Front Suspension - (Coupe): Removal & Installation Dodge Avenger I

Removal

1. Raise vehicle. Drain power steering fluid. See the STEERING - POWER article in the STEERING section. Remove heated oxygen sensor connector. Remove front exhaust pipe and gasket. Remove stabilizer bar. See «STABILIZER BAR»(ref-52707-S20534020342001011600000). Remove power steering rack and pinion. See the STEERING - POWER article in STEERING.
2. Using Engine Lifter (MZ203827 ), support engine assembly. Remove centermember bolts. (Scheme 2) Remove centermember assembly. Remove lower, then upper bushing. Remove collar. Remove centermember.
3. Remove lateral lower arm bolts and compression lower arm bolts. (Scheme 3) Remove lower shock absorber bolt. Remove rear roll stopper bracket bolts. Remove crossmember self-locking nuts and lower plates. Remove crossmember. Remove stoppers. Using Bushing Remover (MB991045 ), remove bushings "A" and "B". (Scheme 4) Using Bushing Remover (MB990828 ), remove bushing "C".

Installation

To install bushings "A" and "B", apply soapy water to contact surface of bushing. Press-fit bushing "A" until inner pipe projection is .31-.39" (8-10 mm). Press-fit bushing "B" until inner pipe projection is .12-.20" (3-5 mm). Press-fit bushing "C" until inner pipe projection is .14-.16" (3.5-4.5 mm). Use NEW crossmember self-locking nuts. To complete installation, reverse removal procedure.

Scheme 2

Scheme 3

Scheme 4

1. Loosen compression lower arm ball joint nut. Using Steering Linkage Puller (MB991113 ), separate ball joint and knuckle. (Scheme 5) Remove nut, bolts and compression lower arm assembly. Remove dust cover.
2. Remove stay. (Scheme 2) Remove shock absorber lower mounting bolt. Loosen lateral lower arm ball joint and knuckle nut. Using steering linkage puller, separate ball joint and knuckle. Remove nut, bolt and lateral lower arm assembly. Remove dust cover.

To install, reverse removal procedure. Use NEW ball joint nuts. Lubricate lip and inside of dust cover with multipurpose lubricant. Using Installer (MB990800 ), install dust cover. Check front wheel alignment. See the WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in the WHEEL ALIGNMENT section.

Scheme 5

1. Remove cotter pin and drive shaft nut. (Scheme 6) On models with anti-lock brake system, remove front speed sensor. On all models, remove caliper and secure it aside. Remove brake disc.
2. Loosen upper arm ball joint nut. Using Steering Linkage Puller (MB991113 ), separate ball joint and knuckle. Being careful to not damage ball joint boot or toothed rotor (if equipped), shift knuckle to outside to maintain clearance between hub mounting bolts and drive shaft. Remove front hub assembly.

To install, reverse removal procedure. Use NEW upper arm ball joint nut. When installing drive shaft washer and nut, washer must be installed with chamfered edge toward nut. Tighten nut to specification. See TORQUE SPECIFICATIONS . If nut does not align with cotter pin hole, tighten nut to a maximum of 188 ft. lbs. (255 N.m). Use NEW cotter pin.

Scheme 6

Removal & Installation

1. On models with anti-lock brake system, remove front wheel speed sensor. (Scheme 6) Remove front hub assembly. See «FRONT HUB ASSEMBLY»(ref-52707-S14301178232001011600000). Remove dust shield. (Scheme 7)
2. Loosen tie rod end, upper ball joint, compression lower arm ball joint, and lateral lower arm ball joint nuts. Using Steering Linkage Puller (MB991113 ), separate all ball joints and tie rod end from knuckle. Remove damper fork-to-lateral lower arm bolt. Remove previously loosened nuts. Remove knuckle.
3. To install, reverse removal procedure. Use NEW ball joint nuts and cotter pin. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-52707-S32345048282001011600000).

Scheme 7

Remove stabilizer link nut. (Scheme 8) Remove upper and lower shock absorber nuts and bolt. Remove damper fork bolt and damper fork. Remove shock absorber from vehicle.

To install, reverse procedure. Use NEW self-locking nut. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS . Check front wheel alignment. See WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in the WHEEL ALIGNMENT section.

Scheme 8

Scheme 9

Scheme 10

Remove stabilizer link nut and stabilizer link. (Scheme 11) Remove stabilizer bar bracket and bushing. Remove stabilizer bar.

1. To install, reverse removal procedure. If replacing stabilizer link ball joint dust cover, remove clip ring and dust cover. Lubricate lip and inside of dust cover with multipurpose lubricant. Cover stabilizer link threads with tape, then install dust cover. Ensure ends of clip ring align at a 90-degree angle from stabilizer link axis.
2. Position stabilizer bar so distance between marking on stabilizer bar and edge of bracket is about .39" (10 mm). Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-52707-S32345048282001011600000) .

Scheme 11

Using Steering Linkage Puller (MB991113 ), loosen upper arm ball joint and knuckle nut. Remove self-locking nut. (Scheme 12) Remove upper arm and upper arm shaft assembly. Remove dust cover.

1. To install, reverse removal procedure. Use NEW self-locking nuts. Lubricate lip and inside of dust cover with multipurpose lubricant. Using Ball Joint Installer (MB990800 ), install dust cover.
2. Ensure upper arm shaft assembly is installed at indicated angle. (Scheme 13) Verify upper arm shaft assembly installation. (Scheme 14) Check front wheel alignment. See the «WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES»(ref-52709) article in the WHEEL ALIGNMENT section.

Scheme 12

Scheme 13

Scheme 14