounting plate and coil spring may be removed.
13. Remove the upper mounting plate and coil spring from the J 45400 . See «Special Tools and Equipment»(ref-187849-S14260925762005090100000) .

1. Install the coil spring and upper mounting plate to the J 45400 . See «Special Tools and Equipment»(ref-187849-S14260925762005090100000) .
2. Turn the spring compressor forcing screw (1) until the coil spring is compressed.
3. Install the shock absorber to the shock module.
4. Install the shock absorber retaining nut. Tighten: Tighten the shock absorber retaining nut to 45 N.m (33 lb ft).
5. Remove the shock module (2) from the J 45400 (1). See «Special Tools and Equipment»(ref-187849-S14260925762005090100000) .
6. Remove the pieces of heater hose from the shock module spring.
7. Install the shock module yoke to the shock absorber.
8. Install the shock module yoke to shock absorber pinch bolt and nut. Tighten: Tighten the shock module yoke to shock absorber pinch bolt to 70 N.m (52 lb ft).
9. Install the shock module to the vehicle. Refer to «Shock Module Replacement»(ref-187849-S18949130892005090100000) .
10. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-187818-S18654946232005090100000) in Tires and Wheels.
11. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-187818-S18654946232005090100000) in Tires and Wheels.
3. Remove the shock module yoke to lower control arm mounting nut.
4. Install J 24319-B to the shock module yoke to lower control arm stud.
5. Disconnect the shock module yoke from the lower control arm using J 24319-B .
6. Remove the shock module yoke to shock absorber pinch bolt and nut.
7. Spread the shock module yoke at the pinch bolt using a flat-bladed tool.
8. Remove the shock module yoke from the shock absorber.

1. Install the shock module yoke to the lower control arm stud and shock absorber.
2. Install the shock module yoke to shock absorber pinch bolt and nut. Tighten: Tighten the shock module yoke to shock absorber pinch bolt to 70 N.m (52 lb ft).
3. Install the shock module yoke to lower control arm mounting nut. Tighten: Tighten the shock module yoke to lower control arm mounting nut to 110 N.m (81 lb ft).
4. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-187818-S18654946232005090100000) in Tires and Wheels.
5. Lower the vehicle.