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Suspension System - Front: Removal & Installation Toyota 4Runner IV

Suspension Front 6 illustrations ~1166 words

REMOVAL & INSTALLATION

Note. For view of Special Tools referred to throughout the following procedures, see SPECIAL TOOLS .

Removal & Installation - With REAS

CAUTIONNever loosen the absorber hoses and the flare nuts at the joint parts.

Note. Conduct the following operations while stretching all the shock absorbers out by jacking up the vehicle.

Raise and support vehicle. Remove wheel. Remove front stabilizer bar. See STABILIZER BAR. Loosen the nut and disconnect the tube. (Scheme 8) Remove nuts and washer retaining shock absorber to bracket. Remove 3 nuts on upper side of front shock absorber. Remove shock absorber and coil spring. To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS.

Scheme 8

Scheme 8
Scheme 8

Removal & Installation - Without REAS

Remove nuts and washer retaining shock absorber to bracket. Remove 3 nuts on upper side of front shock absorber. Remove shock absorber and coil spring. To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS .

Removal

  1. Raise and support vehicle. Remove front wheel. Remove shock absorber. See «LOWER CONTROL ARM & BALL JOINT»(ref-164738-S12382148742004081600000) . Remove hub grease cap. Remove ABS speed sensor and wire harness clamp from steering knuckle. Remove brakeline bracket from steering knuckle. Remove the bolt and separate the brake tube bracket from the steering knuckle. Using Special Tool (09023-00100), disconnect the brake tube from the front disc brake caliper assembly. Remove the bolt and separate the brake tube bracket from the steering knuckle. Remove the 2 bolts and front disc brake caliper assembly. Remove rotor.
  2. On 4WD models, using a screwdriver and a hammer, remove the front axle hub grease cap. Remove the cotter pin and a lock cap. Remove the front axle hub nut. On all models, remove the nut and separate the stabilizer link assembly from the steering knuckle. Remove the cotter pin. Using Special Tool (09628-62011), separate the tie rod end sub-assembly from the steering knuckle.
  3. Remove 2 lower ball joint bolts, and disconnect lower ball joint. Remove upper ball joint, cotter pin and retaining nut. Using ball joint separator, separate upper ball joint from knuckle. On 4WD models, using a plastic hammer, separate the front axle hub from the front drive shaft. Remove the front axle hub sub-assembly. On all models, remove steering knuckle with hub.

Installation

To install, reverse removal procedure. Clean bolt threads. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS . Depress brake pedal several times. Check front wheel alignment. Ensure ABS speed sensor has a good signal.

  1. Raise and support vehicle. Remove front wheel. Remove shock absorber lower nut. Disconnect shock absorber from lower control arm. Remove 2 bolts from lower ball joint and separate from lower control arm.
  2. Mark position of both adjuster cams for reassembly reference. Remove adjuster cams and control arm. Using a ball joint separator, separate lower ball joint from lower control arm.
  1. Install lower control arm and adjuster cams. DO NOT tighten adjuster cam nuts at this time.
  2. To complete installation, reverse removal procedure. Tighten nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-164738-S34666325242004081600000) .
  3. Lower and bounce vehicle several times to stabilize suspension. Align reference marks on adjustment cams. Tighten retaining nuts to specification. See «TORQUE SPECIFICATIONS»(ref-164738-S34666325242004081600000) . Check wheel alignment. For 2003 models, see «SPECIFICATIONS & PROCEDURES»(ref-162256) article in WHEEL ALIGNMENT. For 2004 models, see «SPECIFICATIONS & PROCEDURES»(ref-162221) article in WHEEL ALIGNMENT.
  1. Remove lower control arm. See «LOWER CONTROL ARM & BALL JOINT»(ref-164738-S12382148742004081600000) . Secure lower control arm in a vise. Using a hammer and chisel, pry bushing flange up. Using a press and Bushing Remover/Installer Kit, remove bushing from lower control arm.
  2. Using a press and Bushing Remover/Installer Kit, install replacement bushings into lower control arm. Install lower control arm.
  1. Raise and support vehicle. Remove front wheels. Remove stabilizer bar links from steering knuckle. Remove stabilizer bar retaining bracket bolts, and remove stabilizer bar. Inspect ball joint stud on stabilizer bar link for smooth rotation in all directions. Replace stabilizer bar link if defective.
  2. To install, reverse removal procedure. Use NEW nuts on stabilizer bar links. Leave retaining bracket bolts loose until stabilizer bar links have been installed and tightened. Tighten nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-164738-S34666325242004081600000) .

Raise and support vehicle. Remove front wheel. Remove skid control sensor and wire harness clamp. Remove coil spring and shock absorber. See LOWER CONTROL ARM & BALL JOINT . Support steering knuckle securely. Remove upper ball joint clip and nut. Using a ball joint separator, separate upper ball joint from upper control arm. Remove upper control arm bolts and washers. Remove upper control arm.

To install, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS . Check wheel alignment. For 2003 models, see SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT. For 2004 models, see SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

  1. Remove upper control arm. See «UPPER CONTROL ARM»(ref-164738-S22962738532004081600000) . Secure upper control arm in a vise.
  2. Using a hammer and chisel, pry bushing flange up. Using a press and Bushing Remover/Installer Kit, remove bushing from upper control arm.
CAUTIONDO NOT apply oil or grease to control arm bushings.

Using Bushing Remover/Installer Kit, press NEW bushings into upper control arm. To complete installation, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS .

  1. Remove steering knuckle and hub assembly. See «HUB & STEERING KNUCKLE»(ref-164738-S17362904732004081600000). Secure steering knuckle in soft-jaw vise. On 4WD models, using a screwdriver, remove the oil seal (inside). On 2WD models, using a screwdriver, remove inner grease cap. (Scheme 9)and (Scheme 10). On 2WD models, remove lock nut. (Scheme 10) - (Scheme 12) Using a chisel and hammer, loosen the staked part of the lock nut. Using Special Tool (09318-12010), remove the lock nut.
  2. Remove the 4 bolts and axle hub from the steering knuckle. (Scheme 12) Remove the "O" ring from the axle hub. Fix the front axle hub in soft jawed vise. Using Special Tool (09710-30021, 09710-03051, 09950-40011, 09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), remove the bearing.
  3. Using a screwdriver, remove the front axle hub spacer. (Scheme 12)
  1. Using a brass bar and a hammer, install the new front axle hub spacer. (Scheme 12) Using Special Tool (09649-17010) and a press, install the new bearing to the front axle hub. (Scheme 13) Apply the MP grease to a new "O" ring. Install the new "O" ring to the axle hub. Install the dust cover, axle hub to the steering knuckle with the 4 bolts. Tighten nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-164738-S34666325242004081600000).
  2. On 2WD models, using Special Tool (09318-12010), install a new adjusting nut. (Scheme 13) Using a brass bar and a hammer, install a new knuckle grease retainer cap inner. On 4WD models, using Special Tool (09527-17011, 09950-70010, 09951-07100, 09951-01000) and a press, install a new steering knuckle oil seal. To complete installation, reverse removal procedure. Tighten nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-164738-S34666325242004081600000). Check wheel alignment. For 2003 models, see «SPECIFICATIONS & PROCEDURES»(ref-162256) article in WHEEL ALIGNMENT. For 2004 models, see «SPECIFICATIONS & PROCEDURES»(ref-162221) article in WHEEL ALIGNMENT.

Scheme 9

Scheme 9
Scheme 9

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11
Scheme 11

Scheme 12

Scheme 12
Scheme 12

Scheme 13

Scheme 13
Scheme 13

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