300M, Concorde, Intrepid, LHS, 1998-2004

Shock Absorbers

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Disassembly & Assembly



The shock assembly must be removed from vehicle for it to be disassembled and assembled.


NOTE
For shock assembly disassembly and assembly, use of shock Spring Compressor, Pentastar Service Equipment (PSE) tool W-7200, or equivalent, is recommended to compress coil spring. Follow manufacturer's instructions closely.


CAUTION
Do not remove shock shaft nut before coil spring is compressed. Coil spring is held under pressure and must be compressed, removing spring tension from upper and lower mounts, before shock removal.

  1. Position shock assembly coil spring on hooks of Compressor following manufacturers instructions.
  2.  
  3. Install clamp securing shock to lower spring coil. Position Compressor upper hooks on upper coil spring following manufacturers instructions.
    NOTE
    To ease installation, rotate shock as necessary positioning shock in compressor so that upper spring coil ends (step in upper mount) at straight outward position from Compressor.

  4.  
  5. Compress coil spring until all spring tension is removed from upper mount.
  6.  
  7. Position Wrench, Special Tool 9362, on shock shaft retaining nut. Next, insert 8 mm socket though Wrench onto hex located on end of shock shaft.
  8.  
  9. While holding shock shaft from turning, remove nut from shock shaft using Wrench.
  10.  
  11. Remove clamp from bottom of coil spring and remove shock and lower isolator out through bottom of coil spring.
    NOTE
    If upper mount or coil spring needs to be serviced, proceed with next step, otherwise, proceed with step 8.

  12.  
  13. Remove upper mount from shock shaft and coil spring.
    NOTE
    Prior to removing spring from compressor, note location of lower spring coil end in relationship to compressor to ease assembly of components later.

  14.  
  15. Back off Compressor drive, releasing tension from coil spring. Push back compressor upper hooks and remove coil spring from Compressor.
  16.  
  17. Remove jounce bumper from shock shaft by pulling straight up and off.
  18.  
  19. Remove lower isolator from shock body by pulling straight up and off shock shaft.
  20.  
  21. Inspect shock assembly components for following and replace as necessary:

    Inspect shock for any condition of shaft binding over full stroke of shaft.
     
    Inspect upper mount for cracks and distortion and its retaining studs for any sign of damage.
     
    Inspect upper spring isolator for severe deterioration.
     
    Inspect lower spring isolator for severe deterioration.
     
    Inspect dust shield for tears and deterioration.
     
    Inspect coil spring for cracks in the coating and corrosion.
     
    Inspect jounce bumper for cracks and signs of deterioration.
     

  22.  

To assemble:


WARNING
Use care not to damage coil spring coating during spring assembly. Damage to coating will jeopardize its corrosion protection.


NOTE
Left and right springs must not be interchanged.


NOTE
If coil spring has been removed from spring compressor, place coil spring (part number tag end upward) in compressor lower hooks following manufacturers instructions. To ease shock reassembly, rotate coil spring around until upper coil ends at straight outward position from Compressor. Proper orientation of spring to upper mount (once installed) is necessary.

  1. Position compressor upper hooks over coil spring following manufacturers instructions.
  2.  
  3. Compress coil spring far enough to allow shock installation. If separated, install upper mount onto coil spring. Match step in upper isolator to end of spring coil.
  4.  
  5. Install lower spring isolator on shock body.
  6.  
  7. Install jounce bumper on shock shaft, small end first.
  8.  
  9. Install shock through bottom of coil spring until lower spring isolator (on shock) contacts lower end of coil spring. Match step built into isolator to lower coil end. Once in this position, stabilizer bar bracket, or clevis key on AWD models, should point straight inward toward Compressor body. If not, rotate isolator on shock body until alignment is achieved when isolator is correctly positioned with lower spring coil.
  10.  
  11. Install clamp to hold shock and coil spring together.
  12.  
  13. Install retaining nut on shock shaft as far as possible by hand. Make sure nut is installed far enough for 8 mm socket to grasp hex on end of shaft for tightening.
  14.  
  15. Install Wrench (on end of a torque wrench), Special Tool 9362, on shock shaft retaining nut.
  16.  
  17. Next, insert 8 mm socket though Wrench onto hex located on end of shock shaft.
  18.  
  19. While holding shock shaft from turning, tighten nut using Wrench to 66 ft. lbs. (90 Nm) torque.
  20.  
  21. Slowly release tension from coil spring by backing off Compressor drive fully. As tension is relieved, make sure shock components are properly in place.
  22.  
  23. Remove clamp from lower end of coil spring and shock.
  24.  
  25. Push back spring compressor upper and lower hooks, then remove shock assembly from spring compressor.
  26.  
  27. Install shock assembly on vehicle.
  28.  

Removal & Installation



2-Wheel Drive
  1. Raise and support vehicle.
  2.  
  3. Remove wheel mounting nuts, then tire and wheel assembly.
  4.  
  5. While holding link ball joint stem from rotating, remove nut fastening stabilizer link to shock clevis bracket. Slide link ball joint stem from clevis bracket.
  6.  
  7. Remove nut and pinch bolt fastening clevis bracket to bottom of shock assembly.
  8.  
  9. Remove nut and bolt attaching shock clevis bracket to lower control arm.
  10.  
  11. Pull lower end of clevis bracket outward away from lower control arm bushing, then slide it off shock assembly.
    NOTE
    It may be necessary to use an appropriate prying tool to spread clamp area of clevis bracket allowing removal from shock assembly.

  12.  
  13. Lower vehicle just enough to access upper shock assembly mounting nuts.
  14.  
  15. If equipped, remove shock tower cap from top of shock assembly.
  16.  
  17. Remove three nuts fastening shock assembly to shock tower.
  18.  
  19. Remove shock assembly from vehicle.
  20.  

To install:

  1. Guide shock assembly up into shock tower and into mounting holes.
  2.  
  3. Install three nuts fastening shock assembly to shock tower. Tighten nuts to 20 ft. lbs. (27 Nm) torque.
  4.  
  5. If equipped, align shock tower cap with shock mounting nuts and snap into place.
  6.  
  7. Raise and support vehicle.
  8.  
  9. Pull lower end of shock assembly outward, then slide clevis bracket onto lower end. Slide clevis bracket onto shock assembly until bracket contacts collar on shock housing.
  10.  
  11. Install pinch bolt and nut fastening clevis bracket to bottom of shock assembly. Install pinch bolt from rear. Do not tighten at this time.
  12.  
  13. Slide clevis bracket over bushing mounted in lower control arm.
  14.  
  15. Install bolt and nut attaching shock clevis bracket to lower control arm. Do not tighten at this time.
  16.  
  17. Tighten pinch bolt attaching clevis bracket to shock assembly to 45 ft. lbs.(61 Nm) torque.
  18.  
  19. Slide stabilizer link ball joint stem into clevis bracket. Install nut fastening link to clevis bracket.
  20.  
  21. Tighten nut by holding ball joint stud while turning nut. Tighten nut using crow foot wrench on torque wrench to 95 ft. lbs. (128 Nm) torque.
  22.  
  23. Install tire and wheel assembly.
  24.  
  25. Tighten wheel mounting nuts to 110 ft. lbs. (150 Nm) torque.
  26.  
  27. Lower vehicle.
    NOTE
    When tightening lower shock clevis mounting bolt, do not attempt rotating bolt. Bolt shaft is serrated. Turn nut only.

  28.  
  29. Tighten lower shock clevis bracket bolt nut to 128 ft. lbs. (174 Nm) torque.
  30.  

RWD
  1. If equipped, remove front shock tower cap from top of shock assembly.
  2.  
  3. Remove three nuts fastening shock assembly to shock tower.
  4.  
  5. Raise and support vehicle.
  6.  
  7. Remove wheel mounting nuts, then tire and wheel assembly.
  8.  
  9. Remove nut fastening stabilizer link to shock assembly. Slide link ball joint stem from shock assembly.
  10.  
  11. Remove bolt securing shock assembly to lower control arm.
  12.  
  13. Disconnect wheel speed sensor cable routing clip at brake tube bracket.
  14.  
  15. Loosen nut attaching upper ball joint stud to knuckle. Back nut off until nut is even with end of stud.
    NOTE
    Keeping nut on at this location will help keep end of stud from distorting while using Puller in next step.


    WARNING
    In following step, use care not to damage ball joint seal boot while sliding Puller, Special Tool 9360, into place past seal boot.

  16.  
  17. Using Puller, Special Tool 9360, separate upper ball joint stud from knuckle.
  18.  
  19. Remove nut from end of upper ball joint stud.
  20.  
  21. Tip top of knuckle outward using care not to overextend bake flex hose.
  22.  
  23. Remove shock assembly from vehicle.
  24.  

To install:

  1. Place shock assembly into front suspension using reverse direction in which it was removed.
    WARNING
    It is important to tighten nut as described in following step to avoid damaging ball stud joint.

  2.  
  3. Place upper ball joint stud through hole in top of knuckle and install nut.
  4.  
  5. Tighten nut by holding ball joint stud with a hex wrench while turning nut with a wrench.
  6.  
  7. Tighten nut using crow foot wrench on torque wrench to 35 ft. lbs. (47 Nm) + 90°turn.
  8.  
  9. Connect wheel speed sensor cable routing clip at brake tube bracket.
  10.  
  11. Install lower shock mounting bolt attaching shock assembly to lower control arm. Do not tighten bolt at this time.
  12.  
  13. Slide stabilizer link ball joint stem into shock assembly from front.
  14.  
  15. Install nut fastening link to shock assembly.
  16.  
  17. Tighten nut by holding ball joint stud while turning nut.
  18.  
  19. Tighten nut using crow foot wrench on torque wrench to 95 ft. lbs. (128 Nm) torque.
  20.  
  21. Install tire and wheel assembly.
  22.  
  23. Tighten wheel mounting nuts to 110 ft. lbs. (150 Nm) torque.
  24.  
  25. Lower vehicle. Install three nuts fastening shock assembly to shock tower.
  26.  
  27. Tighten nuts to 20 ft. lbs. (27 Nm) torque.
  28.  
  29. If equipped, align shock tower cap with shock mounting nuts and snap into place.
  30.  

 
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