Front Suspension: Removal & Installation Dodge Intrepid II

Removal

1. Raise and support vehicle. Remove wheel and strut assembly. See «STRUT ASSEMBLY»(ref-91334-S21720616022001030800000). Position strut assembly in vise by clamping steering arm. Using paint, index mark strut unit, lower spring isolator, spring and upper strut mount. WARNING: DO NOT remove strut assembly shaft nut at any time unless coil spring has been properly compressed.
2. Position Spring Compressor (W-7200) onto spring. Ensure 5 coils of spring are between both jaws of compressor. Place clamp on lower end of coil spring to hold strut in place once strut shaft nut is removed. Compress spring until all load is removed from upper strut mount assembly. (Scheme 2)
3. Install Strut Rod Socket (6864) onto strut shaft retaining nut. Place another socket onto hex on end of strut shaft to keep shaft from turning. (Scheme 3) Loosen and remove strut shaft nut. Remove upper strut mount, seat and dust shield. Remove clamp from bottom of coil spring. Pull strut assembly from spring. (Scheme 4) Loosen spring compressor and remove from spring.

Installation

To install, reverse removal procedure. Ensure all index marks are aligned during assembly.

Scheme 2

Scheme 3

Scheme 4

1. Raise and support vehicle. Remove wheel. Remove caliper assembly. DO NOT allow caliper to hang from brake hose. Always support caliper by wiring it to frame. Remove rotor. Remove speed sensor head. If sensor has seized due to corrosion, DO NOT use pliers on sensor head. Use a hammer and punch. CAUTION: When removing hub and bearing assembly from steering knuckle, DO NOT damage flinger disc on assembly. If flinger disc becomes damaged, replace entire hub and bearing assembly.
2. Loosen and remove ABS speed sensor mounting screw. Carefully remove sensor head from steering knuckle. If sensor head is seized due to corrosion, use hammer and brass punch to tap sensor. Tap edge of sensor ear, rocking sensor from side to side until it is free. (Scheme 5) DO NOT use pliers on sensor head.
3. Remove hub and bearing retaining nut. Remove 3 bolts securing hub assembly to steering knuckle. Pull hub straight back from knuckle. If hub is corroded, pry between hub flange and knuckle. (Scheme 6) CAUTION: If metal seal on hub/bearing assembly is seized to steering knuckle and becomes dislodged during removal, replace hub/bearing. (Scheme 7)
4. Fully remove knuckle pinch bolt. Insert pry bar between lower control arm and steering knuckle. Push down on pry bar to separate ball joint stud from steering knuckle. Ensure ball joint dust boot is not damaged during removal. Loosen and remove strut-to-knuckle nuts. Bolts are serrated where installed into knuckle. DO NOT turn bolts in steering knuckle. Use soft-face hammer to drive bolts out of knuckle. Remove knuckle from vehicle.

Scheme 5

Scheme 6

Scheme 7

Note. Axle shaft nut cannot be reused. It must be replaced.

To install, reverse removal procedure. Tighten all nuts and bolts to specification. DO NOT fully tighten axle nut until vehicle is on ground. See TORQUE SPECIFICATIONS . Ensure hub mounting surfaces are clean and free of foreign material or nicks. Coat speed sensor with high temperature grease before installing onto knuckle. Check wheel alignment toe setting on the vehicle and reset if not within specification.

Note. Ball joint used in lower control arm is sealed-for-life and requires no lubrication. If ball joint is defective, replace entire lower control arm.

1. Raise and support vehicle. Remove wheels. Remove steering knuckle pinch bolt.
2. Insert pry bar between lower control arm and steering knuckle. Push down on pry bar to separate ball joint stud from steering knuckle. Ensure ball joint dust boot is not damaged during removal.
3. Remove tension rod-to-cradle attaching nut and washer from end of tension rod. Hold flat on tension rod using a wrench to keep rod from turning.
4. Remove lower control arm pivot bushing-to-cradle assembly pivot bolt. Remove lower control arm and tension rod from cradle as an assembly. Remove tension rod from lower control arm.

Bushing Replacement

1. Position lower control arm on press with large end of bushing inside Receiver (MB-990799), with lower control arm supported. (Scheme 8) Position Remover (6644-4) on top of bushing, and press bushing from lower control arm.
2. Turn lower control arm over and position it in receiver. Position lower control arm bushing square with bushing hole. Position Installer (6644-1) on bushing, with bushing in recess of tool. Press bushing in until installer bottoms on lower control arm.

Scheme 8

1. Install tension rod on lower control arm. Ensure FRONT mark on tension rod is toward front of vehicle. Install washer and NEW retaining nut on end of tension rod at control arm. Place open end wrench on flat of tension rod to keep rod from turning while tightening retaining nut to specification. See «TORQUE SPECIFICATIONS»(ref-91334-S18330328702001030800000) .
2. Install tension rod and isolator bushing end into cradle. Install lower control arm pivot bushing end into cradle bracket. Install lower control arm-to-cradle bracket attaching pivot bolt and nut, but do not tighten at this time.
3. Install washer on end of tension rod. Install NEW tension rod-to-cradle bracket nut on rod while holding rod at flat with open end wrench, and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-91334-S18330328702001030800000) . CAUTION: Pulling steering knuckle out from vehicle after releasing from ball joint can separate inner CV joint. See appropriate FWD AXLE SHAFTS article in DRIVE AXLES. CAUTION: When ball joint stud is installed into steering knuckle, DO NOT let ball joint seal hit against knuckle. If ball joint seal hits knuckle, seal damage may occur. If ball joint seal becomes torn, replace seal before assembling lower control arm and knuckle.
4. Install lower ball joint stud into steering knuckle. Install knuckle to lower ball joint stud. Install clamp bolt and nut into knuckle and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-91334-S18330328702001030800000) .
5. Install wheel and tire assembly, and torque nuts in proper sequence to half of specification. Repeat tightening sequence to full specification. See «TORQUE SPECIFICATIONS»(ref-91334-S18330328702001030800000) . Lower vehicle with weight of vehicle on suspension. Tighten lower control arm pivot bushing to cradle bracket bolt to specification.

Scheme 9

1. Support engine/transaxle assembly using Engine Support Bar (7137). Position engine support bar across engine compartment. (Scheme 9)
2. Remove the 4 strut assembly upper mount-to-strut tower mounting nut and washer assemblies securing right front strut.
3. Raise vehicle on jack stands or centered on frame contact type hoist. Remove right front wheel and tire assembly from vehicle.
4. Remove right stabilizer bar attaching link nut at strut assembly. Remove attaching link from strut assembly. Remove left stabilizer bar attaching link nut at stabilizer bar. Remove attaching link from stabilizer bar.
5. Loosen, but DO NOT remove, right outer tie rod end-to-strut arm attaching nut. Release right outer tie rod end from right strut steering arm using Puller, (C-3894A), then remove nut and tie rod from steering arm.
6. If vehicle is equipped with anti-lock brakes, remove speed sensor cable routing bracket from strut assembly. CAUTION: DO NOT turn strut-to-steering knuckle bolts. Bolts are serrated and will damage steering knuckle if rotated. Remove nuts from strut-to-steering knuckle bolts.
7. Remove 2 strut assembly-to-steering knuckle attaching bolts. Remove right front strut assembly from vehicle.
8. Remove 9 bolts securing structural collar to engine oil pan and transaxle. Remove 4 nuts attaching engine motor mounts to cradle assembly. Remove bolts attaching 2 stabilizer bushing retainers to cradle assembly. Remove stabilizer bar isolator bushing retainers and bushings from stabilizer bar.
9. Position a transmission jack under body of engine oil pan. Place wood block, as a buffer, between jack and engine oil pan. Carefully raise jack until motor mounts clear cradle assembly. While rotating stabilizer bar, remove stabilizer bar out through right wheel opening by routing it in front of right half-shaft, then behind right knuckle.

To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

1. Raise and support vehicle. Remove wheels. Disconnect stabilizer bar link from strut assembly. Loosen, but DO NOT remove, outer tie rod end-to-strut mounting nut. Remove outer tie rod end from strut using Puller (C-3894A). Remove nut and outer tie rod from strut.
2. Remove ABS speed sensor cable routing bracket from strut assembly (if equipped). Remove brake caliper, and wire aside. DO NOT allow caliper to hang by brake hose. Remove brake rotor.
3. Remove 2 strut-to-steering knuckle nuts. Remove strut-to-steering knuckle bolts. Remove 4 upper strut mounting nuts and washers. Remove strut from vehicle. Check strut for fluid leakage. Slight seepage between strut rod and strut shaft seal is not unusual and does not affect strut assembly performance.

To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS .