REMOVAL & INSTALLATION
See Figures 1, 2 and 3
- Place the steering wheel and front wheels in the centered (straight ahead) position.
Whenever the steering linkage is disconnected, the steering system must be centered prior to beginning any work.
- Raise the van and support it safely on jackstands. Place the jackstands beneath the frame at the jacking pads.
- Remove the tire and wheel assemblies, as described earlier in this section.
- Disconnect the stabilizer bar link bolt from the lower control arm.
- Remove the two bolts attaching the shock absorber to the lower arm assembly.
- Remove the upper nut and washer retaining the shock absorber and remove the shock absorber from the vehicle.
- Using spring compressor tool D78P-5310-A or equivalent, install one plate with the pivot ball seat facing downward into the coils of the spring. Rotate the plate so that it is flush with the upper surface of the lower arm.
- Install the other plate with the pivot ball seat facing upward into the coils of the spring, so that the nut rests in the upper plate.
- Insert the compression rod into the opening in the lower arm, through the upper and lower plate and upper ball nut. Insert the securing pin through the upper ball nut and compression rod. This pin can only be inserted one way into the upper ball nut because of a stepped hole design.
- With the upper ball nut secured, turn the upper plate so that it walks up the coil until it contacts the upper spring seat, then back it off 1 / 2 turn.
- Install the lower ball nut and thrust washer on the compression rod, then screw on the forcing nut. Tighten the forcing nut until the spring is compressed enough so that it is free in its seat.
- Loosen the two lower arm pivot bolts. Remove the cotter pin and loosen, but not not remove the nut attaching the lower ball joint to the spindle. Using Pitman arm puller T64P-3590-F, or equivalent, loosen the lower ball joint.
- Remove the puller tool.
- Support the lower control arm with a hydraulic jack, then remove the ball joint nut. Slowly lower the control arm and remove the coil spring.
- If the coil spring is being replaced, measure the compressed length of the old spring and mark the position of the compressor plates on the old spring with chalk. Remove the spring compressor from the old spring carefully.
- Install the spring compressor on the new spring, placing the compressor plates in the same position as marked on the old spring. Make sure the upper ball nut securing pin is installed properly, then compress the new spring to the compressed length of the old spring.
- Position the coil spring assembly into the lower control arm.
- Place a hydraulic jack under the lower control arm and slowly raise it into position. Reconnect the ball joint and install the nut. Tighten the ball joint castle nut to 80-120 ft. lbs. (108-163 Nm) and install a new cotter pin. The nut may be tightened slightly to align the cotter pin hole, but not loosened.
- Slowly release the spring compressor and remove it from the coil spring.
- Reconnect the steering center link to the Pitman arm.
- Install the shock absorber.
- Reconnect the stabilizer bar link bolt to the lower control arm. Tighten the nuts to 9-12 ft. lbs. (12-16 Nm).
- Lower the vehicle. Although this procedure should not disturb any alignment settings, anytime the front end is disassembled for service, the alignment should be checked.