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Front Suspension & Wheel Alignment: Removal & Installation Dodge Avenger II facelift

Suspension Front 22 illustrations ~3838 words

REMOVAL

Note. Before proceeding. Refer to FRONT, WARNING .

Scheme 8

Scheme 8: REMOVAL
Scheme 8: REMOVAL

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Scheme 12

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Scheme 12
  1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-485472-S37758686622012071300000) .
  2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1).
  3. Remove the nut (4) attaching the lower ball joint to the lower control arm (5).
  4. Release the lower ball joint (3) from the lower control arm (1) using Remover (2) (special tool #9360, Remover, Ball Joint). Do not lift the knuckle out of the lower control arm at this time. CAUTION: Upon removing the knuckle from the ball joint stud, do not pull outward on the knuckle. Pulling the knuckle outward at this point can separate the inner C/V joint on the half shaft thus damaging it.
  5. At each end of the stabilizer bar, while holding the stabilizer bar link (1) lower stud stationary, remove the nut (3) securing the link to the stabilizer bar (2).
  6. Rotate the ends of the stabilizer bar (2) upward away from the lower control arm.
  7. Remove the front bolt (1) attaching the lower control arm (3) to the front suspension crossmember.
  8. Remove the nut on the rear bolt (2) attaching the lower control arm (3) to the front suspension crossmember. Remove the bolt.
  9. Remove the lower control arm (3) from the crossmember.

INSTALLATION

  1. Place the lower control arm (3) into the front suspension crossmember.
  2. Insert the rear bolt (2) up through the crossmember and lower control arm (3). Install the nut on the top-end of the bolt, but do not tighten it at this time.
  3. Install, but do not fully tighten, the front bolt (1) attaching the lower control arm (3) to the crossmember.
  4. With no weight or obstruction on the lower control arm, tighten the lower control arm front mounting bolt (1) to 175 N.m (129 ft. lbs.).
  5. With no weight or obstruction on the lower control arm, tighten the lower control arm rear mounting bolt nut to 145 N.m (107 ft. lbs.).
  6. Attach the stabilizer bar link (1) at each end of the stabilizer bar (2). At each link, install and tighten the nut (3) while holding the stabilizer bar link lower stud stationary. Tighten the nuts to 48 N.m (35 ft. lbs.). NOTE: If a new or cleaned lower control arm is being installed, it is important to have a film of general purpose grease around the ball joint mounting hole on the lower control arm to avoid any future corrosion issues. Make sure the grease does not get inside the ball joint mounting hole or on the ball joint stud during installation.
  7. Insert the lower ball joint stud into the mounting hole in the lower control arm (5).
  8. Install a NEW ball joint stud nut (4). Tighten the nut to 95 N.m (70 ft. lbs.).
  9. Install the tire and wheel assembly (1). Refer to «INSTALLATION»(ref-485473-S08436569672012071300000) . Install and tighten the wheel mounting nuts (3) to 135 N.m (100 ft. lbs.).
  10. Lower the vehicle.
  11. Perform wheel alignment as necessary. Refer to «WHEEL ALIGNMENT, STANDARD PROCEDURE»(ref-485471-S16167757252012071300000) .

Note. Before proceeding, review all Warnings and Cautions. Refer to FRONT, WARNING .

Scheme 13

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Scheme 16
  1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-485472-S37758686622012071300000) .
  2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1).
  3. While a helper applies the brakes to keep the hub from rotating, remove the hub nut (1) from the axle half shaft (2).
  4. Access and remove the front brake rotor. Refer to «ROTOR, BRAKE, REMOVAL»(ref-485474-S23533942602012071300000) .
  5. Remove the routing clip (1) securing wheel speed sensor cable to the knuckle (4).
  6. Remove the screw (2) fastening the wheel speed sensor head (3) to the knuckle (4). Pull the sensor head out of the knuckle.
  7. Remove the nut (4) attaching the lower ball joint to the lower control arm (5).
  8. Release the lower ball joint (5) from the lower control arm (1) using Remover (2), Special Tool (special tool #9360, Remover, Ball Joint). Do not lift the knuckle out of the lower control arm at this time.
  9. Lift the knuckle (2) out of the lower control arm (5). NOTE: Do not allow the half shaft (1) to hang by the inner C/V joint; it must be supported to keep the joint from separating during this operation.
  10. Pull the knuckle (2) off the axle half shaft (1) outer C/V joint splines and support the half shaft.
  11. Through the access hole (1) in the knuckle, tap the ends of the snap-ring (2) with a drift punch and remove it from the ball joint.
  12. Install Remover (2), Special Tool (special tool #9964-3, Remover, Ball Joint), and Remover (4), Special Tool (special tool #9964-4, Receiver, Remover) on Remover/Installer (5), Special Tool (special tool #8441-1, Assembly, C-Frame And Screw). Place the tools over the ball joint (3) as shown in illustration, then hand tighten the screw-drive.
  13. Using hand-tools, tighten the screw-drive forcing the ball joint (3) out of the knuckle (1).
  14. Loosen the screw-drive and remove the tools and ball joint.

Scheme 17

Scheme 17: INSTALLATION
Scheme 17: INSTALLATION
  1. Install Installer (2), Special Tool (special tool #9964-1, Receiver, Install), and Installer (4), Special Tool (special tool #9964-2, Installer, Ball Joint) on Remover/Installer (5), Special Tool (special tool #8441-1, Assembly, C-Frame And Screw). Place a new ball joint (stem down) into Installer (special tool #9964-2, Installer, Ball Joint).
  2. Position the assembly onto the knuckle as shown in illustration, then hand tighten the screw-drive.
  3. Using hand-tools, tighten the screw-drive forcing the ball joint (3) into the knuckle (1). Continue to install the ball joint until the flange on the ball joint comes to a stop against the bottom of the knuckle.
  4. Loosen the screw-drive and remove the tools.
  5. Install a NEW snap-ring into the groove in the ball joint using a drift punch.
  6. Slide the hub and bearing in the knuckle (2) onto the splines of the half shaft outer C/V joint (1).
  7. Insert the lower ball joint stud into the mounting hole in the lower control arm.
  8. Install a NEW ball joint stud nut (4). Tighten the nut to 95 N.m (70 ft. lbs.).
  9. Install the wheel speed sensor head (3) into the knuckle (4). Install the mounting screw (2) and tighten it to 12 N.m (106 in. lbs.).
  10. Install the routing clip (1) securing the wheel speed sensor cable to the knuckle (4).
  11. Install the brake rotor, disc brake caliper and adapter. Refer to «ROTOR, BRAKE, INSTALLATION»(ref-485474-S32070309932012071300000) .
  12. Clean all foreign matter from the threads of the half shaft outer C/V joint.
  13. Install the hub nut (1) on the end of the half shaft (2) and snug it.
  14. While a helper applies the brakes to keep the hub from rotating, tighten the hub nut (3) to 132 N.m (97 ft. lbs.).
  15. Install the tire and wheel assembly (1). Refer to «INSTALLATION»(ref-485473-S08436569672012071300000) . Install and tighten wheel mounting nuts (3) to 135 N.m (100 ft. lbs.).
  16. Lower the vehicle.
  17. Perform wheel alignment as necessary. Refer to «WHEEL ALIGNMENT, STANDARD PROCEDURE»(ref-485471-S16167757252012071300000) .

Note. Before proceeding, review all Warnings and Cautions. Refer to FRONT, WARNING .

Scheme 18

Scheme 18
Scheme 18
  1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-485472-S37758686622012071300000) .
  2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1).
  3. While a helper applies the brakes to keep the hub from rotating, remove the hub nut (1) from the axle half shaft (2).
  4. Access and remove the front brake rotor. Refer to «ROTOR, BRAKE, REMOVAL»(ref-485474-S23533942602012071300000) .
  5. Remove the four bolts (2) fastening the hub and bearing to the knuckle (3).
  6. Slide the hub and bearing (1) off the half shaft and out of the knuckle.
  1. Install the hub and bearing (1) by sliding it over the half shaft and into the knuckle.
  2. Install the four bolts (2) fastening the hub and bearing (1) to the knuckle (3). Tighten the four bolts to 82 N.m (60 ft. lbs.).
  3. Install the brake rotor, disc brake caliper and adapter. Refer to «ROTOR, BRAKE, INSTALLATION»(ref-485474-S32070309932012071300000) . NOTE: Always install a new hub nut. The original hub nut is one-time use only and should be discarded when removed.
  4. Clean all foreign matter from the threads of the half shaft outer C/V joint.
  5. Install the hub nut (1) on the end of the half shaft (2) and lightly tighten it.
  6. While a helper applies the brakes to keep the hub from rotating, tighten the hub nut (1) to 132 N.m (97 ft. lbs.).
  7. Install the tire and wheel assembly (1). Refer to «INSTALLATION»(ref-485473-S08436569672012071300000) . Install and tighten wheel mounting nuts (3) to 135 N.m (100 ft. lbs.).
  8. Lower the vehicle.

Note. Before proceeding, review all Warnings and Cautions. Refer to FRONT, WARNING .

Scheme 19

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Scheme 21
  1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-485472-S37758686622012071300000) .
  2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). NOTE: The hub nut is a single use type. A new nut is required for reassembly. Do not reuse the hub nut.
  3. While a helper applies the brakes to keep the hub from rotating, remove the hub nut (1) from the axle half shaft (2).
  4. Access and remove the front brake rotor. Refer to «ROTOR, BRAKE, REMOVAL»(ref-485474-S23533942602012071300000) .
  5. Remove the routing clip (1) securing wheel speed sensor cable to the knuckle (4).
  6. Remove the screw (2) fastening the wheel speed sensor head (3) to the knuckle (4). Pull the sensor head out of the knuckle.
  7. Remove the nut (3) attaching the outer tie rod (6) to the knuckle (2). To do this it might be necessary to hold the tie rod end stud with a wrench while loosening and removing the nut with a standard wrench or crowfoot wrench.
  8. Release the outer tie rod end (1) from the knuckle (3) using Remover (2), Special Tool (special tool #9360, Remover, Ball Joint).
  9. Remove the outer tie rod from the knuckle.
  10. Remove the nut (4) attaching the lower ball joint to the lower control arm (5).
  11. Release the lower ball joint (3) from the lower control arm (1) using Remover (2), Special Tool (special tool #9360, Remover, Ball Joint). Do not lift the knuckle out of the lower control arm at this time. CAUTION: The strut assembly-to-knuckle attaching bolts (5) are serrated and must not be turned during removal. Proper removal is required. Refer to the following steps for the correct method.
  12. While holding the bolt heads stationary, remove the two nuts (2) from the bolts (5) attaching the strut (3) to the knuckle (6).
  13. Remove the two bolts (5) attaching the strut (3) to the knuckle (6) using a pin punch. NOTE: Do not allow the half shaft (1) to hang by the inner C/V joint; it must be supported to keep the joint from separating during this operation.
  14. Pull the knuckle (2) off the half shaft (1) outer C/V joint splines and remove the knuckle from the vehicle.
  15. If required, remove the three screws (2) fastening the shield (3) to the knuckle (1). Remove the shield.
  16. If required, remove the four bolts (2) fastening the hub and bearing (1) to the knuckle (3).
  17. If required, slide the hub and bearing (1) out of the knuckle.
  1. If required, install the hub and bearing (1) by sliding it into the knuckle.
  2. If installing hub and bearing, install the four bolts (2) fastening the hub and bearing (1) to the knuckle (3). Tighten the four bolts to 82 N.m (60 ft. lbs.).
  3. If required, install the shield on the knuckle. Install and tighten the three mounting screws (2) to 10 N.m (89 in. lbs.).
  4. Slide the hub and bearing in the knuckle (2) onto the splines of the half shaft outer C/V joint (1).
  5. Insert the lower ball joint stud into the mounting hole in the lower control arm.
  6. Install a NEW ball joint stud nut (4). Tighten the nut to 95 N.m (70 ft. lbs.). CAUTION: The strut clevis-to-knuckle bolts (5) are serrated and must not be turned during installation. Install the nuts while holding the bolts stationary in the steering knuckle. Refer to the following step.
  7. Position the lower end of the strut assembly (3) in line with the upper end of the knuckle (6), aligning the mounting holes. Install the two mounting bolts (5).
  8. Install the nuts (2) on the two bolts (5). While holding the bolts in place, tighten the nuts to 140 N.m (103 ft. lbs.). NOTE: If a new tie rod end is to be installed, make sure the boot (2) is properly lubricated.
  9. Clean all old grease and debris from the boot (2) with a clean cloth.
  10. Apply outer tie rod grease P/N 68088623AA (1) to the tie rod end boot (2).
  11. Install the outer tie rod (6) ball stud into the hole in the knuckle (2) arm. Start the tie rod end-to-knuckle nut (4) onto the stud. While holding the tie rod end stud with a wrench, tighten the nut with a wrench or crowfoot wrench to 85 N.m (63 ft. lbs.).
  12. Install the wheel speed sensor head (3) into the knuckle (4). Install the mounting screw (2) and tighten it to 12 N.m (106 in. lbs.).
  13. Install the routing clip (1) securing the wheel speed sensor cable to the knuckle (4).
  14. Install the brake rotor, disc brake caliper and adapter. Refer to «ROTOR, BRAKE, INSTALLATION»(ref-485474-S32070309932012071300000) .
  15. Clean all foreign matter from the threads of the half shaft outer C/V joint. NOTE: The hub nut is a single use type. A new nut is required for reassembly. Do not reuse the hub nut.
  16. Install the hub nut (1) on the end of the half shaft (2) and snug it.
  17. While a helper applies the brakes to keep the hub from rotating, tighten the hub nut (3) to 132 N.m (97 ft. lbs.).
  18. Install the tire and wheel assembly (1). Refer to «INSTALLATION»(ref-485473-S08436569672012071300000) . Install and tighten wheel mounting nuts (3) to 135 N.m (100 ft. lbs.).
  19. Lower the vehicle.
  20. Perform wheel alignment as necessary. Refer to «WHEEL ALIGNMENT, STANDARD PROCEDURE»(ref-485471-S16167757252012071300000) .

Note. Before proceeding. Refer to FRONT, WARNING .

  1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-485472-S37758686622012071300000) .
  2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1).
  3. While holding the stabilizer bar link (1) stud stationary, remove the nut (4) securing the link to the strut (3).
  4. While holding the stabilizer bar link (1) lower stud stationary, remove the nut (3) securing the link to the stabilizer bar (2).
  5. Remove the stabilizer bar link (1).
  1. Attach the stabilizer bar link (1) to the stabilizer bar (2). Install and tighten the nut (3) while holding the stabilizer bar link lower stud stationary. Tighten the nut to 48 N.m (35 ft. lbs.).
  2. Attach the stabilizer bar link (1) to the strut (3). Install and tighten the nut (4) while holding the stabilizer bar link stud stationary. Tighten the nut to 48 N.m (35 ft. lbs.).
  3. Install tire and wheel assembly (1). Refer to «INSTALLATION»(ref-485473-S08436569672012071300000) . Install and tighten wheel mounting nuts (3) to 135 N.m (100 ft. lbs.).
  4. Lower the vehicle.

Note. Before proceeding. Refer to FRONT, WARNING .

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Scheme 27
  1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-485472-S37758686622012071300000) .
  2. If equipped, remove the engine belly pan.
  3. Remove the rear engine mount. Refer to «INSULATOR, ENGINE MOUNT, FRONT, REMOVAL»(ref-485475-S40582421332012071300000) «INSULATOR, ENGINE MOUNT, LEFT, REMOVAL»(ref-485475-S22192095732012071300000) «INSULATOR, ENGINE MOUNT, REAR, REMOVAL»(ref-485475-S26787268242012071300000) «INSULATOR, ENGINE MOUNT, RIGHT, REMOVAL»(ref-485475-S11446412792012071300000) «INSULATOR, ENGINE MOUNT, LEFT, REMOVAL»(ref-485476-S02313871212012071300000) «INSULATOR, ENGINE MOUNT, RIGHT, REMOVAL»(ref-485476-S09648900572012071300000) «INSULATOR, ENGINE MOUNT, REAR, REMOVAL»(ref-485476-S39056195622012071300000) «INSULATOR, ENGINE MOUNT, FRONT, REMOVAL»(ref-485476-S23870873392012071300000) .
  4. Remove the front engine mount through-bolt.
  5. At each end of the stabilizer bar, while holding the stabilizer bar link (1) lower stud stationary, remove the nut (3) securing the link to the stabilizer bar (2).
  6. Remove the screws (1) securing the power steering hose routing clamps (2) to the rear of the crossmember.
  7. Remove the screws and push-pins securing the heat shield (1) over the right side of the steering gear (2).
  8. Remove the two bolts (1) securing the steering gear (2) to the crossmember.
  9. Support the steering gear using a bungee cord or other to keep the steering gear from lowering when the crossmember is lowered. NOTE: Before removing the front suspension crossmember from the vehicle, the location of the crossmember must be marked on the body of the vehicle. Do this so the crossmember can be relocated, upon reinstallation, against the body of vehicle in the same location as before removal. If the front suspension crossmember is not reinstalled in exactly the same location as before removal, the preset front wheel alignment settings (caster and camber) may be lost.
  10. Mark the location of the front crossmember (9) on the body near each mounting bolt.
  11. Support the crossmember (9) with a transmission jack.
  12. Remove the four mounting bolts (6) securing the front crossmember (9) to the body.
  13. Sedan only - Remove the mounting screws (8) securing the front crossmember reinforcement brackets (7) (one each side of vehicle) to the body (1). Remove the brackets.
  14. Convertible only - Remove the mounting screws (1) securing the front crossbrace/reinforcement bracket (2) to the body (1). Remove the bracket.
  15. Slowly lower the crossmember using the jack until there is enough space present to remove the stabilizer bar between the rear of the crossmember and the body. Due to the fact that the fore-and-aft crossmember is still attached, do not lower crossmember any more than necessary to remove the stabilizer bar.
  16. Remove the screws (1) securing the stabilizer bushing retainers (3) to the crossmember.
  17. Remove the two stabilizer bushing retainers (3).
  18. Utilizing the slit cut into the cushions (bushings), remove the two cushions from the stabilizer bar.
  19. Remove the stabilizer bar (2) from the vehicle.

Note. Before stabilizer bar installation, inspect the cushions and links for excessive wear, cracks, damage and distortion. Replace any pieces failing inspection.

Note. Before installing the stabilizer bar, make sure the bar is not upsidedown. The stabilizer bar must be installed so that when in mounted position, the ends of the bar curve under the steering gear tie rods, up to the links.

  1. Install the stabilizer bar, link ends first, from the rear over top of the crossmember. Curve the ends of the bar (2) under the steering gear.
  2. Install the two cushions (bushings) on the stabilizer bar utilizing the slit cut into the cushion sides.
  3. Install the two stabilizer bushing retainers (3) over the cushions.
  4. Install the screws (1) securing the stabilizer bushing retainers (3) to the crossmember. Tighten all four stabilizer bar cushion retainer screws to 60 N.m (44 ft. lbs.).
  5. Slowly raise the crossmember (9) into mounted position using the transmission jack matching the crossmember to the marked locations on the body made during removal.
  6. Sedan only - Position the front crossmember reinforcement brackets (7) (one each side of vehicle) over the crossmember rear mounting bushings and install the mounting screws (8), but do not tighten at this time.
  7. Convertible only - Position the front crossbrace/reinforcement bracket (2) over the crossmember rear mounting bushings and body, then install the mounting screws (1). Do not tighten screws at this time.
  8. Install the four mounting bolts (6) securing the front crossmember (1) to the body. Tighten the crossmember mounting bolts to 135 N.m (100 ft. lbs.).
  9. Sedan only - Tighten the crossmember reinforcement bracket mounting screws (8) to 50 N.m (37 ft. lbs.).
  10. Convertible only - Tighten the crossbrace/reinforcement bracket mounting screws (1) to 50 N.m (37 ft. lbs.).
  11. Remove the transmission jack.
  12. Remove the bungee cord or other supporting the steering gear (2).
  13. Install the two bolts (1) securing the steering gear (2) to the crossmember. Tighten the steering gear mounting bolts to 100 N.m (74 ft. lbs.).
  14. Position the heat shield (1) over the steering gear (2). Install the mounting screws and push-pins. Tighten the screws to 6 N.m (53 in. lbs.).
  15. Position the power steering hose routing clamps (2) on the crossmember. Install and tighten the screws to 8 N.m (71 in. lbs.).
  16. Attach the stabilizer bar link (1) at each end of the stabilizer bar (2). At each link, install and tighten the nut (3) while holding the stabilizer bar link lower stud stationary. Tighten the nuts to 48 N.m (35 ft. lbs.).
  17. Install the rear engine mount. Refer to «INSULATOR, ENGINE MOUNT, REAR, INSTALLATION»(ref-485475-S29947108362012071300000) or «INSULATOR, ENGINE MOUNT, REAR, INSTALLATION»(ref-485476-S34182425092012071300000) .
  18. Install the front engine mount through-bolt.
  19. If equipped, install the engine belly pan.
  20. Lower the vehicle.

Note. Before proceeding. Refer to FRONT, WARNING .

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Scheme 29
  1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-485472-S37758686622012071300000) .
  2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). NOTE: If both strut assemblies are to be removed, mark the strut assemblies right or left and keep the parts separated to avoid mix-up. Not all parts of the strut assembly are interchangeable side-to-side.
  3. Remove the screw (1) securing the flex hose (2) routing bracket to the strut (6).
  4. While holding the stabilizer bar link (1) stud stationary, remove the nut (4) securing the link to the strut (3). CAUTION: The strut assembly-to-knuckle attaching bolts (5) are serrated and must not be turned during removal. Hold the bolts stationary in the knuckle while removing the nuts, then tap the bolts out using a pin punch.
  5. While holding the bolt heads stationary, remove the two nuts (2) from the bolts (5) attaching the strut (3) to the knuckle (6).
  6. Remove the two bolts (5) attaching the strut (3) to the knuckle (6) using a pin punch.
  7. Lower the vehicle just enough to open the hood without allowing the tires to touch the floor.
  8. Remove the three nuts (1) attaching the strut assembly (2) upper mount to the strut tower.
  9. Remove the strut assembly (2) from the vehicle.
  10. For disassembly. Refer to «STRUT, SUSPENSION, ASSEMBLY, DISASSEMBLY»(ref-485471-S17082137432012071300000) .
  1. Raise the strut assembly (2) into the strut tower, aligning the three studs on the strut assembly upper mount with the holes in strut tower. Install the three mounting nuts (1) on the studs. Tighten the three nuts to 55 N.m (41 ft. lbs.). CAUTION: The strut clevis-to-knuckle bolts (5) are serrated and must not be turned during installation. Install the nuts while holding the bolts stationary in the knuckle.
  2. Position the lower end of the strut assembly (3) in line with the upper end of the knuckle (6), aligning the mounting holes. Install the two attaching bolts (5). Install the nuts (2). While holding the bolts in place, tighten the nuts to 140 N.m (103 ft. lbs.).
  3. Attach the stabilizer bar link (1) to the strut (3). Install and tighten the nut (4) while holding the stabilizer bar link stud stationary. Tighten the nut to 48 N.m (35 ft. lbs.).
  4. Secure the flex hose (2) routing bracket to the strut (6) with the mounting screw (1). Tighten the mounting screw to 13 N.m (120 in. lbs.).
  5. Install tire and wheel assembly (1). Refer to «INSTALLATION»(ref-485473-S08436569672012071300000) . Install and tighten wheel mounting nuts (3) to 135 N.m (100 ft. lbs.).
  6. Lower the vehicle.

More articles — Front Suspension & Wheel Alignment