S&T Series Blazer, Bravada, Envoy, Jimmy, Rainier, Trailblazer, Xtreme

Front Suspension

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Coil Springs



Removal & Installation
2001 2wd Vehicles
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Wheel
     
    Shock absorber lower bolts
     

  4.  
  5. Push the shock absorber through the control arm and into the spring.
  6.  
  7. With the vehicle supported so the control arms hang free, install tool J-23028, onto a support and into the lower control arm bushings.

    Stabilizer bar from the control arm
     
    Stabilizer from the lower control arm
     

  8.  
  9. Raise and remove the tension on the lower control arm bolts.
  10.  
  11. Install a safety chain around the spring and through the lower control arm.

    Lower control arm pivot bolts, the rear first
     
    Lower control arm and allow it to hang free
     
    Spring assembly
     

  12.  

To install:


NOTE
When positioning the spring in the lower control arm, be sure the spring insulator is in the proper position before lifting the control arm in place.

  1. Install or connect the following:

    Spring assembly
     
    Lower control arm
     
    Lower control arm pivot bolts
     
    Stabilizer to the lower control arm
     

  2.  

2002-05 Vehicles

NOTE
This procedure requires the use of a suitable spring compressor.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Wheel
     
    Shock module
     
    Shock module yoke-to-shock absorber pinch bolt and nut
     

  4.  
  5. Spread the shock module yoke at the pinch bolt using a suitable flat-bladed tool.

    Shock module yoke from the shock absorber
     

  6.  
  7. Install pieces of heater hose or equivalent material to the shock module spring where the spring compressor contacts the lower part of the spring.

    Click image to see an enlarged view

    Fig. Place pieces of heater hose to the spring where the compressor contacts the lower part of the spring-2002-05 vehicles

  8.  
  9. Install the shock module into the spring compressor.
    NOTE
    The spring is compressed when the shock absorber moves freely.

  10.  
  11. Turn the spring compressor forcing screw until the coil spring is compressed.
  12.  
  13. Remove or disconnect the following:

    Shock absorber upper retaining nut
     
    Shock absorber from the shock module
     

  14.  
  15. Loosen the compressor forcing screw until the upper mounting plate and coil spring can be removed.

    Upper mounting plate and coil spring from the spring compressor
     

  16.  

To install:

  1. Install or connect the following:

    Coil spring and upper mounting plate to the spring compressor
     

  2.  
  3. Turn the compressor forcing screw until the coil spring is compressed.

    Shock absorber to the shock module. Tighten the retaining nut to 33 ft. lbs. (45 Nm)
     

  4.  
  5. Remove the shock module from the spring compressor. Remove the pieces of heater hose from the spring..

    Shock module yoke to the shock absorber
     
    Shock module yoke-to-shock pinch bolt and nut and tighten to 52 ft. lbs. (70 Nm)
     
    Shock module to the vehicle
     
    Tire and wheel
     

  6.  
  7. Lower the vehicle
  8.  

Lower Ball Joints



Removal & Installation
2000-01 Vehicles
2wd Models
  1. Before servicing the vehicle, refer to the Precautions section.
    NOTE
    The following procedure requires the use of a ball joint remover/installer set (the particular set may vary upon application but must include a clamping-type tool with the appropriately sized adapters) and a ball joint separator tool, such as J-23742.

  2.  
  3. Remove the tire and wheel assembly.
  4.  
  5. Position a jack under the spring seat of the lower control arm, then raise the jack to support the arm.
    CAUTION
    The jack MUST remain under the lower control arm, during the removal and installation procedures, to retain the arm and spring positions. Make sure the jack is securely positioned and will not slip or release during the procedure or personal injury may result.

  6.  
  7. Remove or disconnect the following:

    Brake caliper and support it aside using a hanger or wire. Make sure the brake line is not stressed or damaged.

    Click image to see an enlarged view

    Fig. Use a ball joint separator to drive the lower joint from the knuckle

     
    Ball joint stud nut
     
    Lower ball joint from the steering knuckle using tool J-23742
     

  8.  
  9. Carefully guide the lower control arm out of the opening in the splash shield using a putty knife. Position a block of wood between the frame and upper control arm to keep the knuckle out of the way.

    Grease fitting

    Click image to see an enlarged view

    Fig. Driving the lower joint from the control arm

     

  10.  

To install:

  1. Clean the tapered hole in the steering knuckle of any dirt or foreign matter, then check the hole to see if it is out of round, deformed or otherwise damaged. If a problem is found, then knuckle must be replaced.
  2.  
  3. Install or connect the following:
    NOTE
    When installing the cotter pin, never loosen the castle nut to expose the cotter pin hole.



    Press the new ball joint (with grease fitting pointing inward) until it bottoms in the control arm using a suitable installation set. Make sure the grease seal is facing inboard.

    Click image to see an enlarged view

    Fig. Installing a new ball joint

     
    Ball joint retaining nut and tighten to 79 ft. lbs. (108 Nm)
     



    Grease fitting into the ball joint, if not already installed
     

  4.  
  5. Use a grease gun to lubricate the joint until grease appears at the seal.

    Brake caliper
     
    Tire and wheel assembly
     

  6.  
  7. Check and adjust the front end alignment, as necessary.
  8.  

4wd Models

On these vehicles both the upper and lower ball joints are removed in the same manner. Please refer to the procedure for the 2WD vehicles.

2002-05 Vehicles

NOTE
This procedure requires the use of the following special tools: J 9519-E Lower Ball Joint Remover and Installer, J 34874 Booster Seal Remover/Installer, J 41435 Ball Joint Installer, J 45105-1 Ball Joint Flaring Adapter and J 45105-2 Receiver.

  1. On 4WD vehicles, remove the wheel center cap and drive axle nut.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove or disconnect the following:

    Tire and wheel
     
    Wheel hub and bearing, if necessary
     
    Outer tie rod retaining nut
     
    Out tie rod from the steering knuckle using a suitable puller
     
    Brake hose bracket retaining bolts and bracket
     
    Upper control arm-to-steering knuckle pinch bolt and nut
     
    Upper control arm from the steering knuckle
     
    Lower ball joint retaining nut
     
    Steering knuckle from the lower control arm using a suitable ball joint removal tool
     
    Steering knuckle from the vehicle
     
    Lower ball joint flange with a chisel
     

  6.  
  7. Install tools J 9519-E and J 34874 to the lower ball joint, then use those tools to remove the lower ball joint from the lower control arm.
  8.  

To install:

  1. Install or connect the following:

    Lower ball joint to the lower control arm, using tools J 9519-E, J 41435 and J 45105-2
     

  2.  
  3. Remove the tools from the lower control arm.

    Tools J 9519-E and J 45105-1 to the lower ball joint
     

  4.  
  5. Flare the lower ball joint flange with J 9519-E and J 45105-1, then remove the tools from the lower ball joint.

    Steering knuckle to the lower control arm
     
    Lower ball joint retaining nut and tighten to 81 ft. lbs. (110 Nm)
     
    Upper control arm to the steering knuckle
     
    Upper control arm pinch bolt and nut and tighten to 30 ft. lbs. (41 Nm)
     
    Brake hose bracket to the steering knuckle
     
    Brake hose bracket retaining nuts and tighten to 7 ft. lbs. (10 Nm)
     
    Outer tie rod to the steering knuckle
     
    Outer tie rod retaining nut and tighten to 33 ft. lbs. (45 Nm)
     
    Wheel hub and bearing, if removed
     
    Tire and wheel
     

  6.  
  7. Lower the vehicle

    Drive axle nut, if 4WD, and tighten to 103 ft. lbs. (140 Nm)
     
    Wheel center cap, if removed
     

  8.  
  9. Check the front wheel alignment.
  10.  

Lower Control Arm



Control Arm Bushing Replacement
2000-01 Vehicles
2wd Models
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove lower control arm and place it in vise.
  4.  
  5. Install tools J 22269-01, 21474-8, 12 and 13 on the rear bushing and tighten until the bushing is removed.
  6.  
  7. Using a blunt chisel, drive the front bushing flare flush with the rubber part of the bushing.
  8.  
  9. Place a wedge or a spacer between the bushing housing to keep the housing from bending while removing or installing the bushing.
  10.  
  11. Install tools J 21474-3, 4, 5 and 6 on the front bushing and tighten until the bushing is removed.

    Click image to see an enlarged view

    Fig. Removing the lower control arm rear bushing-all 2 wheel drive



    Click image to see an enlarged view

    Fig. Installing the lower control arm front bushing-all 2 wheel drive



    Click image to see an enlarged view

    Fig. Installing the lower control arm rear bushing-all 2 wheel drive

  12.  

To install:

  1. Install the front bushing into the control arm.
  2.  
  3. Install tools J 21474-4, 5 and 13. Tighten until the bushing is fully seated.
  4.  
  5. Install the rear bushing into the control arm
  6.  
  7. Install tools J 22269-01, J 21474-2 and 13. Tighten until the bushing is fully seated.
  8.  
  9. Install the lower control arm.
  10.  

4wd Models
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove lower control arm and place it in vise.
  4.  
  5. Using bushing service set J 21474, remove the front and rear bushings.
  6.  

To install:

  1. Using bushing service set J 21474, install the front and rear bushings.
  2.  
  3. Install the lower control arm.

    Click image to see an enlarged view

    Fig. Removing the lower control arm front bushing-all 4 wheel drive



    Click image to see an enlarged view

    Fig. Installing the lower control arm front bushing-all 4 wheel drive



    Click image to see an enlarged view

    Fig. Installing the lower control arm rear bushing-all 4 wheel drive

  4.  

2002-05 Vehicles

NOTE
This procedure requires the use of Steering Linkage and Tie Rod Puller tool No. J 24319-B and Ball Joint Remover tool No. J 43631.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Raise the vehicle.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Make sure to note the direction that the bolts are removed for installation.


    NOTE
    On 4WD vehicles, make sure not to disengage the axle shaft from the transmission.



    Tire and wheel
     
    Outer tie rod retaining nut
     
    Outer tie rod from the steering knuckle using Ball Joint Removal tool No. J 43631
     
    Stabilizer shaft link lower nut, link and washer
     
    Shock module yoke lower nut and shock module using Steering Linkage and Tie Rod Puller tool No. J 24319-B
     
    Lower control arm-to-lower control arm bracket mounting bolts
     



    Lower control arm-to-lower control arm bracket mounting bolts
     
    Lower ball joint retaining nut
     
    Lower ball joint from the steering knuckle using Ball Joint Removal tool No. J 43631
     

  6.  
  7. Pivot the lower control arm out and down to disengage the lower control arm from the bracket, then remove the lower control arm from the knuckle.
  8.  

To install:

  1. Install or connect the following:
    NOTE
    During installation and tightening of the bolts and nuts, make sure that the lower control arm is parallel to the bracket. This is to maintain proper alignment of the lower control arm bushings.


    NOTE
    If it becomes necessary to replace the washer, use only an identical hardened steel, felt lined washer. Standard washers must not be used.



    Lower control arm to the steering knuckle
     
    Lower control to the bracket by pivoting it out and up
     



    Lower control arm-to-bracket mounting bolts and tighten to 81 ft. lbs. (111 Nm)
     
    Shock module yoke to the lower control arm
     
    Shock module yoke lower mounting nut
     



    Stabilizer shaft link and washer to the lower control arm
     
    Stabilizer shaft link retaining bolt and tighten to 74 ft. lbs. (100 Nm)
     
    Outer tie rod to the steering knuckle. Tighten the nuts to 33 ft. lbs. (45 Nm).
     
    Tire and wheel
     

  2.  
  3. Lower the vehicle and check the front end alignment.
  4.  

Removal & Installation
2000-01 Vehicles
2wd Models
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Make sure to note the location of the control arm shims prior to removal so that they may be installed in their original positions.



    Negative battery cable
     
    Wheel
     
    Wheel speed sensor harness bracket retaining bolt and nut, if equipped
     
    Steering knuckle from upper control arm ball joint
     
    Mounting nuts/bolts and shims
     



    Upper control arm
     

  4.  

To install:

  1. Install or connect the following:
    NOTE
    Always tighten nut on the thinner shim pack first.


    NOTE
    Tighten the nut to align the hole never loosen.



    Upper control arm
     



    Mounting nuts/bolts and shims. Torque the nuts to 81-85 ft. lbs. (110-115 Nm).
     
    Steering knuckle to upper control arm ball joint
     
    New cotter pin
     



    Wheel speed sensor harness bracket retaining bolt and nut, if equipped
     
    Wheel
     

  2.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Coil spring
     
    Lower ball joint from the steering knuckle
     
    Lower control arm from the vehicle
     

  4.  

To install:

  1. Install or connect the following:

    Lower control arm
     
    Lower ball joint stud into the steering knuckle
     
    Ball joint-to-steering knuckle nut and tighten to specification
     
    New cotter pin to the lower ball joint stud
     
    Coil spring
     

  2.  
  3. Align the vehicle.
  4.  

4wd Models
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    The 4WD vehicles do not use shims to adjust the front wheel alignment. Instead, the upper control arm bolts are equipped with cams, which are rotated to achieve caster and camber adjustments. In order to preserve adjustment and ease installation, matchmark the cams to the control arm before removal. If the control arm is being replaced, transfer the alignment marks to the new component before installation.



    Tire and wheel assembly
     
    Cotter pin from the ball joint, then loosen the retaining nut
     
    Steering knuckle from the upper ball joint. Be sure to support the steering knuckle/hub assembly to prevent damaging the brake hose.
     



    Front and rear nuts retaining the control arm retaining bolts to the frame
     
    Outer cams from the bolts
     
    Bolts and inner cams
     
    Control arm from the vehicle
     
    Retaining nut and the bumper from the control arm, if necessary
     

  4.  
  5. If the bushings are being replaced, use a suitable bushing service set to remove the bushings from the arm.
  6.  

To install:

  1. Install or connect the following:

    Bushing service set to drive the new bushings into the control arm, if removed
     
    Bumper and retaining nut to the control arm, if removed. Tighten the bumper retaining nut to 20 ft. lbs. (27 Nm).
     
    Control arm, retaining bolts (from the inside of the frame brackets facing outward) and the inner cams. The inner cams must be positioned on the bolts before they are inserted through the control arm and frame brackets.
     
    Outer cams over the retaining bolts, then the nuts to the ends of the bolts at the front and rear of the control arm
     

  2.  
  3. Align the cams to the reference marks made earlier, then tighten the end nuts to 85 ft. lbs. (115 Nm).

    Ball joint to the knuckle
     
    Tire and wheel assembly
     

  4.  
  5. Check and adjust the front end alignment, as necessary.
  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
    NOTE
    Tools Needed: universal tie rod separator J-24319-01, torsion bar unloader J-36202, lower control arm bushing service kit J-36618 (if the control arm bushing are being replaced) and ball joint C-clamp J-9519-23. Parts Needed: whether or not the control arm or bushing are being replaced, NEW control arm retaining nut should be used once the old ones have been loosened and removed.

  2.  
  3. Remove or disconnect the following:

    Front wheels
     
    2 bolts from the front splash shield and pivot it in order to gain access to the tie rod
     
    Stabilizer bar from the control arm (keeping all of the link hardware sorted for proper installation). If necessary, completely remove the bar from the vehicle for access.
     
    Shock absorber
     
    Inner tie rod from the relay rod using a tie rod separator
     
    Outer halfshaft nut and washer
     
    Bolts from the hub and bearing kit
     

  4.  
  5. Unload the torsion bar using the unloading tool J-36202. First, mark the adjuster for installation.

    Adjustment arm. Slide the bar forward and the adapter out of the rear to remove the adjusting arm.
     
    Lower ball joint cotter pin, nut and ball joint from the control arm using a ball joint separator
     
    Nuts and bolts and lower control arm with the torsion bar assembly. Note the direction which the control arm retaining bolts are facing for installation purposes.
     

  6.  

To install:

  1. Install or connect the following:
    NOTE
    The control arm retainers MUST be tightened with the vehicle suspension at normal ride height. This can either be accomplished by starting the nuts now, then installing the remaining components along with the wheels and lowering the vehicle, or by moving jackstands under the ends of the lower control arms and resting the vehicle on them. If the latter solution is tried, make sure front suspension is at actual ride height compression. If you are unsure, it is best to start the nuts now and tighten them to specification once the vehicle is lowered.



    Torsion bar to the lower control arm and place the assembly into the vehicle. Position the front leg of the lower control arm into the crossmember before installing the rear leg into the frame bracket.
     
    Control arm bolts (facing in the direction as noted during removal or shown in the accompanying illustration) with NEW nuts.

    Click image to see an enlarged view

    Fig. Exploded view of the lower control arm assembly mounting

     



    Ball joint stud in the knuckle
     

  2.  
  3. With the suspension at the correct height, tighten the control arm retaining nuts to 98 ft. lbs. (133 Nm).
    NOTE
    The lower ball joint retaining nut MUST be tightened with the vehicle suspension at normal ride height. This can either be accomplished by starting the nut now, then installing the remaining components along with the wheels and lowering the vehicle, or by moving jackstands under the ends of the lower control arms and resting the vehicle on them. If the latter solution is tried, make sure the FULL WEIGHT of the vehicle front end is on the suspension.

  4.  
  5. Install or connect the following:

    Joint-to-control arm nut, then tighten the nut to 92 ft. lbs. (125 Nm) with the suspension at normal ride height and compression.
     
    New cotter pin to the castellated nut. Tighten the nut (but no more than an additional 1 / 6 turn) in order to align the cotter pin. DO NOT loosen the nut from the specified torque.
     
    Adjuster arm by sliding the adapter forward, over the torsion bar to install the sides of the nut. Load the torsion bar and install the adjuster bolt aligning the installation mark.
     
    Drive axle through the hub and bearing assembly
     
    Tighten the hub and bearing assembly retaining bolts
     
    Drive axle shaft nut and washer
     
    Inner tie rod end to the relay rod
     
    Shock absorber
     
    Stabilizer bar, if removed
     
    Stabilizer link(s) to the control arm(s)
     
    Splash shield
     
    Front wheels
     

  6.  
  7. Recheck all fasteners for proper torque and installation before road testing.
  8.  
  9. Refill the differential if any fluid was lost.
  10.  
  11. Check and adjust the front end alignment, as necessary.
  12.  

2002-05 Vehicles
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Tire and wheel assembly
     
    Upper ball joint-to-upper control arm pinch bolt and nut
     
    Upper control arm from the knuckle
     
    Anti-lock Brake System (ABS) wheel speed sensor wiring harness
     
    Upper control arm mounting bolts
     
    Upper control arm
     

  4.  

To install:

  1. Install or connect the following:

    Upper control arm and tighten the bolts to 111 ft. lbs. (150 Nm)
     
    ABS wheel speed sensor wiring harness
     
    Upper control arm to the steering knuckle
     
    Upper ball joint-to-upper control arm pinch bolt and nut and tighten to 30 ft. lbs. (40 Nm)
     
    Tire and wheel
     

  2.  
  3. Check the front wheel alignment.
  4.  

  1. Raise and support the vehicle.
  2.  
  3. Remove the wheel and tire.
  4.  
  5. Remove the outer tie rod retaining nut.
  6.  
  7. Disconnect the outer tie rod from the steering knuckle using a tie rod puller.
  8.  
  9. Remove the stabilizer shaft link lower retaining nut.
  10.  
  11. Disconnect the stabilizer shaft link and washer from the lower control arm.
  12.  
  13. Remove the shock module yoke lower mounting nut.
  14.  
  15. Disconnect the shock module yoke from the lower control arm using a tie rod puller.
  16.  
  17. Remove the lower ball joint retaining nut.
  18.  
  19. Disconnect the lower ball joint from steering knuckle using ball joint remover.
  20.  
  21. Remove the lower control arm-to-lower control arm bracket mounting nuts.
  22.  
  23. Note the direction the bolts are removed for installation.
  24.  
  25. Remove the lower control arm to lower control arm bracket mounting bolts.
  26.  
  27. Take care not to disengage the axle shaft from the transmission (4WD only).
  28.  
  29. Pivot the lower control arm outward and downward in order to disconnect the lower control arm from the lower control arm bracket.
  30.  
  31. Ensure that the spacer stays in position on the front control arm bracket front bushing.
  32.  
  33. Remove the lower control arm from the vehicle.

    Click image to see an enlarged view

    Fig. Front lower control arm mounting

  34.  

To install:

  1. Position the lower control arm ball joint stud to the steering knuckle.
  2.  
  3. Ensure that the spacer stays in position on the front control arm bracket front bushing.
  4.  
  5. Pivot the lower control arm outward and upward in order to connect the lower control arm to the lower control arm bracket.
  6.  
  7. Install the lower control arm to lower control arm bracket mounting bolts.
    NOTE
    Ensure that the lower control arm is parallel to the lower control arm bracket during the installation and tightening of the lower control arm mounting bolts and nuts. This will ensure correct alignment of the lower control arm bushings.

  8.  
  9. Install the lower control arm to lower control arm bracket mounting nuts and tighten to 96 ft. lbs. (130 Nm).
  10.  
  11. Connect the shock module yoke to the lower control arm.
  12.  
  13. Install the shock module yoke lower mounting nut and tighten to 81 ft. lbs. (110 Nm).
  14.  
  15. Install the lower ball joint retaining nut and tighten to 81 ft. lbs. (110 Nm).
  16.  
  17. Install the stabilizer shaft link and washer to the lower control arm.
  18.  
  19. Install the stabilizer shaft link retaining nut and tighten to 114 ft. lbs. (155 Nm).
  20.  
  21. Install the outer tie rod to the steering knuckle.
  22.  
  23. Install the outer tie rod retaining nut and tighten to 33 ft. lbs. (45 Nm).
  24.  
  25. Install the tire and wheel.
  26.  
  27. Lower the vehicle.
  28.  
  29. Check the front wheel alignment.
  30.  

Shock Absorbers



Removal & Installation
2001 Vehicles
2wd Models
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Hold the shock absorber stem with a wrench while backing the nut off.



    Wheel
     
    Mounting nut
     



    Retaining nut and grommet
     
    Shock absorber-to-lower control arm bolts
     
    Shock absorber
     
    Replace the parts, as necessary.
     

  4.  

To install:

  1. Fully extend the shock absorber stem, then push it up through the lower control arm and spring so that the upper stem passes through the mounting hole in the upper control arm frame bracket.
  2.  
  3. Install or connect the following:

    Retaining nut and grommet on the stem. Tighten the nut to 106 inch lbs. (12 Nm).
     
    Shock absorber-to-lower control arm bolts and tighten to 22 ft. lbs. (30 Nm)
     
    Wheel

    Click image to see an enlarged view

    Fig. Front shock absorber mounting-2WD

     

  4.  

4wd Models
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Wheel
     
    Lower nut/bolt and collapse the shock absorber
     
    Shock absorber upper nut and bolt
     
    Shock absorber
     

  4.  

To install:

  1. Install or connect the following:

    Shock absorber to the bracket. Tighten the nuts/bolts to 54 ft. lbs. (73 Nm).
     
    Wheel

    Click image to see an enlarged view

    Fig. Front shock absorber mounting-4WD

     

  2.  

Stabilizer Bar (Sway Bar)



Removal & Installation
2000-01 Vehicles
  1. Raise and support the rear of the vehicle safely using jackstands.
  2.  
  3. Remove the lower nuts, washers and bolts from the sway bar links.
  4.  
  5. Remove the nuts from the U-bolts, the U-bolts, the clamps and the insulators.
  6.  
  7. Remove the sway bar from the vehicle.
  8.  

To install:

  1. Place the sway bar in position.
  2.  
  3. Install the sway bar insulators, clamps, U-bolts and the U-bolt nuts. Tighten the nuts to 44 ft. lbs. (60 Nm).
  4.  
  5. On four door utility models, install the sway bar-to-link mounting bolt.
  6.  
  7. Install the sway bar-to-link nut. Tighten the upper link nuts on all models to 25 ft. lbs. (35 Nm)
  8.  
  9. Lower the vehicle.
  10.  

2002-05 Vehicles
  1. Raise and support the vehicle.
  2.  
  3. Remove the stabilizer shaft links to the stabilizer shaft retaining nuts.
  4.  
  5. Remove the stabilizer shaft insulator clamp mounting bolts.
  6.  
  7. Remove the stabilizer shaft insulator clamp from the stabilizer shaft insulator.
  8.  
  9. Remove the stabilizer shaft insulators from the stabilizer shaft.
  10.  
  11. Remove the stabilizer shaft from the vehicle.
  12.  

To install:

  1. Install the stabilizer shaft to the vehicle.
  2.  
  3. Install the stabilizer shaft insulators to the stabilizer shaft.
  4.  
  5. Install the stabilizer shaft insulator clamp to the stabilizer shaft insulator.
  6.  
  7. Install the stabilizer shaft insulator clamp mounting bolts and tighten to 41 ft. lbs. (55 Nm).
  8.  
  9. Install the stabilizer shaft links to the stabilizer shaft and tighten to 74 ft. lbs. (100 Nm).
  10.  
  11. Lower the vehicle.
  12.  

Steering Knuckle



Removal And Installation
  1. Raise and support the vehicle.
  2.  
  3. Remove the tire and wheel.
  4.  
  5. On 4WD vehicles, remove wheel center cap, if equipped, and the drive axle nut and washer
  6.  
  7. Remove the wheel hub and bearing.
  8.  
  9. Remove the outer tie rod retaining nut.
  10.  
  11. Disconnect the outer tie rod from the steering knuckle using a tie rod puller.
  12.  
  13. Remove the brake hose bracket retaining bolts.
  14.  
  15. Remove the brake hose bracket from the steering knuckle.
  16.  
  17. Disconnect the ABS wheel speed sensor wiring harness bracket from the steering knuckle.
  18.  
  19. Remove the upper control arm to the steering knuckle pinch bolt and nut.
  20.  
  21. Disconnect the upper control arm from the steering knuckle.
  22.  
  23. Remove the lower ball joint retaining nut.
  24.  
  25. Remove the steering knuckle from the lower control arm.
  26.  
  27. Remove the steering knuckle from the vehicle.
  28.  

To install:

  1. Install the steering knuckle to the lower control arm.
  2.  
  3. Install the lower ball joint retaining nut and tighten to 81 ft. lbs. (110 Nm).
  4.  
  5. Connect the upper control arm to the steering knuckle.
  6.  
  7. Install upper control arm pinch bolt and nut and tighten to 30 ft. lbs. (40 Nm).
  8.  
  9. Connect the ABS wheel speed sensor wiring harness bracket to the steering knuckle.
  10.  
  11. Install the brake hose bracket to the steering knuckle.
  12.  
  13. Install the brake hose bracket retaining bolts and tighten to 89 inch lbs. (10 Nm).
  14.  
  15. Install the outer tie rod to the steering knuckle.
  16.  
  17. Install the new outer tie rod retaining nut and tighten to 33 ft. lbs. (45 Nm) on 2WD models, or 44 ft. lbs. (60 Nm) on 4WD models.
  18.  
  19. Install the wheel hub and bearing.
  20.  
  21. On 4WD vehicles, install the drive axle nut and tighten to 103 ft. lbs. (140 Nm), then install the center cap.
  22.  
  23. Install the tire and wheel.
  24.  
  25. Lower the vehicle.
  26.  
  27. Adjust the front toe.
  28.  

Struts (MacPherson Struts)



Strut/Shock Module
Removal & Installation
2002-05 Vehicles

NOTE
On 2002-05 models, a -shock module-, similar to a strut was used on these vehicles. This procedure requires the use of a suitable steering linkage and tie rod puller.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Shock module upper retaining nuts
     
    Tire and wheel
     
    Shock module-to-lower control arm retaining nut
     
    Shock module yoke from the lower control arm using a suitable puller
     
    Shock module from the shock tower and lower control arm

    Click image to see an enlarged view

    Fig. View of the shock module used on the front suspension of 2002-05 vehicles

     

  4.  

To install:

  1. Install or connect the following:

    Shock module to the shock tower and lower control arm
     
    Shock module yoke to the lower control arm
     
    Shock module upper retaining nuts and tighten to 33 ft. lbs. (45 Nm)
     
    Shock module-to-lower control arm retaining nut and tighten to 81 ft. lbs. (110 Nm)
     
    Tire and wheel
     

  2.  

Torsion Bars



Removal & Installation

Instead of the coil spring used on the front suspension of 2000-01 2WD vehicles, the 4WD vehicles are equipped with a torsion bar.

  1. Before servicing the vehicle, refer to the Precautions section.
    NOTE
    The following procedure requires the use of the Torsion Bar Unloader tool J-36202.

  2.  
  3. Remove or disconnect the following:
    NOTE
    Note the direction of the forward end and side of the torsion bar being removed



    Transmission shield, if equipped
     
    Torsion bar unloader tool to relax the tension on the torsion bar adjusting arm screw; record the number of turns necessary to properly install the tool. Remove the adjusting screw and the unloader tool.
     
    Lower link mount nut from one side
     
    Torsion bars by disengaging them
     



    Lower link nut from the opposite side
     
    Lower link mount, upper link mount nut
     
    Upper link mount
     
    Torsion bar from the frame
     

  4.  

To install:

  1. Install or connect the following:

    Torsion bar and support
     
    Upper link mount. Torque the nut to 48 ft. lbs. (68 Nm).
     

  2.  
  3. Place a jack under the torsion bar to release tension.
  4.  
  5. Install or connect the following:

    Lower link mount bushing and nut. Torque the nut to 37 ft. lbs. (50 Nm).
     
    Torsion bar unloader tool. Tighten the tool against the adjusting arm the same number turns recorded earlier and remove the tool. This loads the torsion bars.
     
    Transmission shield, if removed
     

  6.  

Track Bar



Removal & Installation

The track bar (tie rod assembly) is used only on models equipped with the ZR2 suspension.

  1. Raise and support the rear of the vehicle safely using jackstands. Support the rear axle securely using jackstands or a floor jack.
  2.  
  3. Remove the track bar mounting bolts, washers and nuts at the axle bracket and frame bracket.
  4.  
  5. Remove the track bar from the vehicle.
  6.  

To install:

  1. Place the track bar in position and loosely install the bolts, washers and nuts.
  2.  
  3. Once the track bar is properly positioned, tighten the retainers as follows:

    Axle bracket nut: 44 ft. lbs. (61 Nm)
     
    Frame bracket bolt: 44 ft. lbs. (61 Nm)
     

  4.  
  5. Remove the jackstands and lower the vehicle.

    Click image to see an enlarged view

    Fig. Rear track bar-to-axle mounting nuts



    Click image to see an enlarged view

    Fig. Rear track bar-to-frame mounting bolt and nut

  6.  

Upper Ball Joints



Removal & Installation
2000-01 Vehicles
2wd Models
  1. Before servicing the vehicle, refer to the Precautions section.
    NOTE
    The following procedure requires the use of a ball joint separator tool such as J-23742 and J-9519-E ball joint remover and installer set.

  2.  
  3. Raise and support the front of the vehicle safely by placing stands securely under the lower control arms. Because the vehicle's weight is used to relieve spring tension on the upper control arm, the stands must be positioned between the spring seats and the lower control arm ball joints for maximum leverage.
    CAUTION
    With components unbolted, the stand is holding the lower control arm in place against the coil spring. Make sure the stand is firmly positioned and cannot move, or personal injury could result.

  4.  
  5. Remove or disconnect the following:

    Tire and wheel assembly
     
    Brake caliper and support it from the vehicle using a coat hanger or wire. Make sure the brake line is not stretched or damaged and that the caliper's weight is not supported by the line.
     
    Cotter pin and retaining nut from the upper ball joint
     
    Anti-lock brake sensor wire bracket, if equipped
     
    Upper ball joint from the steering knuckle using tool J-23742 and pull the steering knuckle free of the ball joint

    Click image to see an enlarged view

    Fig. Use a ball joint separator tool to drive the upper ball joint from the steering knuckle

     

  6.  
  7. Remove the riveted upper ball joint from the upper control arm as follows:
    1. Drill a 1 / 8 in. (3mm) hole, about 1 / 4 in. (6mm) deep into each rivet.
    2.  
    3. Then use a 1 / 2 in. (13mm) drill bit, to drill off the rivet heads.
    4.  
    5. Using a pin punch and the hammer, drive out the rivets in order to free the upper ball joint from the upper control arm assembly, then remove the upper ball joint.

      Click image to see an enlarged view

      Fig. Drill a small guide hole into each ball joint rivet



      Click image to see an enlarged view

      Fig.



      Click image to see an enlarged view

      Fig.

    6.  

  8.  

To install:

  1. Install or connect the following:
    NOTE
    When installing the cotter pin, never loosen the castle nut to expose the cotter pin hole.



    Ball joint in the upper control arm
     
    Ball joint retaining nuts and bolts. Position the bolts threaded upward from under the control arm. Tighten the ball joint retainers to 17 ft. lbs. (23 Nm).
     
    Anti-lock brake sensor wire bracket, if removed

    Click image to see an enlarged view

    Fig. Service ball joints are bolted to the control arm

     



    Thread the grease fitting into the ball joint. Use a grease gun to lubricate the upper ball joint until grease appears at the seal.
     
    Brake caliper
     
    Tire and wheel assembly
     

  2.  
  3. Check and adjust the front end alignment, as necessary.
  4.  

4wd Models
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  

On 4WD vehicles both the upper and lower ball joints are removed in the same manner. Once the joint is separated from the steering knuckle the rivets are drilled and punched to free the joint from the control arm. Service joints are bolted into position with the retaining bolts threaded upward from beneath the control arm. In this manner, the joint is replaced in an almost identical fashion to the upper joints on 2WD vehicles.

  1. Remove or disconnect the following:

    Tire and wheel assembly
     
    Wheel speed sensor wiring connector from the upper control arm, if removing the upper ball joint
     
    Cotter pin from the ball joint, then loosen the retaining nut
     

  2.  
  3. Position a suitable ball joint separator tool such as J-36607, then carefully loosen the joint in the steering knuckle. Remove the tool and the retaining nut, then separate the joint from the knuckle.
    NOTE
    After separating the steering knuckle from the upper ball joint, be sure to support the steering knuckle/hub assembly to prevent damaging the brake hose.

  4.  
  5. Remove the riveted ball joint from the control arm:
    1. Drill a 1 / 8 in. (3mm) hole, about 1 / 4 in. (6mm) deep into each rivet.
    2.  
    3. Then use a 1 / 2 in. (13mm) drill bit, to drill off the rivet heads.
    4.  
    5. Using a pin punch and the hammer, drive out the rivets in order to free the ball joint from the control arm assembly, then remove the ball joint.
    6.  

  6.  

To install:

  1. Install or connect the following:
    NOTE
    When installing the cotter pin, never loosen the castle nut to expose the cotter pin hole, but DO NOT tighten more than an additional 1 / 6 turn.



    Ball joint in the control arm
     
    Ball joint retaining nuts and bolts. Position the bolts threaded upward from under the control arm. Tighten the ball joint retainers to 17 ft. lbs. (23 Nm).
     
    Ball joint to the knuckle. Make sure the joint is seated, tighten the lower nut to 79 ft. lbs. (108 Nm) and the upper nut to 61 ft. lbs. (83 Nm). Install a new cotter pin.
     

  2.  
  3. Use a grease gun to lubricate the upper ball joint.

    Wheel speed sensor wiring connector to the upper control arm, if the upper ball joint was removed
     
    Tire and wheel assembly
     

  4.  
  5. Check and adjust the front end alignment, as necessary.

    Click image to see an enlarged view

    Fig. The replacement ball joint comes with nuts and bolts for installation

  6.  

2002-05 Vehicles

NOTE
This procedure requires the use of the following special tools: J 9519-E Lower Ball Joint Remover and Installer, J 21474-01 Control Arm Bushing Set and J 45117 Ball Joint Installation Spacer.

  1. On 4WD vehicles, remove the wheel center cap and drive axle nut.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove or disconnect the following:

    Tire and wheel
     
    Wheel hub and bearing, if necessary
     
    Outer tie rod retaining nut
     
    Out tie rod from the steering knuckle using a suitable puller
     
    Brake hose bracket retaining bolts and bracket
     
    Upper control arm-to-steering knuckle pinch bolt and nut
     
    Upper control arm from the steering knuckle
     
    Lower ball joint retaining nut
     
    Steering knuckle from the lower control arm using a suitable ball joint removal tool
     
    Steering knuckle from the vehicle
     
    Upper ball joint retaining clip
     
    Upper ball joint from the steering knuckle using Lower Ball Joint Removal and Installertool No. J 9519-E
     

  6.  

To install:

  1. Install or connect the following:

    Upper ball joint to the steering knuckle using J 9519-E, J 21474-01 and J 45117
     
    Upper ball joint retaining clip
     
    Steering knuckle to the lower control arm
     
    Lower ball joint retaining nut and tighten to 81 ft. lbs. (110 Nm)
     
    Upper control arm to the steering knuckle
     
    Upper control arm pinch bolt and nut and tighten to 30 ft. lbs. (41 Nm)
     
    Brake hose bracket to the steering knuckle
     
    Brake hose bracket retaining nuts and tighten to 7 ft. lbs. (10 Nm)
     
    Outer tie rod to the steering knuckle
     
    Outer tie rod retaining nut and tighten to 33 ft. lbs. (45 Nm)
     
    Wheel hub and bearing, if removed
     
    Tire and wheel
     

  2.  
  3. Lower the vehicle

    Drive axle nut, if 4WD, and tighten to 103 ft. lbs. (140 Nm)
     
    Wheel enter cap, if removed
     

  4.  
  5. Check the front wheel alignment.
  6.  

Upper Control Arm



Control Arm Bushing Replacement
2wd Vehicles
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Upper control arm and place it in a vise
     
    Upper control arm shaft nuts and retainers
     
    Upper control arm bushings using tool J 22269-1, a slotted washer and a short piece if pipe that is slightly larger than the bushing
     
    Upper control arm shaft
     

  4.  

To install:



Upper control arm shaft
 
Upper control arm bushings using tool J 22269-1, a slotted washer and a short piece if pipe that is slightly larger than the bushing
 

  1. Tighten J 22269-1 until the bushing is positioned on the shaft and the control arm as shown in the accompanying illustration. The measurement should be 0.48-0.52 inch (12.8-13.8mm) at both sides when the properly installed.

    Upper control arm shaft nuts and retainers. Tighten to 85 ft. lbs. (115 Nm).
     
    Upper control arm
     

  2.  

4wd Vehicles

If the bushings require replacement, refer to the control arm removal and installation procedure for bushing replacement.

 
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