Front Suspension & Wheel Alignment: Removal & Installation Dodge Dart PF

REMOVAL

Note. Before proceeding, refer to FRONT, WARNING .

Scheme 1

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Scheme 6

1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
2. Remove the wheel mounting bolts, then the tire and wheel assembly.
3. Remove the pinch bolt nut (3) and pinch bolt from the knuckle. NOTE: Use care when separating the ball joint stud from the knuckle so the ball joint boot does not get cut.
4. Insert a pry bar (2) in the opening (1) between the control arm front mounting bolt and the front fascia support beam.
5. Separate the lower control arm from the knuckle by prying down with the pry bar (2).
6. Remove the fasteners (2) securing the lower bumper reinforcement (1) and front fascia support beams to the frame/front end module for the side of the vehicle the lower control arm is being removed from.
7. Remove the front fascia support beam (1) from the side of vehicle the lower control arm is being removed from.
8. Remove the front horizontal bolt (1) attaching the lower control arm to the front suspension crossmember.
9. Remove the nut (1) and rear vertical bolt (2) attaching the lower control arm to the front suspension crossmember.
10. Remove the lower control arm from the crossmember.

Scheme 7

1. Install the lower control arm in the front suspension crossmember.
2. Install a NEW rear bolt (2) and NEW nut (1) to attach the lower control arm to the crossmember but do not tighten to specification at this time.
3. Install a NEW front bolt (1) attaching the lower control arm to the crossmember.
4. Lower the vehicle and install a floor jack under the control arm. Raise the jack until the lower control arm is at ride height and tighten the following bolts: Front Lower Control Arm Horizontal Bolt (1): 100 N.m Plus 135° (74 ft. lbs. Plus 135°). Rear Lower Control Arm Vertical Bolt: 80 N.m Plus 75° (59 ft. lbs Plus 75°.).
5. Raise the vehicle back up to the original position.
6. Install the front fascia support beam (1) that was removed.
7. Install the fasteners (2) securing the lower bumper reinforcement (1) to the frame/front end module for the side of the vehicle the lower control arm was removed from. Tighten the fasteners to 45 N.m (33 ft. lbs.).
8. Install the crossmember to fascia support beam bracket and install the four retaining bolts (1) and tighten to 95 N.m (70 ft. lbs.).
9. Install the lower ball joint in the knuckle.
10. Install a NEW pinch bolt and NEW nut (3) and tighten to 70 N.m (52 ft. lbs.).
11. Install the wheel and tire assembly. Refer to «INSTALLATION»(ref-646212-S30999901622014072800000) .
12. Lower the vehicle.

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

Scheme 8

Scheme 9

Scheme 10

Scheme 11

1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
2. Remove the wheel mounting bolts (1), then the tire and wheel assembly.
3. Using a suitable punch, lift the two staked areas in the hub nut to avoid damaging the halfshaft.
4. While a helper applies the brakes to keep the hub from rotating, remove the hub nut (1) from the halfshaft (2) and discard it. The used hub nut is not reusable.
5. Remove the front wheel speed sensor retaining bolt (2) and remove the sensor (1) from the knuckle.
6. Access and remove the front brake rotor. Refer to «ROTOR, BRAKE, REMOVAL»(ref-646213-S17368759582014072800000) .
7. Remove the four bolts (1) fastening the hub and bearing to the knuckle. NOTE: The bolts are one time use and need to be discarded.
8. Slide the hub and bearing off the half shaft and out of the knuckle.

Scheme 12

Scheme 13

1. Slide the hub and bearing onto the half shaft and install into the knuckle.
2. Install four NEW mounting bolts (1) and tighten to 95 N.m (70 ft. lbs.).
3. Install the front brake rotor. Refer to «ROTOR, BRAKE, INSTALLATION»(ref-646213-S01077585372014072800000).
4. Install the front wheel speed sensor (1) in the knuckle.
5. Install the retaining bolt (2) and tighten to 12 N.m (106 in. lbs.). NOTE: Always install a new hub nut. The original hub nut is one-time use only and must be discarded when removed.
6. Install a NEW hub nut and while a helper applies the brakes, tighten the nut to 200 N.m (148 ft. lbs.) NOTE: Do not use air tools on staking tool while staking hub nut.
7. Using (special tool #10287, Tool, Front Hub Staking), align the leading cutting edge of tool with the top left side channel on axle as shown (1). Tighten fastener on staking tool with hand tools until the threads bottom out completely. NOTE: The hub nut must be staked so that it looks similar to see scheme 19. Both edges must be split and bent into the shape shown (3). The staking must be in the opposite direction from the forward rotation of the wheel.
8. Install the wheel and tire assembly. Refer to «INSTALLATION»(ref-646212-S30999901622014072800000).

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

Scheme 14

Scheme 15

Scheme 16

1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
2. Remove the wheel mounting bolts, then the tire and wheel assembly.
3. Using a suitable punch, lift the two staked areas in the hub nut to avoid damaging the halfshaft.
4. While a helper applies the brakes to keep the hub from rotating, remove the hub nut (1) from the halfshaft (2) and discard it. The used hub nut is not reusable.
5. Access and remove the front brake rotor. Refer to «ROTOR, BRAKE, REMOVAL»(ref-646213-S17368759582014072800000) .
6. Remove the routing clip (1) securing brake hose to the knuckle.
7. While holding the stabilizer bar link stud stationary, remove the nut (1) securing the link (2) to the stabilizer bar. Position the stabilizer bar and link out of the way to provide enough movement to separate the ball joint from the knuckle in the next few steps.
8. Remove the screw (2) fastening the wheel speed sensor head (1) to the knuckle. Remove the sensor (1) from the knuckle.
9. Remove the nut (2) attaching the outer tie rod (1) to the knuckle.
10. Remove the outer tie rod end (1) from the knuckle.
11. Remove the pinch bolt and nut (3) that secures the lower ball joint to the knuckle.
12. Place a pry bar (2) between the front fascia support beams and lower control arm front mounting bolt.
13. Pry down to separate the lower ball joint from the knuckle. NOTE: Do not allow the half shaft to hang by the inner C/V joint; it must be supported to keep the joint from separating during this operation.
14. Remove the lower pinch bolt (1) and nut (2) securing the knuckle to the strut (3).
15. Pull the knuckle off the half shaft outer C/V joint splines and remove the knuckle from the vehicle.
16. If required, remove the four bolts (1) fastening the hub and bearing to the knuckle.
17. If required, slide the hub and bearing (1) out of the knuckle.

INSTALLATION

1. If removed, install the hub and bearing into the knuckle.
2. If removed, install four NEW mounting bolts (1) and tighten to 95 N.m (70 ft. lbs.).
3. Slide the half shaft into the knuckle and install the knuckle into the vehicle.
4. Install a NEW retaining bolt (1) and NEW nut (2) that secures the strut (3) to the knuckle and tighten to 110 N.m (81 ft. lbs.).
5. Install the lower control arm ball joint stud into the knuckle.
6. Install a NEW retaining bolt and NEW nut (3) and tighten to 25 N.m Plus 180° (18 ft. lbs. Plus 180°).
7. Install the outer tie rod (1) to the knuckle and install the retaining nut (2) and tighten to 30 N.m Plus 90° (22 ft. lbs. Plus 90°).
8. Install the stabilizer link stud to the strut.
9. Install the retaining nut (1) and tighten to 63 N.m (46 ft. lbs.).
10. Install the routing clip (1) to secure the brake hose to the knuckle.
11. Install the front brake rotor. Refer to «ROTOR, BRAKE, INSTALLATION»(ref-646213-S01077585372014072800000).
12. Install the wheel speed sensor (1) to the knuckle. NOTE: Always install a new hub nut. The original hub nut is one-time use only and must be discarded when removed.
13. Install a NEW hub nut and while a helper applies the brakes, tighten the nut to 200 N.m (148 ft. lbs.) NOTE: Do not use air tools on staking tool while staking hub nut.
14. Using (special tool #10287, Tool, Front Hub Staking), align the leading cutting edge of tool with the top left side channel on axle as shown (1). Tighten fastener on staking tool with hand tools until the threads bottom out completely. NOTE: The hub nut must be staked so that it looks similar to see scheme 1. Both edges must be split and bent into the shape shown (3). The staking must be in the opposite direction from the forward rotation of the wheel.
15. Install the wheel and tire assembly. Refer to «INSTALLATION»(ref-646212-S30999901622014072800000).

Note. Before proceeding, refer to FRONT, WARNING .

1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
2. Remove the wheel mounting bolts, then the tire and wheel assembly.
3. On the upper and lower end of the stabilizer link, hold the link studs stationary and remove the nuts (1, 3) securing the link to the stabilizer bar (2).
4. Remove the stabilizer bar link (2).

1. Position the stabilizer link (2) in the vehicle and install the upper stud to the knuckle.
2. Install the lower stud into the stabilizer bar.
3. Install the upper and lower nuts (1, 3).
4. While holding the upper stud stationary, tighten the upper nut (1) to 63 N.m (46 ft. lbs.).
5. While holding the lower stud stationary, tighten the lower nut (3) to 55 N.m (41 ft. lbs.).
6. Install the tire and wheel assembly, and the lug bolts. Refer to «INSTALLATION»(ref-646212-S30999901622014072800000) .
7. Lower the vehicle.

Scheme 17

Note. Before proceeding, refer to FRONT, WARNING .

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Scheme 21

Scheme 22

1. Disconnect battery negative cable.
2. Using a steering wheel holder, lock the steering wheel in place to keep it from rotating. This keeps the clockspring in the proper orientation.
3. Remove pinch bolt (3) and separate intermediate shaft (2) from steering gear shaft.
4. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
5. Remove the wheel mounting bolts, then the tire and wheel assembly.
6. If equipped, remove the engine belly pan. Refer to «BELLY PAN, REMOVAL»(ref-646214-S24731623582014072800000) .
7. At each end of the stabilizer bar, while holding the stabilizer bar link stud stationary, remove the nut (1, 3) securing the link (2) to the stabilizer bar.
8. Remove the outer tie rod retaining nut (2) and separate the tie rod (1) from the knuckle.
9. Remove the pinch bolt nut (3) and pinch bolt from the knuckle. NOTE: Use care when separating the ball joint stud from the knuckle so the ball joint boot does not get cut.
10. Insert a pry bar (2) in the opening (1) between the control arm front mounting bolt and the front fascia support beam.
11. Separate the lower control arm from the knuckle by prying down with the pry bar (2).
12. Remove the four bracket retaining bolts (1) from the cross member to fascia support beams bracket, then remove the bracket.
13. Remove the fasteners (2) securing the lower bumper reinforcement (1) and front fascia support beams to the frame/front end module.
14. Remove the front fascia support beams.
15. Disconnect the downstream oxygen sensor harness connector.
16. Remove the exhaust extension pipe.
17. Disconnect the harness connectors (2) at the steering gear module (1).
18. Disconnect the steering gear connector (1) from the body harness connector at the bottom of the dash panel.
19. Separate the steering gear harness from the crossmember by removing the tie strap (2) from the crossmember.
20. Remove the rear engine mount. NOTE: Before lowering the front suspension crossmember, 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.
21. Mark the position of the cross member with a grease pencil or equivalent.
22. Support the crossmember with a transmission jack, or equivalent.
23. Remove the upper mounting bolt (1) from each side of the crossmember.
24. Remove the four rear mounting bolts (1, 3) that secure the crossmember (2) to the vehicle.
25. Slowly lower the crossmember with the jack and remove from the vehicle.
26. Remove the four retaining bolts (1, 3) and remove the stabilizer bar from the crossmember.

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

1. Install the stabilizer bar (2) to the crossmember.
2. Install the four stabilizer bar mounting bolts (1, 3) and tighten to 65 N.m (48 ft. lbs.).
3. Slowly raise the crossmember (2) into mounted position using the transmission jack matching the crossmember to the marked locations on the body made during removal.
4. Install four mounting bolts (1, 3) and tighten to 189 N.m (139 ft. lbs.).
5. Install the upper mounting bolt (1) on each side of the crossmember and tighten to 120 N.m (89 ft. lbs.).
6. Connect the steering harness connector (1) to the body harness connector at the bottom of the dash panel.
7. Install the tie strap (2) to the crossmember.
8. Connect the harness connectors (2) at the steering gear module (1).
9. Install the rear engine mount. Refer to «INSULATOR, ENGINE MOUNT, LEFT, INSTALLATION»(ref-646215-S15249086532014072800000) for 1.4L, «INSULATOR, ENGINE MOUNT, REAR, INSTALLATION»(ref-646215-S32115423112014072800000) for 1.4L, «INSULATOR, ENGINE MOUNT, RIGHT, INSTALLATION»(ref-646215-S02011565972014072800000) for 1.4L, «INSULATOR, ENGINE MOUNT, LEFT, INSTALLATION»(ref-646216-S38752139742014072800000) for 2.0L, «INSULATOR, ENGINE MOUNT, REAR, INSTALLATION»(ref-646216-S06092366102014072800000) for 2.0L, «INSULATOR, ENGINE MOUNT, RIGHT, INSTALLATION»(ref-646216-S27557929332014072800000) for 2.0L, «INSULATOR, ENGINE MOUNT, LEFT, INSTALLATION»(ref-646217-S28607551492014072800000) for 2.4L, «INSULATOR, ENGINE MOUNT, REAR, INSTALLATION»(ref-646217-S11710778622014072800000) for 2.4L, «INSULATOR, ENGINE MOUNT, RIGHT, INSTALLATION»(ref-646217-S05475237812014072800000) for 2.4L.
10. Install the exhaust extension pipe.
11. Connect the downstream oxygen sensor harness connector.
12. Install the front fascia beams (1).
13. Install the fasteners (2) securing the lower bumper reinforcement (1) to the frame/front end module. Tighten the fasteners to 45 N.m (33 ft. lbs.).
14. Install the crossmember to fascia support beam bracket and install the four retaining bolts (1) and tighten to 95 N.m (70 ft. lbs.).
15. Insert the lower ball joint into the knuckle and install the pinch bolt and nut (3) and tighten to 70 N.m (52 ft. lbs.).
16. Install the outer tie rod end (1) into the knuckle and install the retaining nut (2) and tighten to 25 N.m Plus 80° (18 ft. lbs. Plus 80°).
17. Install the stabilizer link stud into the knuckle and install the nut (1).
18. Hold the stabilizer link stud stationary and tighten the nut to 63 N.m (46 ft. lbs.).
19. If equipped, install the engine belly pan. Refer to «BELLY PAN, INSTALLATION»(ref-646214-S07994234782014072800000) .
20. Install the tire and wheel assembly. Refer to «INSTALLATION»(ref-646212-S30999901622014072800000) .
21. Lower the vehicle.
22. Install the intermediate shaft (2) to the steering gear pinion shaft (4).
23. Install a NEW pinch bolt (3) and tighten to 55 N.m (40 ft. lbs.).
24. Remove the steering wheel holder.
25. Perform wheel alignment. Refer to «WHEEL ALIGNMENT, STANDARD PROCEDURE»(ref-646210-S39626530632014072800000) .
26. Connect the battery negative cable.

Scheme 23

A Macpherson type design strut assembly is used in place of the traditional front suspension upper control arm and upper ball joint. The bottom of the strut mounts directly to the steering knuckle using a "shark fin" and pinch bolt going through the knuckle. The top of the strut mounts directly to the strut tower of the vehicle using a retaining clip on the strut assembly upper mount.

The strut assembly includes the following components

1. Strut (damper) (1)
2. Dust shield (2)
3. Strut rod nut (3)
4. Bearing and upper spring seat (4)
5. Upper spring isolator (5)
6. Coil spring (6)
7. Lower spring isolator (7)

Each component is serviced by removing the strut assembly from the vehicle and disassembling it.

Coil springs are rated separately for each corner or side of the vehicle depending on optional equipment and type of vehicle service. If a coil spring requires replacement, be sure that it is replaced with a spring meeting the correct load rating for the vehicle and its specific options.

Note. Before proceeding, refer to FRONT, WARNING .

Scheme 24

Scheme 25

1. 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.
2. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
3. Remove the wheel mounting bolts, then the tire and wheel assembly.
4. Remove the staking from the hub nut and remove the hub nut from the axle.
5. Remove the wheel speed sensor harness from the strut and position out of the way.
6. Remove the clip (1) securing the flex hose to the strut.
7. Remove the caliper adapter bolts (2) and remove the caliper from the rotor. Use a wire or bungee cord to support the caliper.
8. Remove the wheel speed sensor bolt (2) and remove the wheel speed sensor (1) from the knuckle.
9. While holding the stabilizer bar link stud stationary, remove the nut (1) securing the link to the strut.
10. Remove the lower ball joint pinch bolt and nut (1) from the knuckle. NOTE: Use care when separating the ball joint stud from the knuckle so the ball joint boot does not get cut.
11. Insert a pry bar (2) in the opening (1) between the control arm front mounting bolt and the front fascia support beam.
12. Separate the lower control arm from the knuckle by prying down with the pry bar (2).
13. Remove the outer tie rod nut (2) and separate the tie rod (1) from the knuckle.
14. Separate the axle from the knuckle and support the axle.
15. Insert the ball joint back into the knuckle to support the strut during upper strut clip removal.
16. Lower the hoist until a floor jack can be used to raise the strut to relieve tension on the upper strut clip.
17. Using two screwdrivers, pry the two ends (1, 2) of the strut clip in opposite directions to separate and break the clip. Discard the clip after removal.
18. Remove the nut (2) and bolt (1) attaching the strut to the knuckle.
19. Remove the strut from the vehicle.
20. For disassembly, refer to «STRUT, SUSPENSION, ASSEMBLY, DISASSEMBLY»(ref-646210-S30187240022014072800000) .

Scheme 26

Note. The strut assembly must be removed from the vehicle for it to be disassembled and assembled. Refer to STRUT, SUSPENSION, ASSEMBLY, REMOVAL .

For the disassembly and assembly of the strut assembly, use strut spring compressor, teamPSE tool 223-7400, or the equivalent, to compress the coil spring. Follow the manufacturer's instructions closely.

Scheme 27

Scheme 28

1. If both struts are being serviced at the same time, mark both the coil spring and strut assembly according to which side of the vehicle the strut is being removed from.
2. Position the strut assembly (2) in the strut coil spring compressor (1) following the manufacturer's instructions and set the lower and upper hooks of the compressor on the coil spring. Position the strut clevis bracket straight outward, away from the compressor.
3. Compress the coil spring until all coil spring tension is removed from the upper mount and bearing. CAUTION: Never use impact or high speed tools to remove the strut rod nut. Damage to the strut internal bearings can occur.
4. Once the spring is sufficiently compressed, install (special tool #9362, Wrench, Strut Nut) (2), on the strut rod nut. Next, install a hex head wrench (1) into the strut rod internal hex. While holding the strut rod from turning, remove the nut using the strut nut wrench.
5. Remove the clamp (if installed) from the bottom of the coil spring and remove the strut (damper) out through the bottom of the coil spring.
6. Remove the lower spring isolator from the strut seat.
7. Remove the dust shield.
8. Remove the upper strut mount from the top of the bearing and upper spring seat.
9. Remove the upper spring seat and isolator from the top of the coil spring.
10. Release the tension from the coil spring by backing off the compressor drive completely. Push back the compressor hooks and remove the coil spring.
11. Inspect the strut assembly components for the following and replace as necessary

1. Inspect the strut (damper) for shaft binding over the full stroke of the shaft.
2. Inspect the jounce bumper for cracks and signs of deterioration.
3. Inspect the dust shield for cracks and tears.
4. Check the upper mount for cracks and distortion and its retaining studs for any sign of damage.
5. Check the bearing and upper spring seat for any binding.
6. Inspect the upper and lower spring isolators for material deterioration and distortion.
7. Inspect the coil spring for any sign of damage to the coating.

Note. For reassembly, refer to STRUT, SUSPENSION, ASSEMBLY, ASSEMBLY .

Note. The strut retaining clip must be fully closed and the serrations fully engaged after installation.

1. Install the strut into the vehicle and install each half (1, 2) of the upper strut clip.
2. Press each side of the strut clip (1, 2) toward each other to assemble the clip. Make sure that the clip is fully closed and the serrations fully engaged after installation.
3. Install the bottom of the strut (2) into the top of the knuckle.
4. Install a NEW lower retaining bolt (1) and NEW nut and tighten to 110 N.m (81 ft. lbs.).
5. Install the axle into the knuckle.
6. Install the outer tie rod (1) into the knuckle.
7. Install the tie rod retaining nut (2) and tighten to 25 N.m Plus 80° (18 ft. lbs. Plus 80°).
8. Install the lower control arm into the knuckle and install a NEW pinch bolt and NEW nut (3) and tighten to 70 N.m (52 ft. lbs.).
9. Install the stabilizer link (2) to the knuckle and install the retaining nut (1). While holding the link stud stationary, tighten the nut to 55 N.m (41 ft. lbs.).
10. Install the wheel speed sensor (1) to the knuckle and install the retaining bolt (2) and tighten to 12 N.m (106 in. lbs.).
11. Install the disc brake caliper and adapter bracket assembly over the brake rotor and knuckle.
12. Install NEW mounting bolts (2) securing the caliper adapter bracket to the knuckle and tighten to 175 N.m (129 ft. lbs.).
13. Install the clip (1) securing the brake flex hose to the strut.
14. Install the wheel speed sensor harness to the strut. NOTE: Always install a new hub nut. The original hub nut is one-time use only and must be discarded when removed.
15. Install a NEW hub nut and while a helper applies the brakes, tighten the nut to 200 N.m (148 ft. lbs.) NOTE: Do not use air tools on staking tool while staking hub nut.
16. Using (special tool #10287, Tool, Front Hub Staking) align the leading cutting edge of tool with the top left side channel on axle as shown (1). Tighten fastener on staking tool with hand tools until the threads bottom out completely. NOTE: The hub nut must be staked so that it looks similar to see scheme 1. Both edges must be split and bent into the shape shown (3). The staking must be in the opposite direction from the forward rotation of the wheel.
17. Install tire and wheel assembly. Refer to «INSTALLATION»(ref-646212-S30999901622014072800000).
18. Perform alignment procedure. Refer to «WHEEL ALIGNMENT, STANDARD PROCEDURE»(ref-646210-S39626530632014072800000).
19. Lower the vehicle.