Front Suspension: Removal & Installation Dodge Durango II

INSTALLATION

Scheme 18

Scheme 19

Scheme 20

1. Install the hub/bearing to the steering knuckle and tighten the bolts (1) to 163 N.m (120 ft. lbs.).
2. Install the knuckle (1) onto the upper and lower ball joints.
3. Install the upper and lower ball joint nuts (3). Tighten the nut to 75 N.m (55 ft. lbs.).
4. Remove the hydraulic jack from the lower suspension arm (2).
5. Install the tie rod end and tighten the nut to 75 N.m (55 ft. lbs.).
6. Install the front halfshaft (2) into the hub/bearing 4X4 only.
7. Install the halfshaft nut and tighten to 251 N.m (185 ft. lbs.) 4X4 only.
8. Install the ABS wheel speed sensor if equipped (Refer to - «INSTALLATION»(ref-163273-S01489549022004062400000) ) and brake shield, rotor and caliper (Refer to - «INSTALLATION»(ref-212744-S13614586682005122700000) ).
9. Install the wheel and tire assembly (Refer to «STANDARD PROCEDURE»(ref-212834-S09740312592005122700000) - ).
10. Remove the support and lower the vehicle.
11. Perform a wheel alignment (Refer to «STANDARD PROCEDURE -- WHEEL ALIGNMENT»(ref-167530-S02537233552004101500000) ).

Note. Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process.

Scheme 21

1. Install the ball joint (3) into the control arm and press in using special tools C-4212-F (press) (1), 9331-1 (Receiver) (2) and 9331-3 (Driver) (4).
2. Stake the ball joint flange in four evenly spaced places around the ball joint flange, using a chisel and hammer.
3. Remove the support for the halfshaft and install into position 4X4 only.
4. Install the steering knuckle (Refer to - «INSTALLATION»(ref-212732-S07771527752005122700000) ).
5. Install the tie rod end into the steering knuckle (Refer to «INSTALLATION - OUTER TIE ROD END»(ref-212825-S00012266352005122700000) - ).
6. Install and tighten the halfshaft nut to 251 N.m (185 ft. lbs.). (If Equipped).
7. Install the brake caliper and rotor (Refer to - «INSTALLATION»(ref-212744-S13614586682005122700000) ).
8. Install the tire and wheel assembly (Refer to - «STANDARD PROCEDURE»(ref-212834-S09740312592005122700000) ).
9. Check the vehicle ride height (Refer to «RIDE HEIGHT ADJUSTMENT»(ref-167530-S18062044822004101500000) ).
10. Perform a wheel alignment (Refer to «STANDARD PROCEDURE -- WHEEL ALIGNMENT»(ref-167530-S02537233552004101500000) ).

Scheme 22

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Scheme 25

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Scheme 28

Scheme 29

1. Raise and support the vehicle.
2. Remove the wheel and tire assembly.
3. Remove the disc brake caliper assembly (2) (Refer to «CALIPER»(ref-163273-S00378099412004062400000) - ).
4. Remove the disc brake rotor (1) (Refer to - «REMOVAL»(ref-163273-S19296389592004062400000) ).
5. Disconnect the wheel speed sensor at the wheel well.
6. Disconnect the tie rod (2) from the knuckle using special tool 8677 (1) (Refer to «REMOVAL - OUTER TIE ROD END»(ref-212825-S28269917502005122700000) - ).
7. Remove the front halfshaft nut 4X4.
8. Remove the upper ball joint nut. Separate the upper ball joint (1) from the steering knuckle (3) with Remover 8677 (2).
9. Remove the lower ball joint nut. Separate the lower ball joint from the steering knuckle (1) with Remover 8677 (2).
10. Remove the steering knuckle (1).
11. Unload the torsion bar using special tool 8686 (1).
12. Remove the torsion bar (6) from the vehicle (Refer to - «REMOVAL»(ref-212732-S11740869372005122700000) ).
13. Remove the stabilizer bar link (Refer to - «REMOVAL»(ref-212732-S13358323842005122700000) ).
14. Remove the shock absorber lower bolt.
15. Remove the front and rear pivot bolts (3&4).
16. Remove the lower control arm (5) from the vehicle.

Scheme 30

Scheme 31

Scheme 32

1. Position the lower control arm (5) at the frame rail brackets. Install the pivot bolts (3) and nuts (4). Tighten the nuts finger-tight. CAUTION: The ball joint stud taper must be CLEAN and DRY before installing the knuckle. Clean the stud taper with mineral spirits to remove dirt and grease.
2. Install the steering knuckle (1).
3. Insert the lower ball joint into the steering knuckle. Install and tighten the retaining nut to 81 N.m (60 ft. lbs.).
4. Install the torsion bar (6) (Refer to - «INSTALLATION»(ref-212732-S21243514012005122700000) ).
5. Install shock absorber lower bolt and tighten to 81 N.m (60 ft. lbs.).
6. Install the front halfshaft nut 4X4.
7. Insert the upper ball joint into the steering knuckle (1). Install and tighten the retaining nut to 75 N.m (55 ft. lbs.).
8. Install the stabilizer bar link (Refer to - «INSTALLATION»(ref-212732-S33191043922005122700000) ) and tighten to 169 N.m (125 ft. lbs.).
9. Tighten the lower control arm pivot nut (4) and bolts (3) (to 244 N.m (180 ft. lbs.).
10. Insert the outer tie rod end into the steering knuckle (1). Install and tighten the retaining nut to 75 N.m (55 ft. lbs.).
11. Install the disc brake rotor (Refer to - «INSTALLATION»(ref-163273-S01489549022004062400000) ).
12. Install the disc brake caliper and adaptor assembly (2) and tighten to 135 N.m (100 ft. lbs.)(Refer to - «CALIPER»(ref-163273-S00378099412004062400000) ).
13. Install the wheel and tire assembly,(Refer to «WHEEL INSTALLATION»(ref-212834-S35188437942005122700000) - ).
14. Remove the support and lower the vehicle.
15. Adjust the front suspension height and perform a wheel alignment (Refer to «STANDARD PROCEDURE -- WHEEL ALIGNMENT»(ref-167530-S02537233552004101500000) ).

REMOVAL

Note. To service the stabilizer bar the vehicle should be on a drive on hoist. The vehicle suspension must be at curb height for stabilizer bar installation.

Scheme 33

1. Remove the stabilizer link upper nut and remove the retainers and grommets (Refer to - «REMOVAL»(ref-212732-S13358323842005122700000) ).
2. Remove the stabilizer bar retainer bolts (5) and nuts (4) also remove the retainers (5) from the frame sway bar and remove the bar (6).
3. If necessary, remove the bushings from the stabilizer bar.

Note. To service the stabilizer bar the vehicle must be on a drive on hoist. The vehicle suspension must be at curb height for stabilizer bar installation.

Scheme 34

1. If removed, install the bushings on the stabilizer bar.
2. Position the stabilizer bar (6) on the frame cross-member brackets and install the bracket and bolts (5) finger-tight. NOTE: Check the alignment of the bar to ensure there is no interference with the either frame rail or chassis component. Spacing should be equal on both sides.
3. Install the stabilizer bar (6) to the stabilizer link (7) and install the grommets and retainers.
4. Tighten the brackets to the frame and tighten to 61N.m (45 ft. lbs.).
5. Install the nuts to the stabilizer link and tighten to 169 N.m (125 ft. lbs.) (Refer to - «INSTALLATION»(ref-212732-S33191043922005122700000) ).

Scheme 35

1. Raise and support the vehicle.
2. Remove the lower nut (9).
3. Remove the upper nut, retainers and grommets from the stabilizer bar.
4. Remove the stabilizer link (7) from the vehicle.

Scheme 36

1. Install the stabilizer link (7) to the vehicle.
2. Install the retainers, grommets and upper nut to the stabilizer bar (6) and Tighten to 37 N.m (27 ft. lbs.).
3. Install the lower nut and Tighten to 169 N.m (125 ft. lbs.).
4. Remove the support and lower the vehicle.

Scheme 37

1. Raise and support the vehicle with the front suspension hanging.
2. Remove the transfer case skid plate (Refer to «REMOVAL»(ref-212818-S34930382332005122700000) ). NOTE: Count and record the number of turns for installation reference.
3. Mark the adjustment bolt setting.
4. Install Special Tool - 8686 (1) to the anchor arm (2) and the cross member (3).
5. Increase the tension on the anchor arm tool 8686 (1) until the load is removed from the adjustment bolt and the adjuster nut.
6. Turn the adjustment bolt counterclockwise to remove the bolt and the adjuster nut..
7. Remove the Special Tool - 8686 (1), allowing the torsion bar to unload.

Scheme 38

1. Insert torsion bar ends into anchor and suspension arm.
2. Position the anchor (2) in the crossmember frame (3).
3. Install Special Tool - 8686 (1) to the anchor (2) and the crossmember (3).
4. Increase the tension on the anchor in order to load the torsion bar.
5. Install the adjustment bolt and the adjuster nut.
6. Turn adjustment bolt clockwise the recorded amount of turns.
7. Remove tool - 8686 (1)from the torsion bar cross-member (3).
8. Install the transfer case skid plate (Refer to «INSTALLATION»(ref-212818-S34681251852005122700000) ).
9. Lower vehicle and adjust the front suspension height (Refer to «RIDE HEIGHT ADJUSTMENT»(ref-167530-S18062044822004101500000) ).
10. Perform a wheel alignment (Refer to «STANDARD PROCEDURE -- WHEEL ALIGNMENT»(ref-167530-S02537233552004101500000) ).

Scheme 39

1. Raise the front of the vehicle. Place safety floor stands under both lower control arms as far outboard as possible. Lower the vehicle to allow the stands to support some or all of the vehicle weight.
2. Remove the front tires.
3. Mount a dial indicator (1) solidly to the frame and then zero the dial indicator.
4. Position dial indicator plunger on the topside of the upper ball joint (5). NOTE: The dial indicator plunger must be perpendicular to the machined surface of the ball joint. NOTE: Use care not to pry or tear the ball joint boot, when checking the free play.
5. Position a pry bar (3) between the steering knuckle (4) and the upper control arm (2). Pry upwards on the upper control arm.
6. If the travel exceeds 0.5 mm (0.020 in.), replace the upper control arm since the upper ball joint is integral to the arm (Refer to - «REMOVAL»(ref-212732-S26932483772005122700000) ).
7. If the upper ball joint is within specs reinstall the front tires (Refer to - «WHEEL INSTALLATION»(ref-212834-S35188437942005122700000) ).

Scheme 40

Scheme 41

1. Raise and support vehicle.
2. Remove wheel and tire assembly.
3. Remove the nut from upper ball joint.
4. Separate upper ball joint (1) from the steering knuckle (3) with Remover 8677 (2). CAUTION: When installing Remover 8677 (2) to separate the ball joint, be careful not to damage the ball joint seal.
5. Remove the control arm pivot bolts (1&2) and remove control arm (3).

Scheme 42

1. Position the control arm (3) into the frame brackets (1&2). Install bolts and tighten to 102 N.m (75 ft. lbs.).
2. Insert ball joint in steering knuckle and tighten ball joint nut to 75 N.m (55 ft. lbs.).
3. Install the wheel and tire assembly,(Refer to - «WHEEL INSTALLATION»(ref-212834-S35188437942005122700000) ).
4. Remove the support and lower vehicle.
5. Perform a wheel alignment, (Refer to «STANDARD PROCEDURE -- WHEEL ALIGNMENT»(ref-167530-S02537233552004101500000) ).