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Exj 2
 

Exj 2

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    Exj 2 Exj 2 Document Transcript

    • XJ SUSPENSION 2-1 SUSPENSION CONTENTS page pageALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . 13FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . 6 ALIGNMENT INDEX page pageGENERAL INFORMATION SERVICE PROCEDURES WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . 1 PRE-ALIGNMENT INSPECTION . . . . . . . . . . . . . 2DIAGNOSIS AND TESTING WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . 2 SUSPENSION AND STEERING SYSTEM . . . . . . 2 SPECIFICATIONS ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 5GENERAL INFORMATION • WHEEL TOE POSITION is the difference between the leading inside edges and trailing insideWHEEL ALIGNMENT edges of the front tires. Incorrect wheel toe position Wheel alignment involves the correct positioning of is the most common cause of unstable steering andthe wheels in relation to the vehicle. The positioning uneven tire wear. The wheel toe position is the finalis accomplished through suspension and steering front wheel alignment adjustment.linkage adjustments. An alignment is considered • STEERING AXIS INCLINATION ANGLE isessential for efficient steering, good directional stabil- measured in degrees and is the angle that the steer-ity and to minimize tire wear. The most important ing knuckles are tilted. The inclination angle has ameasurements of an alignment are caster, camber fixed relationship with the camber angle. It will notand toe position (Fig. 1). change except when a spindle or ball stud is dam- • CASTER is the forward or rearward tilt of the aged or bent. The angle is not adjustable, the dam-steering knuckle from vertical. Tilting the top of the aged component(s) must be replaced to correct mis-knuckle rearward provides positive caster. Tilting the alignment.top of the knuckle forward provides negative caster. • THRUST ANGLE is the angle of the rear axleCaster is a directional stability angle. This angle relative to the centerline of the vehicle. Incorrectenables the front wheels to return to a straight thrust angle can cause off-center steering and exces-ahead position after turns. sive tire wear. This angle is not adjustable, the dam- • CAMBER is the inward or outward tilt of the aged component(s) must be replaced to correct mis-wheel relative to the center of the vehicle. Tilting the alignment.top of the wheel inward provides negative camber.Tilting the top of the wheel outward provides positive CAUTION: Do not attempt to modify any suspen-camber. Incorrect camber will cause wear on the sion or steering component by heating and bend-inside or outside edge of the tire. The angle is not ing.adjustable, the damaged component(s) must bereplaced to correct mis-alignment.
    • VEHICLE OF CAMBER (NOT SHOWN)(−)TOP AXLE AXLE CASTER REAR ANGLERELATIVE TO TRUE TICAL POSITIVE CENTER- VER- LINE TRUST CAMBER TERLINE OF ANGLE WHEELOUTBOARD WHEELSCRUBRIGHT CENTER-CEN- PIVOTLINE RADIUS NEGATIVE CAM- BER ANGLE POINTS IN) FRONT B > POSITIVE OF A (TOE OUT) TOE (TOE NEGATIVETOE VEHICLE B <A FRONT OF VEHICLEPIN POSITIVE CASTER TOE A KING (+) AXLE POINTS VERTICAL LEFT2-2 SUSPENSION XJ Fig. 1 Wheel Alignment MeasurementsDIAGNOSIS AND TESTINGSUSPENSION AND STEERING SYSTEMSERVICE PROCEDURES specifications with the vehicle at its NORMAL RIDE HEIGHT.PRE-ALIGNMENT INSPECTION Before starting wheel alignment, the following CAMBERinspection is necessary and must be completed. The wheel camber angle is preset. This angle is not (1) Inspect tires for size, air pressure and tread adjustable and cannot be altered.wear. CASTER (2) Inspect front wheel bearings for wear or adjust- Before checking the caster of the front axle for cor-ment. rect angle, be sure the axle is not bent or twisted. (3) Inspect front wheels and tires for excessive Road test the vehicle, make left and right turns. Ifradial or lateral runout and balance. the steering wheel returns to the center position (4) Inspect ball studs, linkage pivot points and unassisted, the caster angle is correct. If steeringsteering gear for looseness, roughness or binding. wheel does not return toward the center position (5) Inspect suspension components for wear and unassisted, an incorrect caster angle is probable.noise. Caster can be adjusted by installing the appropri- ate size shims (Fig. 2). Changing caster angle willWHEEL ALIGNMENT also change the front propeller shaft angle. The Before each alignment reading, the vehicle should propeller shaft angle has priority over caster.be jounced (rear first, then front). Grasp each Refer to Group 3 Differential & Driveline forbumper at the center and jounce the vehicle up and additional information.down several times. Always release the bumper inthe down position. Set the front end alignment to
    • SUSPENSION ARM SHIMXJ SUSPENSION 2-3SERVICE PROCEDURES (Continued) CONDITION POSSIBLE CAUSES CORRECTION FRONT END 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings. NOISE 2. Loose or worn steering or suspension components 2. Tighten or replace components as necessary. EXCESSIVE 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings. PLAY IN 2. Loose or worn steering or suspension components 2. Tighten or replace components as necessary. STEERING 3. Loose or worn steering gear. 3. Adjust or replace steering gear. FRONT 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings. WHEELS 2. Loose or worn steering or suspension components 2. Tighten or replace components as necessary. SHIMMY 3. Tires worn or out of balance. 3. Replace or balance tires. 4. Alignment. 4. Align vehicle to specifications. 5. Leaking steering dampener. 5. Replace steering dampener. VEHICLE 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings. INSTABILITY 2. Loose or worn steering or suspension components 2. Tighten or replace components as necessary. 3. Tire pressure. 3. Adjust tire pressure. 4. Alignment. 4. Align vehicle to specifications. EXCESSIVE 1. Loose or worn steering gear. 1. Adjust or replace steering gear. STEERING 2. Power steering fluid low. 2. Add fluid and repair leak. EFFORT 3. Column coupler binding. 3. Replace coupler. 4. Tire pressure. 4. Adjust tire pressure. 5. Alignment. 5. Align vehicle to specifications. VEHICLE 1. Tire pressure. 1. Adjust tire pressure. PULLS TO 2. Alignment. 2. Align vehicle to specifications. ONE SIDE 3. Loose or worn steering or suspension components 3. Tighten or replace components as necessary. 4. Radial tire lead. 4. Rotate or replace tire as necessary. 5. Brake pull. 5. Repair brake as necessary. 6. Weak or broken spring. 6. Replace spring. (1) Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. Turn off the engine. (2) Loosen the adjustment sleeve clamp bolts (Fig. 3). (3) Adjust the right wheel toe position with the drag link. Turn the sleeve until the right wheel is at correct TOE-IN specifications. Position the clamp bolts as shown (Fig. 4) and tighten to 49 N·m (36 ft. lbs.). NOTE: Make sure the toe setting does not change during clamp tightening. (4) Adjust the left wheel toe position with the tie rod. Turn the sleeve until the left wheel is at specifi- cations. Position the clamp bolts as shown (Fig. 4) and tighten to 27 N·m (20 ft. lbs.). NOTE: Make sure the toe setting does not change Fig. 2 Caster Adjustment during clamp tightening.TOE POSITION (LHD) (5) Verify the right toe setting.NOTE: The wheel toe position adjustment should (6) Road test the vehicle on a flat level road to ver-be the final adjustment. ify the steering wheel is centered.
    • DRAGCLAMPS LINK DRAG LINK PITMANARM TIE ROD CLAMP STEERING DAMPENER TIE ROD ADJUSTMENT SLEEVE FWD2-4 SUSPENSION XJSERVICE PROCEDURES (Continued)NOTE: Once the toe setting is correct, the steering correct TOE-IN specifications. Position the clampwheel can be re-centered by adjusting only the drag bolts to their original position and tighten to 49 N·mlink. (36 ft. lbs.). NOTE: Make sure the toe setting does not change during clamp tightening. (4) Adjust the right wheel toe position with the tie rod. Turn the sleeve until the right wheel is at cor- rect TOE-IN specifications. Position the clamp bolts to their original position and tighten to 27 N·m (20 ft. lbs.). NOTE: Make sure the toe setting does not change during clamp tightening. (5) Verify the right toe setting. (6) Road test the vehicle on a flat level road to ver- ify the steering wheel is centered. Fig. 4 Drag Link and Tie Rod Clamp (LHD) NOTE: Once the toe setting is correct, the steering wheel can be re-centered by adjusting only the dragTOE POSITION (RHD) link.NOTE: The wheel toe position adjustment shouldbe the final adjustment. (1) Start the engine and turn wheels both waysbefore straightening the wheels. Secure the steeringwheel with the front wheels in the straight-aheadposition. Turn off the engine. (2) Loosen the adjustment sleeve clamp bolts (Fig.5). (3) Adjust the left wheel toe position with the draglink. Turn the sleeve until the left wheel is at the Fig. 3 Steering Linkage (LHD)
    • STEERING MENTNER LINK TIE ROD ADJUST- DAMP- SLEEVE DRAG FWD PITMAN ARMXJ SUSPENSION 2-5 Fig. 5 Steering Linkage (RHD)SPECIFICATIONSALIGNMENTNOTE: All alignment specifications are in degrees. MAX RT/LT ADJUSTMENT PREFERRED RANGE DEFFERENCE CASTER + 7.0° + 5.25° to + 8.5° 1.25° CAMBER − 0.25° − 0.75° to + 0.5° 1.0° (fixed angle) WHEEL TOE-IN 0° − 0.10° to + 0.25° .05° (each wheel)
    • 2-6 SUSPENSION XJ FRONT SUSPENSION INDEX page pageDESCRIPTION AND OPERATION STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . 10 SUSPENSION COMPONENTS . . . . . . . . . . . . . . 6 STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . 8DIAGNOSIS AND TESTING TRACK BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SHOCK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . 7 UPPER SUSPENSION ARM . . . . . . . . . . . . . . . . 8REMOVAL AND INSTALLATION WHEEL MOUNTING STUDS . . . . . . . . . . . . . . . 11 AXLE BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . 9 SPECIFICATIONS COIL SPRING/JOUNCE BUMPER . . . . . . . . . . . 7 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 12 HUB BEARING . . . . . . . . . . . . . . . . . . . . . . . . . 10 SPECIAL TOOLS LOWER SUSPENSION ARM . . . . . . . . . . . . . . . 8 FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . 12 SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . 7DESCRIPTION AND OPERATION allow for adjustment of caster and drive shaft pinion angle. The suspension arm travel is limited throughSUSPENSION COMPONENTS the use of jounce bumpers in compression and shocks The front suspension is a link/coil design (Fig. 1). absorbers in rebound.This suspension is use on Left Hand Drive (LHD) Stabilizer Bar: The stabilizer bar is used to min-and Right Hand Drive (RHD) vehicles. The suspen- imize vehicle body roll during turns. The spring steelsion is comprised of: bar helps to control the vehicle body in relationship • Drive axle (4WD), tube axle (2WD) to the suspension. The bar extends across the front • Dual-action shock absorbers underside of the chassis and connects to the body • Coil springs rails. Links are connected from the bar to the axle • Upper and lower suspension arms brackets. Stabilizer bar mounts are isolated by rub- • Stabilizer bar ber bushings. • Track bar Track Bar: The track bar is used to locate the • Jounce bumpers axle laterally. The bar is attached to a body rail Link/Coil Suspension: This suspension allows bracket with a ball stud and isolated with a bushingeach wheel to adapt to different road surfaces with- at the axle bracket.out greatly affecting the opposite wheel. Wheels areattached to a hub/bearings which bolts to the knuck- CAUTION: Components attached with a nut andles. The hub/bearing is not serviceable and is cotter pin must be torqued to specification. Then ifreplaced as a unit. Steering knuckles pivot on the slot in the nut does not line up with the cotterreplaceable ball studs attached to the axle tube pin hole, tighten nut until it is aligned. Never loosenyokes. the nut to align the cotter pin hole. Shock Absorbers: The shocks dampen jounce andrebound of the vehicle over various road conditions. CAUTION: Suspension components with rubberThe top of the shock absorbers are bolted to the body. bushings should be tightened with the vehicle atThe bottom of the shocks are bolted to the axle normal ride height. It is important to have thespring bracket. springs supporting the weight of the vehicle when Coil Springs: The springs control ride quality and the fasteners are torqued. If springs are not at theirmaintain proper ride height. The coil springs mount normal ride position, vehicle ride comfort could beup in the fender shield to a bracket which is part of affected and premature bushing wear may occur.the unitized body. A rubber isolator is located Rubber bushings must never be lubricated.between the top of the spring and the body. The bot-tom of the spring seats on a axle pad and is retainedwith a clip. NOTE: Periodic lubrication of the front suspension Upper & Lower Suspension Arms: The suspen- (steering) system components is required. Refer tosion arms are different lengths, with bushings at Group 0, Lubrication And Maintenance for the rec-both ends. They bolt the axle assembly to the body. ommended maintenance schedule.The lower arms use shims at the body mount to
    • LOWER SHOCK TRACKAXLE UPPER SUSPENSION ARM LINKS COILBUMPER JOUNCE SPRING STABILIZER BAR ABSORBERXJ SUSPENSION 2-7DIAGNOSIS AND TESTING REMOVAL AND INSTALLATIONSHOCK DIAGNOSIS SHOCK ABSORBER A knocking or rattling noise from a shock absorbermay be caused by movement between mounting REMOVALbushings and metal brackets or attaching compo- (1) Remove the nut, retainer and grommet fromnents. These noises can usually be stopped by tight- the upper stud in the engine compartment (Fig. 2).ening the attaching nuts. If the noise persists, (2) Remove the lower nuts and bolts from the axleinspect for damaged and worn bushings, and attach- bracket. Remove the shock absorber.ing components. Repair as necessary if any of theseconditions exist. INSTALLATION A squeaking noise from the shock absorber may be (1) Position the lower retainer and grommet on thecaused by the hydraulic valving and may be intermit- upper stud. Insert the shock absorber through thetent. This condition is not repairable and the shock shock tower hole.absorber must be replaced. (2) Install the lower bolts and nuts. Tighten nuts The shock absorbers are not refillable or adjust- to 23 N·m (17 ft. lbs.).able. If a malfunction occurs, the shock absorber (3) Install the upper grommet and retainer on themust be replaced. To test a shock absorber, hold it in stud in the engine compartment. Install the nut andan upright position and force the piston in and out of tighten to 10 N·m (8 ft. lbs.).the cylinder four or five times. The action throughouteach stroke should be smooth and even. COIL SPRING/JOUNCE BUMPER The shock absorber bushings do not require any REMOVALtype of lubrication. Do not attempt to stop bushing (1) Raise and support the vehicle. Position anoise by lubricating them. Grease and mineral oil- hydraulic jack under the axle to support it.base lubricants will deteriorate the bushing. (2) Remove the wheel if necessary. Fig. 1 Suspension Components (LHD)
    • SHOCK ABSORBER CONTROL FWD GROMMET GROMMET RETAINER FRAME ARM SPRING RETAINER NUT SPRING SCREW SCREW SPRING FWD NUT RETAINER ISOLATOR2-8 SUSPENSION XJREMOVAL AND INSTALLATION (Continued) Fig. 2 Coil Spring & Shock Absorber (3) Mark and disconnect the front propeller shaft STEERING KNUCKLEfrom the axle. For service procedures on the steering knuckle and (4) Disconnect the lower suspension arms from the ball studs refer to Group 3 Differentials And Driv-axle (Fig. 2). eline. (5) Disconnect the stabilizer bar link and shockabsorber from the axle. LOWER SUSPENSION ARM (6) Disconnect the track bar from the body railbracket. REMOVAL (7) Disconnect the drag link from the pitman arm. (1) Raise and support the vehicle. (8) Lower the axle until the spring is free from the (2) Remove the lower suspension arm nut and boltupper mount. Remove the coil spring clip and remove from the axle bracket.the spring. (3) Remove the nut and bolt from the rear bracket (9) Pull jounce bumper out of mount. and remove the lower suspension arm (Fig. 3).INSTALLATION INSTALLATION (1) Install jounce bumper into mount. (1) Position the lower suspension arm at the axle (2) Position the coil spring on the axle pad. Install bracket and rear bracket.the spring clip and bolt. Tighten bolt to 21 N·m (16 (2) Install the bolts and finger tighten the nuts.ft. lbs.). (3) Remove support and lower the vehicle. (3) Raise the axle into position until the spring (4) Tighten the front and rear nuts to 115 N·m (85seats in the upper mount. ft. lbs.). (4) Connect the stabilizer bar links and shockabsorbers to the axle bracket. Connect the track bar UPPER SUSPENSION ARMto the body rail bracket. (5) Install the lower suspension arms to the axle. REMOVALDO NOT TIGHTEN AT THIS TIME. (1) Raise and support the vehicle. (6) Install the front propeller shaft to the axle. (2) Remove the upper suspension arm nut and bolt (7) Remove the supports and lower the vehicle. at the axle bracket. (8) Tighten lower suspension arms nuts to 115 (3) Remove the nut and bolt at the frame rail andN·m (85 ft. lbs.). remove the upper suspension arm (Fig. 3). INSTALLATION (1) Position the upper suspension arm at the axle and frame rail.
    • (LT-2WD) (LT-4WD) FWD NUT BOLT UPPER ARM LOWER ARM NUT FRAMEBOLT NUTBOLT RAIL NUT (J-35581-2)TOOL SPECIAL 7932–2 SPECIAL 7932–2 TOOL TOOL SPECIAL 7603 7603 TOOL (J-35581-2) (J-21474-18) (J-21474-18) SPECIAL AXLE SPECIAL BRACKETTOOL SPECIAL7932-1 7604 (J-35581-1) 7932-1 AXLE (J-21474-19) SPECIAL TOOL (J-35581-1) SPECIAL 7604 (J-21474-19) BRACKET TOOL TOOLXJ SUSPENSION 2-9REMOVAL AND INSTALLATION (Continued) Fig. 3 Upper and Lower Suspension Arms Fig. 4 Bushing Removal (2) Install the bolts and finger tighten the nuts. (3) Remove the supports and lower the vehicle. (4) Tighten the nut at the axle to 75 N·m (55 ft.lbs.). Tighten the nut at the frame bracket to 90 N·m(66 ft. lbs.).AXLE BUSHINGREMOVAL (1) Remove the upper suspension arm from axle (2) Position Receiver 7932-1 (J-35581-1) over thebushing in the axle and install Bushing Removal/In-staller (Fig. 4). (3) Remove the bushing by tightening the LongNut.NOTE: For two-wheel drive axles and right side onModel 30 axle, do not remove Receiver 7932-1(J-35581-1) at this time.INSTALLATION (1) Position new bushing, Receiver and Installer Fig. 5 Bushing Installationon axle (Fig. 5). (2) Install the bushing by tightening the Long Nut. (3) Remove tools and install the upper suspensionarm.
    • STABILIZER BAR RETAINER CLAMP GROMMET BUSHING LINK NUT PLATE STUD SUPPORT NUTFWD COTTERIN P BRACKET TRACK BAR FRAME BRACKET NUT LEFT BALL FRAME SCREW STUD RAIL ENDNUT2 - 10 SUSPENSION XJREMOVAL AND INSTALLATION (Continued)STABILIZER BAR NOTE: A puller tool may be necessary to separate the ball stud from the frame rail bracket.REMOVAL (1) Raise and support the vehicle. (3) Remove the bolt and flag nut from the axle (2) Disconnect the stabilizer bar links from the shaft tube bracket (Fig. 7).axle brackets (Fig. 6). (4) Remove the track bar. Fig. 7 Track Bar (LHD) Fig. 6 Stabilizer Bar (LHD) INSTALLATION (3) Disconnect the stabilizer bar from the links. (1) Install the track bar at axle tube bracket. (4) Disconnect the stabilizer bar clamps from the Loosely install the retaining bolt and flag nut.body rails. Remove the stabilizer bar. (2) It may be necessary to pry the axle assemblyINSTALLATION over to install the track bar at the body rail. Install (1) Inspect stabilizer bar bushings. Replace bush- track bar at the body rail bracket. Install the retain-ings if cracked, cut, distorted, or worn. ing nut on the stud. (2) Position the stabilizer bar on the body rail and (3) Remove the supports and lower the vehicle.install the bushings and clamps. Ensure the bar is (4) Tighten the retaining bolt at the axle shaftcentered with equal spacing on both sides. Tighten tube bracket to 100 N·m (74 ft. lbs.).the bolts to 75 N·m (40 ft. lbs.). (5) Tighten the ball stud nut to 81 N·m (60 ft. (3) Install the links and grommets onto the stabi- lbs.). Install a new cotter pin.lizer bar and axle brackets. Tighten the nut at theconnecting links at the axle bracket to 95 N·m (70 ft. HUB BEARINGlbs.). The Hub Bearing is serviced as an assembly. (4) Tighten the stabilizer bar to connecting link REMOVALnut to 36 N·m (27 ft. lbs.). (1) Raise and support the vehicle. (5) Remove the supports and lower the vehicle. (2) Remove the wheel and tire assembly.TRACK BAR (3) Remove the brake components from the axle, refer to Group 5 Brakes.REMOVAL (4) Remove the cotter pin, nut retainer and axle (1) Raise and support the vehicle. hub nut (Fig. 8). (2) Remove the cotter pin and nut from the ball (5) Remove the hub mounting bolts and removestud end at the body rail bracket. hub bearing from the steering knuckle and axle shaft.
    • TONE WHEEL (ABS) BOLT STEERINGNUCKLE K REMOVER ANDASSEMBLY HUB BRAKE SHIELD BEARING WHEEL STUD WASHER NUT COTTER PIN RETAINERXJ SUSPENSION 2 - 11REMOVAL AND INSTALLATION (Continued) Fig. 8 Hub Bearing & KnuckleINSTALLATION (1) Install the hub bearing and brake dust shieldto the knuckle. (2) Install the hub to knuckle bolts and tighten to102 N·m (75 ft. lbs.). (3) Install the hub washer and nut. Tighten thehub nut to 237 N·m (175 ft. lbs.). Install the nutretainer and a new cotter pin. (4) Install the brake components, refer to Group 5Brakes. (5) Install the wheel and tire assembly. (6) Remove support and lower the vehicle.WHEEL MOUNTING STUDSREMOVAL (1) Raise and support vehicle. Fig. 9 Wheel Stud Removal (2) Remove wheel and tire assembly. (5) Install the brake rotor and caliper, refer to (3) Remove brake caliper and rotor, refer to Group Group 5 Brakes for procedure.5 Brakes for procedure. (6) Install wheel and tire assembly, use new lug (4) Remove stud from hub with Remover C-4150A nut on stud or studs that were replaced.(Fig. 9). (7) Remove support and lower vehicle.INSTALLATION (1) Install new stud into hub flange. (2) Install three washers onto stud, then installlug nut with the flat side of the nut against thewashers. (3) Tighten lug nut until the stud is pulled intothe hub flange. Verify that the stud is properlyseated into the flange. (4) Remove lug nut and washers.
    • 2 - 12 SUSPENSION XJSPECIFICATIONSTORQUE CHARTDESCRIPTION TORQUEShock Absorber Upper Nut . . . . . . . . . . . . . . . . . 11 N·m (8 ft. lbs.) Lower Nut . . . . . . . . . . . . . . . . 23 N·m (17 ft. lbs.)Suspension Arm Upper Front Nut . . . . . . . . . . . . . . . . 74 N·m (55 ft. lbs.) Rear Nut . . . . . . . . . . . . . . . . . 89 N·m (66 ft. lbs.) Nut, Long 7603 (J-21474–18)Suspension Arm Lower Front Nut . . . . . . . . . . . . . . . 115 N·m (85 ft. lbs.) Rear Nut . . . . . . . . . . . . . . . . 115 N·m (85 ft. lbs.)Stabilizer Bar Clamp Bolt . . . . . . . . . . . . . . . 54 N·m (40 ft. lbs.) Link Upper Nut . . . . . . . . . . . 36 N·m (27 ft. lbs.) Link Lower Nut . . . . . . . . . . . 95 N·m (70 ft. lbs.)Track Bar Ball Stud Nut . . . . . . . . . . . . . 81 N·m (60 ft. lbs.) Axle Bracket Bolt . . . . . . . . . 100 N·m (74 ft. lbs.)Track Bar Bracket Bolt, Special 7604 (J-21474–19) Bolts . . . . . . . . . . . . . . . . . . . 125 N·m (92 ft. lbs.) Nut . . . . . . . . . . . . . . . . . . . . 100 N·m (74 ft. lbs.) Support Bolts . . . . . . . . . . . . . 42 N·m (31 ft. lbs.)Hub/Bearing Bolts . . . . . . . . . . . . . . . . . . . 102 N·m (75 ft. lbs.) Axle Nut . . . . . . . . . . . . . . . 237 N·m (175 ft. lbs.)SPECIAL TOOLSFRONT SUSPENSION Remover C-4150A Remover/Installer Suspension Bushing 7932 (J-35581) Remover Tie Rod End MB-990635
    • XJ SUSPENSION 2 - 13 REAR SUSPENSION INDEX page pageDESCRIPTION AND OPERATION LEAF SPRING . . . . . . . . . . . . . . . . . . . . . . . . . 14 SUSPENSION COMPONENT . . . . . . . . . . . . . . 13 SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . 13DIAGNOSIS AND TESTING STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . 14 SPRING AND SHOCK DIAGNOSIS . . . . . . . . . . 13 SPECIFICATIONSREMOVAL AND INSTALLATION TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 15 LEAF SPRING AND SHACKLE BUSHING . . . . . 15DESCRIPTION AND OPERATION DIAGNOSIS AND TESTINGSUSPENSION COMPONENT SPRING AND SHOCK DIAGNOSIS The rear suspension is comprised of: A knocking or rattling noise from a shock absorber • Drive Axle may be caused by movement between mounting • Leaf Springs bushings and metal brackets or attaching compo- • Dual-Action Shock Absorbers nents. These noises can usually be stopped by tight- • Stabilizer Bar (optional) ening the attaching nuts. If the noise persists, • Jounce Bumpers inspect for damaged and worn bushings, and attach- Leaf Springs: The rear suspension system uses a ing components. Repair as necessary if any of thesemulti-leaf springs and a solid drive axle. The forward conditions exist.end of the springs are mounted to the body rail hang- A squeaking noise from the shock absorber may beers through rubber bushings. The rearward end of caused by the hydraulic valving and may be intermit-the springs are attached to the body by the use of tent. This condition is not repairable and the shockshackles. The spring and shackles use rubber bush- absorber must be replaced.ings. The bushing help to isolate road noise. The The shock absorbers are not refillable or adjust-shackles allow the springs to change their length as able. If a malfunction occurs, the shock absorberthe vehicle moves over various road conditions. must be replaced. To test a shock absorber, hold it in Shock Absorbers: Ride control is accomplished an upright position and force the piston in and out ofthrough the use of dual-action shock absorbers. The the cylinder four or five times. The action throughoutshocks dampen the jounce and rebound as the vehicle each stroke should be smooth and even.travels over various road conditions. The top of the The spring eye and shock absorber bushings do notshock absorbers are bolted to the body crossmember. require any type of lubrication. Do not attempt toThe bottom of the shocks are bolted to the axle stop spring bushing noise by lubricating them.bracket. Grease and mineral oil-base lubricants will deterio- Stabilizer Bar: The stabilizer bar is used to min- rate the bushing rubber.imize vehicle body roll. The spring steel bar helps to If the vehicle is used for severe, off-road operation,control the vehicle body in relationship to the sus- the springs should be examined periodically. Checkpension. The bar extends across the underside of the for broken and shifted leafs, loose and missing clips,vehicle and is bolted body. Links at the end of the and broken center bolts. Refer to Spring and Shockbar are bolted to axle. Absorber Diagnosis chart for additional information. Jounce Bumpers: The jounce bumpers are usedto limit the spring and axle travel. They are bolted tothe frame rail above the axle. REMOVAL AND INSTALLATIONCAUTION: Suspension components which use rub- SHOCK ABSORBERber/urethane bushings, should be tightened at vehi-cle ride height. This will prevent premature bushing REMOVALfailure and maintain vehicle ride comfort. (1) Remove the shock absorber upper bolts from the body bracket (Fig. 1). (2) Remove lower attaching nut and washer from the bracket stud. Remove the shock absorber.
    • SHOCKABSORBER FWD SHACKLE BUSHING SPRING U-BOLTS BRACKET SPRING NUTSHOCK ABSORBERBUSHING FWDRETAINER NUT BUMPER BRACKET FWD2 - 14 SUSPENSION XJREMOVAL AND INSTALLATION (Continued) SPRING AND SHOCK ABSORBER DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION SPRING SAGS 1. Broken leaf. 1. Replace spring. 2. Spring fatigue. 2. Replace spring. SPRING NOISE 1. Loose spring clamp bolts. 1. Tighten to specification. 2. Worn bushings. 2. Replace spring. 3. Worn or missing spring liner. 3. Replace liner. SHOCK NOISE 1. Loose mounting fastener. 1. Tighten to specification. 2. Worn bushings. 2. Replace shock. 3. Leaking shock. 3. Replace shock. Fig. 1 Rear Suspension ComponentsINSTALLATION INSTALLATION (1) Install the shock absorber lower eye on the (1) Position the stabilizer bar links at the springspring bracket stud. Install the shock absorber and brackets. Install the attaching bolts and nuts andupper bolts on the body bracket. tighten to 74 N·m (55 ft. lbs.). (2) Tighten the lower nut to 62 N·m (46 ft. lbs.). (2) Attach the stabilizer bar to the body rail brack- (3) Tighten the upper bolts to 23 N·m (17 ft. lbs.). ets with the bolts. Tighten to 54 N·m (40 ft. lbs.). (3) Remove the supports and lower the vehicle.STABILIZER BAR LEAF SPRINGREMOVAL (1) Raise and support the vehicle. REMOVAL (2) Disconnect stabilizer bar links from spring (1) Raise vehicle at body rails.brackets (Fig. 2). (2) Remove the wheel and tire assemblies. (3) Disconnect the stabilizer bar brackets from the (3) Support axle with hydraulic jack to relieve axlebody rails. Remove the stabilizer bar and links. weight.
    • SPRING BAR FWD SWAY LINK BOLT BRACKET SCREW GROMMET BUSHING SCREW NUT FRAMERAIL CLAMP SOCKET WRENCHWASHER (DRIVER) FLAT NUT THREADED ROD (RECEIVER)EYENUT SPRING PIPEXJ SUSPENSION 2 - 15REMOVAL AND INSTALLATION (Continued) (1) Assemble tools shown (Fig. 3). Tighten nut at the socket wrench end of the threaded rod until the bushing is forced out. Fig. 2 Stabilizer Bar (4) Disconnect the stabilizer bar link from thespring bracket stud. (5) Remove nuts, U-bolts and spring bracket from Fig. 3 Spring Eye Bushing Removalaxle. (6) Remove nut and bolt attaching spring front eye (2) Assemble and align the bushing installation tools.to shackle. (3) Align the bushing with the spring eye or (7) Remove nut and bolt from spring rear eye. shackle eye and tighten the nut at the socket wrench (8) Remove spring from vehicle. end of the threaded rod. Tighten until the bushing is forced into the spring eye.INSTALLATION (1) Position the spring front eye in the bracket. NOTE: The bushing must be centered in the springLoosely install the attaching bolt and nut. Do not eye. The ends of the bushing must be flush ortighten at this time. slightly recessed within the end surfaces of the (2) Position the rear eye in the shackle bracket. spring eye.Loosely install the attaching bolt and nut. Do not (4) For front bushings bend tabs up after installation.tighten at this time. (3) Position the axle. Install the spring bracket,U-bolts and nuts. Tighten the nuts to 70 N·m (52 ft. SPECIFICATIONSlbs.). (4) Connect the stabilizer bar link to the spring TORQUE CHARTbracket. DESCRIPTION TORQUE (5) Remove the hydraulic jack. Shock Absorber (6) Lower the vehicle. Upper Bolt . . . . . . . . . . . . . . . 23 N·m (17 ft. lbs.) (7) Tighten the spring front eye attaching bolts to Lower Nut . . . . . . . . . . . . . . . . 62 N·m (46 ft. lbs.)156 N·m (115 ft. lbs.). Stabilizer Bar (8) Tighten the spring rear eye attaching bolts to Clamp Bolt . . . . . . . . . . . . . . . 54 N·m (40 ft. lbs.)108 N·m (80 ft. lbs.). Link Upper Bolt . . . . . . . . . . . . 12 N·m (9 ft. lbs.) (9) Tighten the stabilizer bar link to 74 N·m (55 ft. Link Lower Nut . . . . . . . . . . . 74 N·m (55 ft. lbs.)lbs.). Spring U-Bolt Nut . . . . . . . . . . . . . . . 70 N·m (52 ft. lbs.)LEAF SPRING AND SHACKLE BUSHING Front Pivot Bolt . . . . . . . . . . 156 N·m (115 ft. lbs.) For front bushings bend tabs DOWN before Upper Shackle Bolt . . . . . . . 156 N·m (115 ft. lbs.)removal. Use an appropriate driver tool and force the Lower Shackle Bolt . . . . . . . . 108 N·m (80 ft. lbs.)original bushing out of the spring eye.