Front Suspension & Wheel Alignment: Other RAM Pickup 2500

CASTER

Moving the front or rear position of the lower control arm in or out, will change the caster angle and camber angle significantly. To maintain the camber angle while adjusting caster, move one pivot bolt of the lower control arm in or out. Then move the other pivot bolt of the lower control arm in the opposite direction.

To increase positive caster angle, move the rear position of the lower control arm inward (toward the engine). Move the front of the lower control arm outward (away from the engine) slightly until the desired camber angle is obtained.

CAMBER

Move both pivot bolts of the lower control arm together in or out. This will change the camber angle significantly and little effect on the caster angle.

After adjustment is made, tighten the lower control arm nuts to proper torque specification. Refer to SPECIFICATIONS .

TIE ROD BALL STUD HOUSING MISALIGNMENT CHECK

Note. This procedure describes how to check for parallel alignment of the RH and LH steering tie rod ball stud housings. It is essential to have these within +/-3 degrees of parallel to prevent ball stud durability issues.

Note. All views, left side shown in illustration, right side similar.

Scheme 74

Scheme 75

Scheme 76

1. Position the vehicle on a level surface with vehicle weight on the front tires, and place the front wheels in the straight ahead position
2. Make sure the circular bottom plane (2) of the LH and RH tie rod ball stud housings (1) are free of debris and burrs. NOTE: Measure and record the RH tie rod angle first to establish a baseline for the truck, then measure and record the LH tie rod angle using the same procedure used on the right tie rod. Measure both the RH and LH tie rod ball stud housing angles from underneath the truck using the following steps.
3. Hold the (special tool #10326-1, Adapter, Tie Rod Alignment) (2) securely under the circular bottom plane of the ball stud housing (1). Make sure the tool makes contact with the entire perimeter of the ball stud housing (1) and is not resting on the domed cap or grease fitting. NOTE: The angle on the inclinometer is POSITIVE WHEN THE NEEDLE IS FORWARD of the zero degree mark (pointing toward the front of the truck on both the LH or RH sides) and NEGATIVE WHEN AFTER the zero (pointing toward the rear of the truck). The tie rod angle readings should always be positive unless castor is significantly out of specifications.
4. Mount the (special tool #10326-2, Inclinometer) (2) on the flat bottom surface of (special tool #10326-1, Adapter, Tie Rod Alignment) (1) in the fore-aft orientation. Record the tie rod angle, then repeat steps 3, 4 on the LH tie rod end.
5. Determine the offset of the RH and LH tie rod ball stud housings by calculating the difference between the LH and RH ball stud angles. For example, if one side is +3 degrees and the other side is -4 degrees then the difference is 7 degrees. Equal to or less than 3 degree difference - no further action needs to be taken, return to the previous procedure step and continue that procedure. Over 3 degree difference with a new LH tie rod end - Loosen the LH tie rod adjustment sleeve bolts and rotate the tie rod end to adjust the ball stud housing to within 3 degrees of the RH side, then proceed with alignment or toe adjustment. Refer to «Wheel Alignment , Standard Procedure»(ref-457771-S15548608852012030200000) . Over 3 degree difference without a new LH tie rod end - Replace the LH tie rod end. Refer to «END, Tie Rod , Removal»(ref-457772-S28246462362012030200000) or «END, Tie Rod, Link and Coil , Removal»(ref-457772-S41471723292012030200000) .

Note. Any future alignment process on a recirculating ball steering systems should use this procedure.

CURB HEIGHT MEASUREMENT

The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its required curb height specification.

Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle alignment rack. The tires are to be inflated to the recommended pressure. All tires are to be the same size as standard equipment. Vehicle height is checked with the fuel tank full of fuel, and no passenger or luggage compartment load.

Inspect the vehicle for bent or weak suspension components. Compare the parts tag on the suspect coil spring(s) to the parts book and the vehicle sales code, checking for a match. Once removed from the vehicle, compare the coil spring height to a correct new or known good coil spring. The heights should vary if the suspect spring is weak.

Scheme 77

Scheme 78

1. Front - On each side of the vehicle, measure the distance from the center of the rear lower control arm bolt (1) to the ground (2) Record the measurement . Next measure the distance from the spindle center (3) to the ground (4) Record the measurement.
2. Take the two measurements and subtract them to get the curb height specification.
3. Rear - On each side of the vehicle, measure the distance from the center of the lower control arm forward bolt (2) to the ground (3) Record the measurement . Next measure the distance from the center of the rear wheel (1) to the ground (4) Record the measurement.
4. Subtract the control arm bolt to floor measurement from the wheel to floor measurement to calculate the ride height. (wheel - control arm = ride height).

CURB HEIGHT SPECIFICATIONS - FRONT

CURB HEIGHT SPECIFICATIONS - REAR, 120 WHEELBASE

CURB HEIGHT SPECIFICATIONS - REAR, 140 WHEELBASE

CURB HEIGHT MEASUREMENT (HD)

The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its required curb height specification.

Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle alignment rack. The tires are to be inflated to the recommended pressure. All tires are to be the same size as standard equipment. Vehicle height is checked with the fuel tank full of fuel, and no passenger or luggage compartment load.

Inspect the vehicle for bent or weak suspension components. Compare the parts tag on the suspect coil spring(s) to the parts book and the vehicle sales code, checking for a match. Once removed from the vehicle, compare the coil spring height to a correct new or known good coil spring. The heights should vary if the suspect spring is weak.

Scheme 79

Scheme 80

Scheme 81

1. Front 4X2 On each side of the vehicle, measure the distance from the top of the jounce bumper flange (2) to the bottom of the frame rail (1).
2. Front 4X4 On each side of the vehicle, measure the distance from the top of the axle (2) to the bottom of the jounce bumper flange (1).
3. Rear ALL - On each side of the vehicle, measure the distance at the top of the axle tube (2) to the bottom of the frame rail (1).
4. Compare the measurements to the specifications listed in the following Curb Height Specifications chart.

FRONT CURB HEIGHT SPECIFICATIONS

REAR CURB HEIGHT SPECIFICATIONS

4X2

The front suspension is designed to allow each wheel to adapt to different road surfaces independently. The wheels are mounted to hub/bearings units bolted to the steering knuckle. The double-row hub bearings are sealed and lubricated for life. The steering knuckles turn (pivot) on ball joints.

Scheme 82

The front suspension is comprised of

1. Shock Absorbers
2. Coil Spring
3. Control Arms (1 and 3)
4. Steering Knuckles (2)
5. Stabilizer Bar
6. Stabilizer Link
7. Tie Rod Ends
8. Hub/Bearing
9. Rack and Pinion
10. Ball Joints

Note. Components attached with a nut must be torqued to specification.

Note. Suspension components with rubber/urethane bushings should be tightened with the vehicle at normal ride height. It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. If springs are not at their normal ride position, vehicle ride comfort could be affected and premature bushing wear may occur.

4X4

The front suspension is designed to allow each wheel to adapt to different road surfaces independently. The wheels are mounted to hub/bearings units bolted to the steering knuckle. The double-row hub bearings are sealed and lubricated for life. The steering knuckles turn (pivot) on ball joints.

Scheme 83

The front suspension is comprised of

1. Coil over Shock absorbers (5)
2. Coil over Springs (4)
3. Control arms (1,7)
4. Steering knuckles (3)
5. Stabilizer bar (9)
6. Stabilizer link (8)
7. Tie Rod Ends (6)
8. Hub/Bearing
9. Rack and Pinion
10. Ball Joints (2)

Note. Components attached with a nut must be torqued to specification.

Note. Suspension components with rubber/urethane bushings should be tightened with the vehicle at normal ride height. It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. If springs are not at their normal ride position, vehicle ride comfort could be affected and premature bushing wear may occur.

CONTROL ARMS

The lower control arm (2) bolts in frame brackets. The frame brackets have slotted holes which allow the arms (2) to be adjusted with cam bolts (1) for caster and camber adjustment.

Scheme 84

The upper control arms (2) bolt to the upper frame brackets and pivots through bushings.

The control arms have lube for life ball studs (3). The control arm travel (jounce) is limited through the use of rubber/urethane bumpers. Rebound travel is limited by the shock absorber.

Having the suspension at curb ride height when torquing bolts ensures good ride characteristics and longer bushing life by preventing excessive "wind-up" of the bushing.

1. Install the lower control arm into place on the vehicle.
2. Install the front and rear control arm pivot bolts finger tight.
3. Install the coil spring (1) into the frame pocket. Refer to «SPRING, Front Coil , Installation»(ref-457771-S05470369002012030200000) .
4. Install the Spring Compressor (special tool #DD-1278, Compressor, Front Spring) (2) up through the lower suspension arm, coil spring and shock hole in the frame.
5. Tighten the tool nut to compress the coil spring (1).
6. Install the knuckle (1) to the control arms.
7. Position the lower ball joint into the steering knuckle.
8. Install the retaining nut on the lower ball joint and tighten to specifications. Refer to «SPECIFICATIONS»(ref-457771-S20789387792012030200000) .
9. Position the upper ball joint to the knuckle (1).
10. Install the retaining nut on the upper ball joint and tighten to specifications. Refer to «SPECIFICATIONS»(ref-457771-S20789387792012030200000) .
11. Support the lower control arm at the outboard side of the lower control arm to support vehicle weight.
12. Remove the spring compressor tool (3).
13. Install the shock absorber. Refer to «SHOCK ABSORBER, Suspension , Installation»(ref-457771-S37575475172012030200000) .
14. Install the stabilizer link. Refer to «LINK, Stabilizer Bar , Installation»(ref-457771-S04033077222012030200000) .
15. Remove the lower control arm support.
16. Install the wheel and tire assembly and lower the vehicle. Refer to «Wheels , Standard Procedure»(ref-457774-S22159730232012030200000) .
17. Lower the vehicle to the floor with vehicle weight and tighten the front and rear pivot bolts to the frame to specifications. Refer to «SPECIFICATIONS»(ref-457771-S20789387792012030200000) .
18. Perform a wheel alignment. Refer to «Wheel Alignment , Standard Procedure»(ref-457771-S15548608852012030200000) .

Scheme 85

1. Position the lower control arm (2) at the frame rail brackets. Install the pivot bolts (1) and nuts, and 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. Insert the lower ball joint stud into the steering knuckle. Install and tighten the retaining nut to specifications. Refer to «SPECIFICATIONS»(ref-457771-S20789387792012030200000) .
3. Install shock absorber lower bolt/nut (7) and tighten to specifications. Refer to «SPECIFICATIONS»(ref-457771-S20789387792012030200000) .
4. Install the stabilizer bar link lower nut (8) and tighten to specifications. Refer to «SPECIFICATIONS»(ref-457771-S20789387792012030200000) .
5. Install the front halfshaft to the axle by pushing the inner C/V (1) firmly to engage axle shaft snap ring into the inner C/V housing.
6. Clean hub bearing bore, hub bearing mating surface and half shaft splines (2) and apply a light coating of grease to the front axle shaft output splines.
7. Install half shaft (2) into the knuckle.
8. Insert the upper ball joint (4) into the steering knuckle (6).
9. Install and tighten the upper ball joint retaining nut to specifications. Refer to «SPECIFICATIONS»(ref-457771-S20789387792012030200000) .
10. Tighten the lower control arm front pivot nut and rear pivot bolt to specifications. Refer to «SPECIFICATIONS»(ref-457771-S20789387792012030200000) .
11. Install half shaft hub nut (1) and tighten to specifications. Refer to «SPECIFICATIONS»(ref-457771-S20789387792012030200000) .
12. Install the wheel and tire assembly. Refer to «Wheels , Standard Procedure»(ref-457774-S22159730232012030200000) .
13. Remove the support and lower the vehicle.
14. Perform a wheel alignment. Refer to «Wheel Alignment , Standard Procedure»(ref-457771-S15548608852012030200000) .

Scheme 86

1. Raise and support the vehicle.
2. Remove wheel and tire assembly.
3. Remove the disc brake caliper adapter with the caliper. Refer to «ADAPTER, Disc Brake Caliper , Removal»(ref-457773-S33358142482012030200000) .
4. Remove the rotor.
5. Remove the wheel speed sensor wire from the upper control arm.
6. Remove the nut from upper ball joint (4). CAUTION: When installing Remover (special tool #9360, Remover, Ball Joint) (5) to separate the ball joint, be careful not to damage the ball joint seal.
7. Separate upper ball joint (4) from the steering knuckle (6) with Ball Joint Remover (special tool #9360, Remover, Ball Joint) (5).
8. Remove the control arm pivot bolts (3) and flag nuts (2) remove control arm (1).

Scheme 87

1. Position the control arm (1) into the frame brackets. Install bolt (3) and nut (2), and tighten to specifications. Refer to «SPECIFICATIONS»(ref-457771-S20789387792012030200000) .
2. Insert the ball joint in the steering knuckle (3) and tighten the upper ball joint nut (2) to specifications. Refer to «SPECIFICATIONS»(ref-457771-S20789387792012030200000) .
3. Install the rotor to the hub.
4. Install the disc brake caliper and adapter to the knuckle. Refer to «ADAPTER, Disc Brake Caliper , Installation»(ref-457773-S04718048592012030200000) .
5. Install the wheel speed sensor wire to the upper control arm.
6. Install the wheel and tire assembly. Refer to «Wheels , Standard Procedure»(ref-457774-S22159730232012030200000) .
7. Remove the support and lower vehicle.
8. Perform a wheel alignment. Refer to «Wheel Alignment , Standard Procedure»(ref-457771-S15548608852012030200000) .

1. Raise and support the vehicle.
2. Remove the wheel and tire assembly.
3. Remove the brake caliper and rotor. Refer to «ROTOR, Brake , Removal»(ref-457773-S05897377922012030200000) .
4. Remove the ABS wheel speed sensor if equipped. Refer to «SENSOR, Wheel Speed, Front , Removal»(ref-457776-S19416339052012030200000) .
5. Remove the halfshaft nut. NOTE: Do not strike the knuckle with a hammer to remove the tie rod end or the ball joint. Damage to the steering knuckle will occur.
6. Remove the tie rod end nut and separate the tie rod from the knuckle using Ball Joint Remover (special tool #9360, Remover, Ball Joint).
7. Remove the upper ball joint nut and separate the upper ball joint from the knuckle using Ball Joint Remover (special tool #9360, Remover, Ball Joint).
8. Pull down on the steering knuckle to separate the halfshaft (2) from the hub/bearing.
9. Remove the three hub/bearing mounting bolts (1) from the steering knuckle.
10. Slide the hub/bearing out of the steering knuckle.
11. Remove the brake dust shield.

Scheme 88

1. Install the brake dust shield (2).
2. Install the hub/bearing (1) into the steering knuckle (3) and tighten the bolts (5) to specifications. Refer to «SPECIFICATIONS»(ref-457771-S20789387792012030200000) .
3. Install the brake rotor and caliper. Refer to «ROTOR, Brake , Installation»(ref-457773-S03930091312012030200000) .
4. Install the ABS wheel speed sensor (4) if equipped. Refer to «SENSOR, Wheel Speed, Front , Installation»(ref-457776-S17244010282012030200000) .
5. Install the wheel and tire assembly. Refer to «Wheels , Standard Procedure»(ref-457774-S22159730232012030200000) .
6. Remove the support and lower vehicle.

Scheme 89

1. Install the brake dust shield (2).
2. Install the hub/bearing (1) into the steering knuckle (3) and tighten the bolts to specifications. Refer to «SPECIFICATIONS»(ref-457771-S20789387792012030200000) . .
3. Install the brake rotor and caliper. Refer to «ROTOR, Brake , Installation»(ref-457773-S03930091312012030200000) .
4. Install the ABS wheel speed sensor if equipped. Refer to «SENSOR, Wheel Speed, Front , Installation»(ref-457776-S17244010282012030200000) .
5. Install the upper ball joint nut to the steering knuckle and tighten to specifications. Refer to «SPECIFICATIONS»(ref-457771-S20789387792012030200000) .
6. Install the tie rod end nut to the steering knuckle and tighten to specifications. Refer to «SPECIFICATIONS»(ref-457771-S20789387792012030200000) .
7. Install the halfshaft nut and tighten to specifications. Refer to «SPECIFICATIONS»(ref-457771-S20789387792012030200000) .
8. Install the wheel and tire assembly. Refer to «Wheels , Standard Procedure»(ref-457774-S22159730232012030200000) .
9. Remove the support and lower vehicle.

Note. Upper shock nut must be replaced or use Mopar Lock 'N Seal or Loctite R 242 on existing nut.

1. Install the lower retainer and grommet on the shock absorber stud. Insert the shock absorber through the frame bracket hole.
2. Install the lower bolts and tighten the bolts to specifications. Refer to «SPECIFICATIONS»(ref-457771-S20789387792012030200000) .
3. Install the upper grommet, retainer (2) and new nut or use Mopar Lock 'N Seal or Loctite R 242 on existing nut, on the shock absorber stud. Using Strut Nut Wrench (special tool #9362, Wrench, Strut Nut) (1), tighten nut to specifications. Refer to «SPECIFICATIONS»(ref-457771-S20789387792012030200000) .
4. Remove the support from the lower control arm outboard end.
5. Remove the support and lower the vehicle.

4X4-COIL OVER

Note. All suspension components should be tighten with the weight of the vehicle on them (curb height).

1. Install the shock (1) back in place in the vehicle.
2. Install the upper part of the shock (2) into the frame bracket (3).
3. Install the upper nuts (1) and tighten to specifications. Refer to «SPECIFICATIONS»(ref-457771-S20789387792012030200000) .
4. Install the lower part of the shock (5) into the lower control arm shock bushing (7).
5. Install and position bolt (6) so head of bolt is facing rearward of vehicle and hand start nut. Tighten the bolt (6) and nut to specifications. Refer to «SPECIFICATIONS»(ref-457771-S20789387792012030200000) .
6. Install the upper ball joint to the knuckle and install the retaining nut and tighten to specifications. Refer to «SPECIFICATIONS»(ref-457771-S20789387792012030200000) .
7. Install the axle hub nut and tighten to specifications. Refer to «SPECIFICATIONS»(ref-457771-S20789387792012030200000) .
8. Install the stabilizer link lower nut and tighten to specifications. Refer to «SPECIFICATIONS»(ref-457771-S20789387792012030200000) .
9. Reconnect the wheel speed sensor wiring to the knuckle and upper control arm.
10. Install the rotor. Refer to «ROTOR, Brake , Installation»(ref-457773-S03930091312012030200000) .
11. Install the caliper adapter with the caliper. Refer to «ADAPTER, Disc Brake Caliper , Installation»(ref-457773-S04718048592012030200000) .
12. Remove the support from the lower control arm outboard end.
13. Install the tire and wheel assembly. Refer to «Wheels , Standard Procedure»(ref-457774-S22159730232012030200000) .
14. Remove the support and lower the vehicle.

Scheme 90

1. Raise and support vehicle. Refer to «Hoisting , Standard Procedure»(ref-457775-S03796115192012030200000) .
2. Remove the front wheel and tire assembly.
3. Support the lower control arm (4) at the outboard side of the lower control arm to support vehicle weight.
4. Remove the shock absorber (5). Refer to «SHOCK ABSORBER, Suspension , Removal»(ref-457771-S25413292092012030200000) .
5. Install Front Spring Compressor (special tool #DD-1278, Compressor, Front Spring) (3) up through the lower suspension arm, coil spring and shock hole in the frame. The bell-shaped adapter (3) goes against the lower suspension arm. Install the nut on top of the tool at the shock hole.
6. Tighten the spring compressor nut against bell-shaped adapter finger tight then loosen 1/2 turn. NOTE: This will hold the spring in place until the lower suspension arm is separated from the steering knuckle.
7. Remove the steering knuckle. Refer to «KNUCKLE, Steering , Removal»(ref-457771-S26010942512012030200000) .
8. Remove the stabilizer link. Refer to «LINK, Stabilizer Bar , Removal»(ref-457771-S04875923992012030200000) .
9. Remove the lower control arm support.
10. Tighten the spring compressor tool (2) to collapse the coil spring. NOTE: It may necessary to loosen the control arm pivot bolt to allow downward swing.
11. Loosen the tension on the spring compressor tool (2) slowly allowing the lower suspension arm to pivot downward.
12. Remove the spring compressor tool (2).
13. Remove coil spring (1) and isolator pad from the vehicle.

Scheme 91

Scheme 92

Scheme 93

1. Remove the shock (1). Refer to «SHOCK ABSORBER, Suspension , Removal»(ref-457771-S25413292092012030200000) .
2. Install the shock assembly (3) in the Branick 7200 R spring removal/installation tool or equivalent (1).
3. Compress the spring (2).
4. Position Strut Nut Wrench (special tool #9362, Wrench, Strut Nut) (1), on shock shaft retaining nut. Next, insert 8 mm socket though Wrench onto hex located on end of shock shaft. While holding shock shaft from turning, remove nut from shock shaft using Wrench (1).
5. Remove the upper shock nut.
6. Remove the shock upper mounting plate.
7. Remove the dust cover.
8. Remove and inspect the upper spring isolator (2).
9. Remove the shock.

1. Tape the isolator pad to the top of the coil spring. Position the spring in the lower suspension arm well. Be sure that the coil spring is seated in the well.
2. Install Front Spring Compressor (special tool #DD-1278, Compressor, Front Spring) (2) up through the lower suspension arm, coil spring and shock hole in the frame.
3. Tighten the tool nut to compress the coil spring.
4. Install the steering knuckle. Refer to «KNUCKLE, Steering , Installation»(ref-457771-S32131093912012030200000) .
5. Install the retaining nut on the upper ball joint and tighten to specifications. Refer to «SPECIFICATIONS»(ref-457771-S20789387792012030200000) .
6. Remove the spring compressor tool.
7. Support the lower control arm at the outboard side of the lower control arm to support vehicle weight.
8. Install the shock absorber. Refer to «SHOCK ABSORBER, Suspension , Installation»(ref-457771-S37575475172012030200000) .
9. Install the stabilizer link. Refer to «LINK, Stabilizer Bar , Installation»(ref-457771-S04033077222012030200000) .
10. Remove the lower control arm support.
11. Install the wheel and tire assembly. Refer to «Wheels , Standard Procedure»(ref-457774-S22159730232012030200000) .
12. Remove the support and lower the vehicle to the floor with vehicle weight. Tighten the front and rear control arm frame pivot bolts if loosened to specifications. Refer to «SPECIFICATIONS»(ref-457771-S20789387792012030200000) .
13. Perform a wheel alignment. Refer to «Wheel Alignment , Standard Procedure»(ref-457771-S15548608852012030200000) .

1. Position the shock (1) into the coil spring (3).
2. Install the upper isolator (2).
3. Install the dust cover.
4. Install the upper shock mounting plate (2).
5. Install the shock upper mounting nut.
6. Install Strut Nut Wrench (special tool #9362, Wrench, Strut Nut) (1) (on end of a torque wrench), on shock shaft retaining nut. Next, insert 8 mm socket though Wrench onto hex located on end of shock shaft. While holding shock shaft from turning, tighten nut to specifications. Refer to «SPECIFICATIONS»(ref-457771-S20789387792012030200000) .
7. Decompress the spring (2).
8. Remove the shock assembly from the spring compressor tool (1).
9. Install the shock assembly (1). Refer to «SHOCK ABSORBER, Suspension , Installation»(ref-457771-S37575475172012030200000) .

Scheme 94

The stabilizer bar (4) extends across the front underside of the chassis and connects to the frame crossmember. The ends of the bar mount to the stabilizer links (2), The stabilizer links (2) are then connected to the lower control arms (5). All mounting points of the stabilizer bar (4) are isolated by bushings.

RIGHT

Note. Discard the nuts and bolts and do not reuse. New nuts and bolts should be used when replacing or servicing the control arms.

1. Position the upper control arm (2) at the axle and frame rail.
2. Install the bolts, then finger tighten the nuts (1).
3. Tighten nut at the axle bracket and frame bracket to specifications. Refer to «SPECIFICATIONS»(ref-457771-S11676084182012030200000) .
4. Remove the support for the axle.
5. Install the exhaust system back into place.
6. Reconnect the rubber exhaust mounts.
7. Reconnect the exhaust (2) at the manifold(s) (1).
8. Reconnect the exhaust bracket (4) at the transmission.
9. Remove the supports and lower the vehicle.

4500 AND 5500

Note. The upper ball joints screw in and out (they are not pressed in).

Scheme 95

Scheme 96

1. Remove the wheel and tire assembly.
2. Support the lower part of the steering knuckle.
3. Remove the upper ball joint nut (1).
4. Disconnect the wheel speed sensor wire from the bracket (3).
5. Install a 60 mm socket (1) and unscrew the upper ball joint (2) from the steering knuckle.
6. Remove the wheels speed sensor wire bracket (3).

Scheme 97

1. Position Remover/ Installer (special tool #8445-2, Installer, Cup) (DRIVER) (2) and Ball Joint Remover/Installer (special tool #8975-5, Receiver, Ball Joint) (RECEIVER) (5) with Ball Joint Press (special tool #C-4212F, Press, Ball Joint) (1) as shown in illustration to install upper ball stud (3).
2. Install the axle shaft into the axle. Refer to appropriate DRIVELINE/AXLES article.
3. Install the steering knuckle. Refer to «KNUCKLE, Steering , Installation»(ref-457771-S37549024682012030200000) .

1. Install the wheel speed sensor bracket (3) to the upper ball joint (2).
2. Screw the upper ball joint (2) into the steering knuckle and tighten to specifications. Refer to «SPECIFICATIONS»(ref-457771-S11676084182012030200000) .
3. Reconnect the wheel speed sensor wire into the bracket (3).
4. Install the upper ball joint mounting nut and tighten to specifications. Refer to «SPECIFICATIONS»(ref-457771-S11676084182012030200000) .
5. Remove the support from the steering knuckle.
6. Install the tire and wheel assembly.

Scheme 98

Scheme 99

1. Raise and support the vehicle.
2. Remove the wheel and tire assembly.
3. Remove the hub extension (1) mounting nuts and remove the extension from the rotor if equipped.
4. Remove the brake caliper. Refer to «CALIPER, Disc Brake , Removal»(ref-457773-S34405021932012030200000) .
5. Remove the cotter pin (2) and the hub nut (1) from the axle shaft.
6. Remove the caliper adapter. Refer to «ADAPTER, Disc Brake Caliper , Removal»(ref-457773-S33358142482012030200000) .
7. Remove the disc brake rotor. Refer to «ROTOR, Brake , Removal»(ref-457773-S05897377922012030200000) .
8. Disconnect the wheel speed sensor wire.
9. Remove the hub/bearing 4 mounting bolts and remove the hub/bearing.

Scheme 100

Scheme 101

Scheme 102

1. Raise and support the vehicle.
2. Remove the wheel and tire assembly.
3. Remove the brake caliper. Refer to «CALIPER, Disc Brake , Removal»(ref-457773-S34405021932012030200000) .
4. Remove the caliper adapter. Refer to «ADAPTER, Disc Brake Caliper , Removal»(ref-457773-S33358142482012030200000) .
5. Remove the hub extension (2) and disc brake rotor (1). Refer to «ROTOR, Brake , Removal»(ref-457773-S05897377922012030200000) .
6. Remove the axle shaft nut (3) from the axle shaft.
7. Disconnect the wheel speed sensor wire and remove the wheel speed sensor bolt (1) from the hub/bearing then remove the sensor (2).
8. Remove the hub/bearing 4 mounting bolts (1) and remove the hub/bearing.

Scheme 103

1. Position the brake shield (1) on bolts.
2. Install the hub/bearing to the knuckle and tighten the hub/bearing bolts (2) to specifications. Refer to «SPECIFICATIONS»(ref-457771-S11676084182012030200000) .
3. Install the hub nut and tighten to specifications. Refer to «SPECIFICATIONS»(ref-457771-S11676084182012030200000) .
4. Install the wheel speed sensor to the hub. Refer to «SENSOR, Wheel Speed, Front , Installation»(ref-457776-S17244010282012030200000) .
5. Install the disc brake rotor. Refer to «ROTOR, Brake , Installation»(ref-457773-S03930091312012030200000) .
6. Install the brake caliper adapter with the caliper. Refer to «ADAPTER, Disc Brake Caliper , Installation»(ref-457773-S04718048592012030200000) .
7. If equipped, install the hub extension and nuts to the front rotor and tighten nuts to specifications. Refer to «SPECIFICATIONS»(ref-457771-S11676084182012030200000) .
8. Install the wheel and tire assemblies. Refer to «Wheels , Standard Procedure»(ref-457774-S22159730232012030200000) .
9. Remove the support and lower the vehicle.
10. Apply the brakes several times to seat the brake shoes and caliper piston. Do not move the vehicle until a firm brake pedal is obtained.

Note. If installing a NEW hub/bearing on a 4X4 only Steps 1 - 3 should be followed for the correct shim size.

Scheme 104

Scheme 105

1. Measure from the new hub/bearing unit crimp (2) to the flange (3).
2. Choose the correct shim according to the table: HUB MEASURED 29.50 to 29.83 mm (1.16 to 1.17 in) 29,84 to 30,18 (1.17 to 1.18 in) 30,19 to 30,53 (1.18 to 1.20 in) 30,54 to 30,88 (1.20 to 1.21 in) 30,89 to 31,23 (1.21 to 1.22 in) 31,24 to 31,50 (1.22 to 1.23 in) SHIM THICKNESS 7.00 mm (0.27 in) 6.65 (0.26 in) 6.30 (0.24 in) 5.95 (0.23 in) 5.60 (0.22 in) 5.25 (0.20 in)
3. Check the shim (2) on the axle shaft (3). Be sure that the shim (2) is placed with the radius side (1) to the joint.
4. Install the hub/bearing to the knuckle and tighten the hub/bearing bolts (1) to specifications. Refer to «SPECIFICATIONS»(ref-457771-S11676084182012030200000) .
5. Install the axle nut (3) and tighten to specifications. Refer to «SPECIFICATIONS»(ref-457771-S11676084182012030200000) .
6. Install the wheel speed sensor 2) to the hub and tighten the bolt (1). Refer to «SENSOR, Wheel Speed, Front , Installation»(ref-457776-S17244010282012030200000) .
7. Install the disc brake rotor (1). Refer to «ROTOR, Brake , Installation»(ref-457773-S03930091312012030200000) .
8. Install the hub extension (2) and nuts to the front rotor and tighten nuts to specifications. Refer to «SPECIFICATIONS»(ref-457771-S11676084182012030200000) .
9. Install the brake caliper adapter with the caliper. Refer to «ADAPTER, Disc Brake Caliper , Installation»(ref-457773-S04718048592012030200000) .
10. Install the wheel and tire assemblies. Refer to «Wheels , Standard Procedure»(ref-457774-S22159730232012030200000) .
11. Remove the support and lower the vehicle.
12. Apply the brakes several times to seat the brake shoes and caliper piston. Do not move the vehicle until a firm brake pedal is obtained.

Scheme 106

1. Remove the hub bearing. Refer to «HUB AND BEARING , Removal»(ref-457771-S06073901972012030200000) .
2. Remove tie-rod or drag link end from the steering knuckle arm.
3. Remove the wheel speed sensor. Refer to «SENSOR, Wheel Speed, Front , Removal»(ref-457776-S19416339052012030200000) .
4. Loosen the upper ball stud nut. Do not remove the nut at this time.
5. Remove the lower ball joint nut.
6. Separate the lower ball joint (4) using Ball Joint Press (special tool #C-4150A, Press, Ball Joint) (3).
7. Remove the upper ball joint nut.
8. Remove the steering knuckle (2).

Scheme 107

Scheme 108

Scheme 109

Scheme 110

Scheme 111

1. Remove tie-rod or drag link end from the steering knuckle arm.
2. Remove the disc brake caliper bolts (1) and the disc brake caliper (2).
3. Remove the disc brake caliper adapter bolts (1) and remove the adapter (2).
4. Remove the disc brake rotor (1) and the hub extension (2).
5. Remove the wheel speed sensor (2). Refer to «SENSOR, Wheel Speed, Front , Removal»(ref-457776-S19416339052012030200000) .
6. Remove the hub bearing bolts (1) and the hub/bearing. Refer to «HUB AND BEARING , Removal»(ref-457771-S06073901972012030200000) .
7. Remove the axle shaft nut (3) if equipped.
8. Remove the upper ball stud nut (1).
9. Remove the upper ball joint (2). Refer to «BALL JOINT, Suspension, Upper , Removal»(ref-457771-S37471480852012030200000) .
10. Remove the lower ball joint nut (3).
11. Separate the lower ball joint (3) from the knuckle (2) using special tool (special tool #8677, Remover, Ball Joint) separator (4).
12. Remove the steering knuckle (2).
13. Remove the dust shield (2) from the knuckle if needed.

2500, 3500

1. Position the steering knuckle on the ball studs.
2. Install and tighten lower ball stud nut to initial torque specifications. Refer to «SPECIFICATIONS»(ref-457771-S11676084182012030200000) .
3. Install and tighten upper ball stud nut to specifications. Refer to «SPECIFICATIONS»(ref-457771-S11676084182012030200000) .
4. Re-torque lower ball stud nut to final torque specifications. Refer to «SPECIFICATIONS»(ref-457771-S11676084182012030200000) .
5. Install the hub bearing. Refer to «HUB AND BEARING , Installation»(ref-457771-S27188599192012030200000) .
6. Install tie-rod or drag link end onto the steering knuckle arm and tighten to specifications. Refer to «SPECIFICATIONS»(ref-457771-S11676084182012030200000) .
7. Install the wheel speed sensor. Refer to «SENSOR, Wheel Speed, Front , Installation»(ref-457776-S17244010282012030200000) .

1. Position the steering knuckle (1) on the ball stud.
2. Install and tighten the lower ball stud nut (3) to specifications. Refer to «SPECIFICATIONS»(ref-457771-S11676084182012030200000) . NOTE: Make sure the wheel speed sensor bracket (3) for the wire is installed between the knuckle and ball joint (2).
3. Install the upper ball joint (2) into the steering knuckle and tighten to specifications. Refer to «SPECIFICATIONS»(ref-457771-S11676084182012030200000) .
4. Install and tighten the upper ball stud nut (1) to specifications. Refer to «SPECIFICATIONS»(ref-457771-S11676084182012030200000) .
5. Retorque the lower ball stud nut to specifications. Refer to «SPECIFICATIONS»(ref-457771-S11676084182012030200000) .
6. Install the hub bearing and tighten the bolts (1) to specifications. Refer to «SPECIFICATIONS»(ref-457771-S11676084182012030200000) .
7. Install the wheel speed sensor (2). Refer to «SENSOR, Wheel Speed, Front , Installation»(ref-457776-S17244010282012030200000) .
8. Install the dust shield (2) if removed.
9. Install the disc brake rotor (1) and extension (2) to the hub/bearing.
10. Install the disc brake caliper adapter (2) and bolts (1).
11. Install the disc brake caliper (2) and tighten the bolts (1).
12. Install tie-rod or drag link end onto the steering knuckle arm.

Scheme 112

Scheme 113

1. Raise and support the vehicle.
2. Hold the stabilizer link (5) shafts with a wrench and remove the link nuts at the stabilizer bar (3).
3. Remove the retainers (1) and grommets (2) from the stabilizer bar links (5). 1 - PULLER 2 - LINK
4. Remove the stabilizer bar link nuts from the axle brackets.
5. Remove the links (2) from the axle brackets with Puller (special tool #C-3894-A, Puller, Tie Rod) (1). (Scheme 105)

Scheme 114

Scheme 115

1. Raise and support the vehicle.
2. Hold the stabilizer link (1) shafts with a wrench and remove the link nuts (3) at the stabilizer bar (2).
3. Remove the stabilizer bar link nuts from the axle brackets (2).
4. Remove the links (1) from the axle brackets (2) with Puller (special tool #9360, Remover, Ball Joint) (3) .

STANDARD LINK

1. Install links (5) to the axle bracket (4) and tighten nut to specifications. Refer to «SPECIFICATIONS»(ref-457771-S11676084182012030200000) .
2. Install links (5), retainers (1), grommets (2) and nuts to the stabilizer bar. Hold the link shaft with a wrench and tighten the nuts to specifications. Refer to «SPECIFICATIONS»(ref-457771-S11676084182012030200000) .
3. Remove the supports and lower the vehicle.

WITH DISCONNECTING STABILIZER BAR

1. Install links (1) to the axle bracket (5) and tighten nut (4) to specifications. Refer to «SPECIFICATIONS»(ref-457771-S11676084182012030200000) .
2. Install links (1) and nuts (3) to the stabilizer bar (2). Hold the link shaft with a wrench and tighten the nuts to specifications. Refer to «SPECIFICATIONS»(ref-457771-S11676084182012030200000) .
3. Remove the supports and lower the vehicle.

Scheme 116

A knocking or rattling noise from a shock absorber (5) may be caused by movement between mounting grommets (1AND6) and metal brackets (3) or attaching components. These noises can usually be stopped by tightening the attaching nuts. If the noise persists, inspect for damaged and worn bushings, and attaching components. Repair as necessary if any of these conditions exist.

A squeaking noise from the shock absorber may be caused by the hydraulic valving and may be intermittent. This condition is not repairable and the shock absorber must be replaced.

The shock absorbers are not refillable or adjustable. If a malfunction occurs, the shock absorber must be replaced. To test a shock absorber, hold it in an upright position and force the piston in and out of the cylinder four or five times. The action throughout each stroke should be smooth and even.

The shock absorber bushings do not require any type of lubrication. Do not attempt to stop bushing noise by lubricating them. Grease and mineral oil-base lubricants will deteriorate the bushing.

Scheme 117

Scheme 118

1. Remove the nut, retainer (4) and grommet (1) from the upper stud in the engine compartment.
2. Remove three nuts from the upper shock bracket (3). (Scheme 107)
3. Remove the lower bolt (4) from the axle bracket. (Scheme 108) Remove the shock absorber (1) from engine compartment.

Scheme 119

Scheme 120

1. Position the lower retainer (4) and grommet (6) on the upper stud. Insert the shock absorber (5) through the spring from engine compartment. 1 - SHOCK 2 - SPRING 3 - FLAG NUT 4 - SHOCK BOLT
2. Install the lower bolt (4) and tighten to specifications. Refer to «SPECIFICATIONS»(ref-457771-S11676084182012030200000) . 1 - GROMMET 2 - RETAINER 3 - BRACKET 4 - RETAINER 5 - SHOCK 6 - GROMMET
3. Install the upper shock bracket (3) and three nuts and tighten nuts to specifications. Refer to «SPECIFICATIONS»(ref-457771-S11676084182012030200000) .
4. Install upper grommet (1) and retainer (2). Install upper shock nut and tighten to specifications. Refer to «SPECIFICATIONS»(ref-457771-S11676084182012030200000) .

STABILIZER BAR

The bar extends across the front underside of the chassis and connects to the frame crossmember. The ends of the bar mount to the lower suspension arm. All mounting points of the stabilizer bar are isolated by bushings.

Scheme 121

Note. The stabilizer links (5), stabilizer bar retainers/bushings (3), stabilizer bar with the disconnecting unit as an assembly (4) and the stabilizer bar actuator (1) are the only are serviceable components.

Note. When replacing the disconnecting stabilizer bar with a new bar you must use a scan tool to program the new stabilizer bar to the vehicle.

This system allows greater front suspension travel in off-road situations. It consists of a disconnecting unit (2), electronic actuator (1), stabilizer bar (4), stabilizer bar mounting retainers (3), stabilizer links (5) and a anti-rotational bracket (6) connected to the stabilizer bar retainer (3).

Scheme 122

The electronic disconnecting stabilizer bar is operated by a combined transfer case and disconnecting stabilizer switch on the dash: The 2 mode positions are: On-Road mode (1), and Off-Road mode (2). The electronic disconnecting stabilizer bar is designed to be driven in On-Road mode (1) (indicated by a solid on-road mode light) for normal street and highway conditions (dry hard surfaced roads).

To service the switch, remove the Instrument panel center bezel. Refer to BEZEL, Instrument Panel, Center , Removal and BEZEL, Instrument Panel, Driver Side , Removal .

The stabilizer bar is used to minimize vehicle front sway during turns. The bar helps to maintain a flat attitude to the road surface.

DISCONNECTING STABILIZER BAR

Note. The off-road mode(2) is intended for use at low speed only and is equipped with a vehicle speed sensor. When in off-road mode, if the vehicle speed exceeds 18 MPH, the system will return to on-road mode (indicated by a flashing off-road mode light). If vehicle speed is reduced to 14 MPH, the system will once again return to off-road mode (indicated by a solid off-road mode light).

When in a severe off-road situation, the stabilizer bar may be placed into off-road mode to increase maneuverability. To engage the off-road mode, place the vehicle in 4WD HI or LO, and depress the Stabilizer Bar Control Switch for off-road mode (2). The off-road mode indicator light will flash until mode has been fully engaged, indicated by a solid light.

To disengage off-road mode, depress the Stabilizer Bar Control Switch for on-road mode (1). The on-road mode indicator light will flash until mode has been fully engaged, indicated by a solid light.

1. Raise and support the vehicle.
2. Hold the stabilizer link (5) shafts with a wrench and remove the link nuts at the stabilizer bar (3).
3. Remove the retainers (1) and grommets (2) from the stabilizer bar links (5).
4. Remove the stabilizer bar clamps from the frame rails and remove the stabilizer bar.

Note. The stabilizer links (5), stabilizer bar retainers/bushings (3), stabilizer bar with the disconnecting unit as an assembly (4) and the stabilizer bar actuator (1) are the only are serviceable components.

Note. When replacing the disconnecting stabilizer bar with a new bar you must use a scan tool to program the new stabilizer bar to the vehicle.

Scheme 123

Scheme 124

1. Raise and support the vehicle.
2. Hold the stabilizer link (1) shafts with a wrench and remove the link nuts (3) at the stabilizer bar (2). NOTE: Before removing the connector (4) from the actuator clean the outside of the connector with a cleaner and compressed air, to remove any dirt or debris.
3. Disconnect the electronic actuator electrical connector (4) for the disconnecting stabilizer bar (5).
4. Remove the 3 bolts securing the disconnecting stabilizer actuator If replacing the stabilizer bar , refer to «ACTUATOR, Stabilizer Bar , Removal»(ref-457771-S06811486922012030200000) .
5. Remove the stabilizer bar retainers (1) from the frame rails and remove the stabilizer bar (4).

STANDARD STABILIZER BAR

1. Position the stabilizer bar on the frame rail and install the clamps and bolts. Ensure the bar is centered with equal spacing on both sides.
2. Tighten the clamp bolts to specifications. Refer to «SPECIFICATIONS»(ref-457771-S11676084182012030200000) .
3. Install links (5), retainers (1), grommets (2) and nuts to the stabilizer bar (3). Hold the link shaft with a wrench and tighten the nuts to specifications. Refer to «SPECIFICATIONS»(ref-457771-S11676084182012030200000) .
4. Remove the supports and lower the vehicle.

Note. The stabilizer links (3), stabilizer bar retainers/bushings (1), stabilizer bar with the disconnecting unit as an assembly (4) and the stabilizer bar actuator are the only are serviceable components.

Note. When replacing the disconnecting stabilizer bar with a new bar you must use a scan tool to program the new stabilizer bar to the vehicle.

1. Position the stabilizer bar (4) on the frame rail and install the retainers with bushings and bolts (1). Ensure the bar is centered with equal spacing on both sides.
2. Tighten the retainer bolts (1) to specifications. Refer to «SPECIFICATIONS»(ref-457771-S11676084182012030200000) . NOTE: The seal must be clean and intact in the electrical connector when reconnecting to the actuator.
3. If the actuator was removed , install the actuator (4) to the disconnecting unit (3). Refer to «ACTUATOR, Stabilizer Bar , Installation»(ref-457771-S13661285902012030200000) .
4. Reconnect the electronic actuator electrical connector for the disconnecting stabilizer bar (5).
5. Install links (1) and nuts (3) to the stabilizer bar (2). Hold the link shaft with a wrench and tighten the nuts to specifications. Refer to «SPECIFICATIONS»(ref-457771-S11676084182012030200000) .
6. Remove the supports and lower the vehicle.
7. Using a scan tool program the new stabilizer bar to the vehicle.

Scheme 125

1. Raise and support the axle.
2. Remove the track bar bolts (2) and nuts (3). see scheme 173
3. Remove the track bar (1). see scheme 173

Scheme 126

1. Install the track bar (1).
2. Install the new bolts (2) and nuts (3) and torque to specifications. Refer to «SPECIFICATIONS»(ref-457771-S11676084182012030200000) .
3. Remove the supports under the axle and lower the vehicle to the ground.