LS400 1990-1997

Struts (MacPherson Struts)

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Removal & Installation



With Air Suspension

Specific to:

Lexus LS400 1993-1994

  1. Move the height control switch to OFF.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Remove the wheel.
  6.  
  7. Disconnect the upper ball joint from the steering knuckle. Suspend the knuckle with wire to prevent excessive force on the brake line and ABS speed sensor.
  8.  
  9. Remove the height control sensor link from the lower strut bracket.
  10.  
  11. Remove the strut from the lower bracket.
  12.  
  13. Disconnect the air tube from the strut.
  14.  
  15. Remove the nuts and suspension control actuator.
  16.  
  17. Remove the suspension control actuator and position it aside.
  18.  
  19. Remove the 3 upper mounting nuts and strut from the vehicle.
  20.  

To install:

  1. If disposing the strut perform the following procedure:
    1. Using a screwdriver, remove the air from inside the cylinder.
    2.  
    3. Fully extend the cylinder.
    4.  
    5. Drill a hole in the cylinder in the area shown to remove the gas inside.
      NOTE
      The gas coming out is harmless, but be careful of chips which may fly up while drilling.

    6.  

  2.  
  3. Install the strut and torque the upper mounting nuts to 27 ft. lbs. (36 Nm).
  4.  
  5. Match the rods of the strut with the holes in the suspension control actuator.
  6.  
  7. Install the suspension control actuator and tighten the bolts.
  8.  
  9. Install the suspension control actuator cover and torque the nuts to 27 ft. lbs. (36 Nm).
  10.  
  11. Install 2 new O-rings to the air tube. Install the tube and torque it to 13 ft. lbs. (17 Nm). Install the grommet.
  12.  
  13. Install the strut to the lower strut bracket and temporarily install the nut and bolt.
  14.  
  15. Connect the height control sensor link and torque a new nut to 48 inch lbs. (5 Nm).
  16.  
  17. Connect the steering knuckle to the upper ball joint. Torque the nut to 48 ft. lbs. (65 Nm) and install a new cotter pin.
  18.  
  19. Install the wheel.
  20.  
  21. Lower the vehicle.
  22.  
  23. Turn the height control switch ON.
  24.  
  25. Start the engine to fill the strut with air.
  26.  
  27. Bounce the vehicle several times to normalize the suspension.

    Click image to see an enlarged view

    Fig. Air tube O-ring installation on air suspension vehicles



    Click image to see an enlarged view

    Fig. Matching the strut rods to the suspension control actuator

  28.  
  29. Support the lower control arm with a jack.
  30.  
  31. Remove the front wheel.
  32.  
  33. Torque the lower strut mounting nut and bolt to 76 ft. lbs. (106 Nm).
  34.  
  35. Install the wheel.
  36.  
  37. Lower the vehicle.
  38.  
  39. Check the front wheel alignment.
  40.  

Specific to:

Lexus LS400 1995-1997

  1. Move the height control switch to OFF.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Remove the wheel.
  6.  
  7. Bleed the air in the suspension.
  8.  
  9. Remove the height control sensor link from the lower strut bracket.
  10.  
  11. Remove the cotter pin and nut holding the upper control arm to the steering knuckle.
  12.  
  13. Disconnect the upper ball joint from the steering knuckle. Suspend the knuckle with wire to prevent excessive force on the brake line and ABS speed sensor.
  14.  
  15. Disconnect the pneumatic cylinder from the lower bracket by removing the through-bolt.
  16.  
  17. Disconnect the air tube from the strut.
  18.  
  19. Remove the three nuts holding the actuator cover to the strut tower. Remove the actuator cover.
    CAUTION
    Do not remove the center nut from the pneumatic cylinder.

  20.  
  21. Disconnect the actuator electrical connector.
  22.  
  23. Remove the two bolts to the suspension control actuator and position the actuator aside.
  24.  
  25. Remove the three upper mounting nuts and the strut from the vehicle.
  26.  

To install:

  1. If disposing the strut perform the following procedure:
    1. Using a screwdriver, remove the air from inside the cylinder.
    2.  
    3. Fully extend the cylinder.
    4.  
    5. Drill a hole in the cylinder at a point above 1.57 in. (40mm) from the bottom of the strut assembly. This will release the gas charge in the strut. Do not puncture the pneumatic cylinder.
      NOTE
      The gas coming out is harmless, but be careful of chips which may fly up while drilling.

    6.  

  2.  
  3. Install the strut and torque the upper mounting nuts to 43 ft. lbs. (58 Nm).
  4.  
  5. Match the rods of the strut with the holes in the suspension control actuator.
  6.  
  7. Install the suspension control actuator and tighten the bolts. Torque the two nuts to 13 ft. lbs. (17 Nm).
  8.  
  9. Install the suspension control actuator cover and torque the nuts to 43 ft. lbs. (58 Nm).
  10.  
  11. Install two new O-rings to the air tube. Install the tube and torque it to 13 ft. lbs. (17 Nm). Install the grommet.
  12.  
  13. Install the strut to the lower strut bracket and temporarily install the nut and bolt.
  14.  
  15. Connect the steering knuckle to the upper ball joint. Torque the nut to 48 ft. lbs. (65 Nm) and install a new cotter pin.
  16.  
  17. Connect the height control sensor link and torque a new nut to 48 inch lbs. (5 Nm).
  18.  
  19. Install the wheel.
  20.  
  21. Lower the vehicle.
  22.  
  23. Turn the height control switch ON.
  24.  
  25. Start the engine to fill the strut with air.
  26.  
  27. Bounce the vehicle several times to normalize the suspension.
  28.  
  29. Support the lower control arm with a jack.
  30.  
  31. Remove the front wheel.
  32.  
  33. Torque the lower strut mounting nut and bolt to 76 ft. lbs. (106 Nm).
  34.  
  35. Install the wheel.
  36.  
  37. Lower the vehicle.
  38.  
  39. Check the front end alignment.
  40.  

Specific to:

Lexus LS400 1990-1992

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Move the height control switch to OFF .
  4.  
  5. Bleed the air from the suspension.
  6.  
  7. Remove or disconnect the following:
    CAUTION
    Do not remove the center nut from the pneumatic cylinder.



    Wheel
     
    Height control sensor link from the lower strut bracket.
     
    Cotter pin and nut holding the upper control arm to the steering knuckle.
     
    Upper ball joint from the steering knuckle.
     
    Pneumatic cylinder from the lower bracket by removing the through-bolt.
     
    Air tube from the strut
     
    The actuator cover.
     



    Actuator electrical connector
     
    2 bolts to the suspension control actuator and position the actuator aside.
     
    3 upper mounting nuts and the strut from the vehicle.
     

  8.  
  9. If disposing the strut perform the following procedure:
    1. Using a screwdriver, remove the air from inside the cylinder.
    2.  
    3. Fully extend the cylinder.
    4.  
    5. Drill a hole in the cylinder at a point above 1.57 in. (40mm) from the bottom of the strut assembly. This will release the gas charge in the strut. Do not puncture the pneumatic cylinder.
      CAUTION
      The gas coming out is harmless, but be careful of chips that may fly up while drilling.

    6.  

  10.  

To install:

  1. Install or connect the following:

    Strut and tighten the upper mounting nuts to 43 ft. lbs. (58 Nm).
     
    Suspension control actuator and tighten the bolts. Tighten the 2 nuts to 13 ft. lbs. (17 Nm).
     
    Suspension control actuator cover and tighten the nuts to 43 ft. lbs. (58 Nm).
     
    2 new O-rings to the air tube. Install the tube and tighten it to 13 ft. lbs. (17 Nm). Install the grommet.
     
    The strut to the lower strut bracket and temporarily install the nut and bolt.
     
    Steering knuckle to the upper ball joint. Tighten the nut to 48 ft. lbs. (65 Nm) and install a new cotter pin.
     
    Height control sensor link and tighten a new nut to 48 inch lbs. (5 Nm).
     
    Wheel
     

  2.  
  3. Turn the height control switch ON .
  4.  
  5. Start the engine to fill the strut with air.
  6.  
  7. Bounce the vehicle several times to normalize the suspension.
  8.  
  9. Support the lower control arm with a jack.
  10.  
  11. Install or connect the following:

    Front wheel
     
    Lower strut mounting nut and bolt to 76 ft. lbs. (106 Nm).
     
    Wheel
     

  12.  
  13. Check the front end alignment.
  14.  

Without Air Suspension

Specific to:

Lexus LS400 1993-1994

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the tire and wheel assembly.
  4.  
  5. Remove the steering knuckle from the upper ball joint with the proper tool. Support the steering knuckle using a piece of wire.
  6.  
  7. Disconnect the strut assembly from the lower strut bracket. Remove the plug from the upper strut mount.
  8.  
  9. Loosen the nut on the middle of the strut mount support. Do not remove it.
  10.  
  11. Remove the other 3 mounting nuts and remove the strut assembly with the coil spring from the vehicle.
  12.  
  13. Using compressor 09727-30020 or equivalent, compress the coil spring.
  14.  
  15. Remove the piston rod locknut.
  16.  
  17. Remove the suspension support, coil spring and bumper.
  18.  

To install:

  1. If disposing the strut, perform the following procedure:
    1. Fully extend the strut rod.
    2.  
    3. Drill a hole within the shaded area shown in the illustration to remove the gas inside.
      NOTE
      The gas is harmless, but be careful of chips which may fly up when drilling.

    4.  
    5. Properly dispose of the strut assembly.
    6.  

  2.  
  3. Match the bolt of the suspension support with the cut out portion of the insulator.
  4.  
  5. Install the spring bumper.
  6.  
  7. Install the compressed coil spring. Match the end of the coil into the recess of the strut spring seat.
  8.  
  9. Install the suspension support to the rod and temporarily install a new nut.
  10.  
  11. Turn the suspension support so one of the bolts on the support faces the same direction as shown in the illustration.
    NOTE
    Align the bolt so a line drawn between the rod and bolt would be at 90° to the direction of the lower bushing.

  12.  
  13. Remove the spring compressor.
  14.  
  15. Install the strut and torque the upper retaining nuts to 27 ft. lbs. (36 Nm).
  16.  
  17. Torque a new strut rod nut to 20 ft. lbs. (27 Nm) and install the cap.
  18.  
  19. Connect the strut to the lower bracket and temporarily install the nut and bolt.
  20.  
  21. Connect the upper suspension arm to the steering knuckle. Torque the nut to 48 ft. lbs. (65 Nm) and install a new cotter pin.

    Click image to see an enlarged view

    Fig. Aligning the insulator to the support-except air suspension



    Click image to see an enlarged view

    Fig. Aligning the suspension support to the strut housing-except air suspension - 1993-94 LS400

  22.  
  23. Install the wheel.
  24.  
  25. Lower the vehicle.
  26.  
  27. Bounce the vehicle several times to stabilize the suspension.
  28.  
  29. Torque the lower strut bolt and nut to 106 ft. lbs. (143 Nm).
  30.  
  31. Check the front wheel alignment.
  32.  

Specific to:

Lexus LS400 1995-1997



Click image to see an enlarged view

Fig. Exploded view of the strut and spring REMOVAL & INSTALLATION procedure - 1995-97 LS400-except air suspension

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the tire and wheel assembly.
  4.  
  5. Remove the steering knuckle from the upper ball joint with the proper tool. Support the steering knuckle using a piece of wire.
  6.  
  7. Disconnect the strut assembly from the lower strut bracket.
  8.  
  9. Remove the strut cover from the upper strut mount.
  10.  
  11. Remove the three mounting nuts and remove the strut assembly with the coil spring from the vehicle.
    CAUTION
    Do not remove the center nut to the strut at this time. The spring on the strut is under high pressure and can cause serious injury.

  12.  
  13. Using compressor 09727-30020 or equivalent, compress the coil spring.
  14.  
  15. Remove the piston rod locknut.
  16.  
  17. Remove the suspension support, coil spring and the bumper.
  18.  

To install:

  1. If disposing the strut, perform the following procedure:
    1. Fully extend the strut rod.
    2.  
    3. Drill a hole within the shaded area shown in the illustration to remove the gas inside.
      NOTE
      The gas is harmless, but be careful of chips which may fly up when drilling.

    4.  
    5. Properly dispose of the strut assembly.
    6.  

  2.  
  3. Match the bolt of the suspension support with the cut out portion of the insulator.
  4.  
  5. Install the spring bumper.
  6.  
  7. Install the compressed coil spring. Match the end of the coil into the recess of the strut spring seat.
  8.  
  9. Install the suspension support to the rod and temporarily install a new nut.
  10.  
  11. Turn the suspension support so one of the bolts on the support faces the same direction as shown in the illustration.
    NOTE
    Align the bolt so a line drawn between the rod and bolt would be at 90° to the direction of the lower bushing.

  12.  
  13. Torque the strut rod nut to 20 ft. lbs. (27 Nm) and install the cap.
  14.  
  15. Remove the spring compressor.
  16.  
  17. Install the strut and torque the upper retaining nuts to 43 ft. lbs. (58 Nm).
  18.  
  19. Connect the strut to the lower bracket and temporarily install the nut and bolt.
  20.  
  21. Connect the upper control arm to the steering knuckle. Torque the nut to 48 ft. lbs. (65 Nm) and install a new cotter pin.
  22.  
  23. Install the wheel.
  24.  
  25. Lower the vehicle.
  26.  
  27. Bounce the vehicle several times to stabilize the suspension.
  28.  
  29. Torque the lower strut bolt and nut to 116 ft. lbs. (157 Nm).
  30.  
  31. Check the front wheel alignment.
  32.  

Specific to:

Lexus LS400 1990-1992



Click image to see an enlarged view

Fig. Exploded view of the strut and spring mounting-without air suspension shown

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:
    CAUTION
    Do not remove the center nut to the strut at this time.



    Tire and wheel assembly
     
    Steering knuckle from the upper ball joint
     
    Strut assembly from the lower strut bracket
     
    Strut cover from the upper strut mount
     
    3 mounting nuts and remove the strut assembly with the coil spring from the vehicle.
     

  4.  
  5. Compress the coil spring.
  6.  
  7. Remove or disconnect the following:

    Piston rod locknut
     
    Suspension support, coil spring and the bumper
     

  8.  
  9. If disposing the strut, perform the following procedure:
    1. Fully extend the strut rod.
    2.  
    3. Drill a hole within the shaded area shown in the illustration to remove the gas inside.
      CAUTION
      The gas is harmless, but be careful of chips that may fly up when drilling.

    4.  
    5. Properly dispose of the strut assembly.
    6.  

  10.  

To install:

  1. Install or connect the following:

    Spring bumper
     
    Coil spring. Match the end of the coil into the recess of the strut spring seat.
     
    Suspension support to the rod and temporarily install a new nut.
     

  2.  
  3. Turn the suspension support so one of the bolts on the support faces the same direction as shown in the illustration.
    NOTE
    Align the bolt so a line drawn between the rod and bolt would be at 90° to the direction of the lower bushing.



    Click image to see an enlarged view

    Fig. Be sure to align the suspension support with one of the upper mounting bolts as shown-LS400 without air suspension

  4.  
  5. Tighten the strut rod nut to 20 ft. lbs. (27 Nm) and install the cap.
  6.  
  7. Remove the spring compressor
  8.  
  9. Install or connect the following:

    Strut and tighten the upper retaining nuts to 43 ft. lbs. (58 Nm).
     
    Strut to the lower bracket and temporarily install the nut and bolt.
     
    Upper control arm to the steering knuckle. Tighten the nut to 48 ft. lbs. (65 Nm) and install a new cotter pin.
     
    Wheel
     

  10.  
  11. Lower the vehicle.
  12.  
  13. Bounce the vehicle several times to stabilize the suspension.
  14.  
  15. Tighten the lower strut bolt and nut to 116 ft. lbs. (157 Nm).
  16.  
  17. Check the front wheel alignment.
  18.  

 
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