REMOVAL & INSTALLATION
See Figures 1 and 2
- Raise and support the van on jackstands.
- Support the lower control arm with a floor jack.
- Remove the wheel and tire.
- If necessary, remove the caliper assembly or the brake hose bracket. Do not allow the caliper to hang by the brake hose.
- Remove the cotter pin from the upper control arm ball stud and loosen the stud nut until the bottom surface of the nut is slightly below the end of the stud.
- Install a spring compressor on the coil spring for safety.
- Loosen the upper control arm ball stud in the steering knuckle using a ball joint stud removal tool. Remove the nut from the ball stud and raise the upper arm to clear the steering knuckle.
- Remove the nuts securing the control arm shaft studs to the crossmember bracket and remove the control arm.
- Tape the shims and spacers together and tag for proper reassembly.
- Place the control arm in position and install the nuts. Before tightening the nuts, insert the caster and camber shims in the same order as when removed.
- Install the nuts securing the control arm shaft studs to the crossmember bracket. Tighten the nuts to 70 ft. lbs. (95 Nm) for 10/1500 and 20/2500 series; 105 ft. lbs. (142 Nm) for 30/3500 series on 1987-95 models and 140 ft. lbs. (190 Nm) on 1996-97 models.
- Install the ball stud nut. Tighten the nut to 90 ft. lbs. (122 Nm) for 10/1500 series 130 ft. lbs. (176 Nm) for 30/3500 series 1987-95 models and on 1996-97 models, install the ball stud nut and tighten it to 94 ft. lbs. (128 Nm) on the lower nut and 74 ft. lbs. (100 Nm) on the upper nut.
- Install the cotter pin. Never back off the nut to install the cotter pin. Always advance it.
- Install the brake caliper.
- Remove the spring compressor.
- Install the wheel and tire.
- Have the front end alignment checked, and as necessary adjusted.
CONTROL ARM BUSHING REPLACEMENT
The following special tools, or their equivalents, are necessary for this procedure: J-24435-1, J-24435-3, J-24435-4, J-24435-5 and J-24435-7.
- Remove the upper control arm as explained earlier in this Section.
- Remove the pivot shaft nuts and washers.
- Assemble tool J-24435-1. J-24435-3, and J-24435-7 on the control arm. Tighten the tool until the front bushing is forced out.
- Remove the pivot shaft.
- Use the forcing procedure to remove the rear bushing.
- Position the new front bushing in the arm and assemble tools J-24435-4, J-24435-5 and J-24435-7. Force the bushing into place until it is fully seated.
- Install the pivot shaft.
- Repeat the forcing procedure to install the rear bushing.
- Install the lower control arm.
- Install the nuts and washers. Tighten the nuts to 115 ft. lbs. (156 Nm).
- Install the control arm.
See Figure 3
- Raise and support the front end on jackstands.
- Take up the weight of the suspension with a floor jack positioned under the lower control arm as near to the ball joint as possible.
- Loosen, but do not remove, the pivot shaft-to-frame nuts.
- Tape together and matchmark each shim pack's position for exact installation.
- Install a chain over the control arm, inboard of the stabilizer bar and outboard of the shock absorber to hold the control arm close to the crossmember.
- Remove the pivot shaft nuts, bolts and spacers.
- Remove the grease fittings and unscrew the bushings from the control arm.
- Remove the pivot shaft. Discard the seals.
- Install new seals on the pivot shaft.
- Slide the shaft into the arm.
- Start the bushings into the arm and center the shaft in the bushings. Hand tighten the bushings to make sure the shaft doesn't bind.
- Tighten the bushings to 190 ft. lbs. (257 Nm).
- Check the pivot shaft for free rotation.
- Install the grease fittings and lubricate the bushings.
- Position the control arm on the frame and install the shim packs, spacers, nuts and bolts. Tighten the nuts to 105 ft. lbs. (142 Nm).
- Remove the chain and install the wheel.
- Have the alignment checked.