EXJ_299 jeep xj service manual

7/29/2019 EXJ_299 jeep xj service manual

1/18

SUSPENSION

CONTENTS

page page

ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . 7

REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . 14

ALIGNMENT

INDEX

page page

GENERAL INFORMATION

WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . 1DIAGNOSIS AND TESTING

SUSPENSION AND STEERING SYSTEM . . . . . . . 3SERVICE PROCEDURES

PRE-ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . 4

WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . 4

SPECIFICATIONSALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

GENERAL INFORMATION

WHEEL ALIGNMENTWheel alignment involves the correct positioning of

the wheels in relation to the vehicle. The positioningi s a c com p li s h ed t h r o ug h s u s pe n si on a n d s t e er i n g

l in k a g e a d ju s t men t s . An a l i gn m en t i s con s id er ed

essential for efficient steering, good directional stabil-

i t y a n d t o m i n i m iz e t i r e w e a r . Th e m o s t i m por t a n t

m ea s u r em en t s of a n a l i gn m en t a r e ca s t e r, ca m b er

and toe position (Fig. 1).

CASTER i s t h e f o r w a r d o r r e a r w a r d t i l t o f t h esteering knuckle from vertical . Tilt ing t he t op of the

knuckle rearw a rd provides positive caster. Tilting t he

top of the knuckle forward provides negative caster.

C a s t e r i s a d ir ect i on a l s t a b il it y a n g l e. Th i s a n g l e

en a b les t h e f ron t w h eel s t o r et u rn t o a s t ra i gh t

a h e a d p o s i t i o n a f t e r t u r n s .

CAMBER i s t h e i n w a r d o r o u t w a r d t i l t o f t h ewheel relat ive to t he center of th e vehicle. Tilt ing t he

t o p o f t h e w h e el i n w a r d p r ov i de s n e g a t i v e c a m be r.

Tilting t he t op of t he w heel outw ar d provides positive

ca m b er. I n cor r ect ca m b er w i l l ca u s e w e a r on t h e

i n s id e or ou t s i d e e d ge of t h e t i r e. Th e a n g l e i s n ot

adjusta ble, dama ged component(s) must be replaced

to correct the camber angle.

WHEEL TOE POSITION i s t h e d i ff er en cebe t w e e n t h e l e a d i n g i n s i d e e d g e s a n d t r a i l i n g i n s i d e

edges of the front t ires. Incorrect wheel toe position

i s t h e m o s t c o m m o n c a u s e o f u n s t a bl e s t e e r i n g a n d

uneven tire wear. The wheel toe position is the finalfront wheel al ignment adjustment.

STEE RING AXIS INCLINATION ANGLE ism e a s u r e d i n d e g r e e s a n d i s t h e a n g l e t h a t t h e s t e e r -

i n g k n u c k l e s a r e t i l t e d . T h e i n c l i n a t i o n a n g l e h a s a

f i x e d r e l a t i o n s h i p w i t h t h e c a m be r a n g l e . I t w i l l n o t

ch a n g e e xce pt w h e n a s pi n dl e or b a l l s t u d i s d a m -

a g e d o r ben t . Th e a n g l e i s n o t a d ju st a bl e, d a m a g e d

component(s) must be replaced to correct the steering

axis inclination angle.

THRUST ANGLE i s t h e a n g l e o f t h e r e a r a x l er e la t i ve t o t h e ce n t er l in e of t h e v eh i cl e. I n c or r e ct

thrust angle can cause off-center steering and exces-

sive t ire wear. This angle is not adjustable, damaged

component(s) must be replaced t o correct the thrust

angle.

CAUTION: Never attempt to modify suspension orsteering components by heating or bending.

NOTE: Periodic lubrication of the front suspension/steering system components may be required. Rub-

ber bushings must never be lubricated. Refer toGroup 0, Lubrication And Maintenance for the rec-ommended maintenance schedule.

XJ SUSPENSI ON 2 - 1


2/18

Fig. 1 Wheel Alignment Measurements

2 - 2 SUSPENSI ON XJ

GENERAL INFORMATION (Continued)


3/18

DIAGNOSIS AND TESTING

SUSPENSION AND STEERING SYSTEM

CONDITION POSSIBLE CAUSES CORRECTION

FRONT END NOISE 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.

2. Loose or worn steering orsuspension components.

2. Tighten or replace components asnecessary.

EXCESSIVE PLAY INSTEERING

1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.



3. Loose or worn steering gear. 3. Adjust or replace steering gear.

FRONT WHEELS SHIMMY 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.

2. Loose or worn steering orsuspension components. 2. Tighten or replace components asnecessary.

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 INSTABILITY 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.



3. Tire pressure. 3. Adjust tire pressure.


EXCESSIVE STEERING

EFFORT

1. Loose or worn steering gear. 1. Adjust or replace steering gear.

2. Power steering fluid low. 2. Add fluid and repair leak.

3. Column coupler binding. 3. Replace coupler.



VEHICLE PULLS TO ONESIDE





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.



4/18

SERVICE PROCEDURES

PRE-ALIGNMENTB e f or e s t a r t i n g w h e el a l i gn m en t , t h e f ol low i n g

i n s pe ct i on a n d n e ce ss a r y cor r e ct i on s m u s t be com -

p let e d. R ef er t o S u s pe ns ion a n d S t e er i ng S y s t em

Di a g n o si s C h a r t f or a d d i t i on a l i n f or m a t i o n .(1) I n s p ect t i r es f or s i ze a n d t r e a d w e a r .

(2) Set t ire air pressure.

(3) Inspect front wheel bearings for wear.

(4) Inspect front wheels for excessive radial or lat-

e r a l r u n o u t a n d ba l a n c e .

(5) I n s pect b a l l s t u ds , l in k a g e p iv ot p oi n t s a n d

steering gear for looseness, roughness or binding.

(6) I n s p ect s u s pe n si on com p on e n t s f or w e a r a n d

noise.

WHEEL ALIGNMENTBefore each al ignment reading, the vehicle should

b e jou n ced (r ea r f ir st , t h en f ron t ). G r a s p ea ch

bu m p e r a t t h e c e n t e r a n d jo u n c e t h e v e h i c l e u p a n d

d ow n s ev er a l t i m es . Al w a y s r e le a s e t h e bu m pe r i n

t h e d ow n p os it i on . S e t t h e f r on t e nd a l i gn m en t t o

specifications with the vehicle at i ts NORMAL RIDE

HE IG HT.

CAMBERThe wheel camber angle is preset. This angle is not

a d ju s t a bl e a n d c a n n o t be a l t e r e d .

CASTER

Before checking the caster of the front axle for cor-r e c t a n g l e , be s u r e t h e a x l e i s n o t be n t o r t w i s t e d .

R o a d t e s t t h e v e h i c l e , m a k e l e f t a n d r i g h t t u r n s . I f

t h e s t eer i ng w h e el r et u r n s t o t h e ce nt e r p os it i on

u n a s si st e d, t h e ca s t e r a n g l e i s cor r ect . I f s t ee ri n g

w h e el d oe s n ot r et u r n t ow a r d t h e ce nt e r p os it i on

unassisted, an incorrect caster angle is probable.

C a s t e r c a n be a d ju s t e d by i n s t a l l i n g t h e a p p r o p r i -

ate size shims (Fig. 2).

NOTE: Changing caster angle will also change the

front propeller shaft angle. The propeller shaftangle has priority over caster. Refer to Group 3 Dif-

ferential & Driveline for additional information.

TOE POSITION ( LHD)

NOTE: The wheel toe position adjustment is thefinal adjustment. The engine must remain runningduring the entire toe position adjustment.

(1) S t a r t t h e en gi ne a n d t u rn w h eel s b ot h w a y s

bef or e s t r a i g h t e n in g t h e w h e e ls . Se cu r e t h e s t e er i n g

w h e el w i t h t h e f r on t w h e el s i n t h e s t r a i gh t -a h e a d

position.

(2) Loosen the adjustment sleeve clamp bolts (Fig.

3).

(3) Ad ju s t t h e r i g h t w h e el t o e p os i t ion w i t h t h e

d r a g l in k . Tu r n t h e s l ee ve u n t i l t h e r i g h t w h e el i s a t

cor r e ct TO E -I N s pe ci fi ca t i on s . P o s it i on t h e cl a m p

bolts as shown (Fig. 4) and t ighten to 49 Nm (36 ft .

lbs.).

NOTE: Make sure the toe setting does not changeduring clamp tightening.

(4) Ad ju s t t h e l ef t w h e e l t o e p os i t ion w i t h t h e t i e

rod. Turn the sleeve unti l t he left wh eel is at specifi-

ca t i on s . P os i t ion t h e cl a m p bol t s a s s h ow n (Fi g . 4 )

and t ighten to 27 Nm (20 ft . lbs.).

NOTE: Make sure the toe setting does not change

during clamp tightening.

(5) Verify the right toe setting and turn off engine.

(6) Road test the vehicle on a flat level road to ver-

ify the steering wheel is centered.

NOTE: Once the toe setting is correct, the steeringwheel can be re-centered by adjusting only the draglink.

Fig. 2 Caster Adjustment



5/18

TOE POSITION ( RHD)

NOTE: The wheel toe position adjustment is thefinal adjustment. The engine must remain running

during the entire toe position adjustment.

(1) S t a r t t h e en g in e a n d t u rn w h eel s b ot h w a y s

bef or e s t r a i g h t e n in g t h e w h e e ls . Se cu r e t h e s t e er i n g

w h e el w i t h t h e f r on t w h e el s i n t h e s t r a i gh t -a h e a d

position.

(2) Loosen the adjustment sleeve clamp bolts (Fig.

5).

(3) Adjust the left wheel toe position with the drag

l in k . Tu r n t h e s le ev e u n t i l t h e l e ft w h e el i s a t t h e

cor r e ct TO E -I N s pe ci f ica t i o n s. P o s it i on t h e cl a m p

bolts to their original position and t ighten to 49 Nm

(36 ft. lbs.).


(4) Adjust the right wheel toe position with the t ie

r od . Tu r n t h e s l ee ve u n t i l t h e r i g h t w h e e l i s a t cor -

rect TOE-IN specificat ions. P osition the clamp bolts

t o t h e i r o r i g i n a l p o s i t i o n a n d t i g h t e n t o 2 7 N m (2 0ft. lbs.).


(5) Verify the right toe setting and turn off engine.

(6) Road test the vehicle on a flat level road to ver-

ify the steering wheel is centered.

NOTE: Once the toe setting is correct, the steeringwheel can be re-centered by adjusting only the draglink.

Fig. 3 Steering Linkage (LHD)

Fig. 4 Drag Link and Tie Rod Clamp (LHD)


SERVICE PROCEDURES (Continued)


6/18

SPECIFICATIONS

ALIGNMENT

NOTE: All alignment specifications are in degrees.

ADJUSTMENT PREFERRED RANGEMAX RT/LT

DIFFERENCE

CASTER + 7.0 + 5.25to +8.5

1.25

ADJUSTMENT PREFERRED RANGEMAX RT/LT

DIFFERENCE

CAMBER(fixed angle)

0.25 0.75to +

0.51.0

TOTALTOE-IN

+ 0.250to +0.45

.05

THRUST ANGLE 0 0.15

Fig. 5 Steering Linkage (RHD)


SPECIFICATIONS (Continued)


7/18

FRONT SUSPENSION

INDEX

page page

DESCRIPTION AND OPERATIONSUSPENSION COMPONENTS . . . . . . . . . . . . . . . 7


SHOCK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 8REMOVAL AND INSTALLATION

SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . 9COIL SPRING/JOUNCE BUMPER . . . . . . . . . . . . 9

STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . . 9LOWER SUSPENSION ARM . . . . . . . . . . . . . . . . 10UPPER SUSPENSION ARM . . . . . . . . . . . . . . . . 10

FRONT AXLE BUSHING . . . . . . . . . . . . . . . . . . . 10STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . 11

TRACK BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11FRONT HUB BEARING . . . . . . . . . . . . . . . . . . . 12WHEEL MOUNTING STUDS-FRONT . . . . . . . . . 12

SPECIFICATIONSTORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 13

SPECIAL TOOLSFRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . 13

DESCRIPTION AND OPERATION

SUSPENSION COMPONENTSThe front suspension is a link/coil design (Fig. 1).

Th i s s u sp en s ion i s u s e o n L ef t H a n d D r i ve (L H D )

a n d R i g h t H a n d Dr i v e (RH D) v eh i cl es . Th e s u s pe n -

sion is comprised of:

Drive axle (4WD), tube axle (2WD)

Dual-action shock absorbers Coil springs

Upper and lower suspension arms

St a bi l i z e r ba r

Tra ck ba r

J ounce bumpers

Link/Coil Suspension: This suspension al lowse a c h w h e e l t o a d a p t t o d i f f e r e n t r o a d s u r f a c e s w i t h -

Fig. 1 Suspension Components (LHD)



8/18

out greatly affecting the opposite wheel. Wheels are

at ta ched to a hub/bearings w hich bolts t o the knuck-

l es . Th e h u b/b ea r i ng i s n ot s er vi cea b le a n d i s

r epl a ced a s a u n it . S t eer in g k nu ck les pi vot on

r epl a cea b le b a ll s t ud s a t t a c hed t o t h e a x le t u be

yokes.

Shock Absorbers: The shocks dampen jounce andrebound of the vehicle over various road conditions.The top of the shock absorbers are bolted to the body.

Th e b ot t om of t h e s hock s a r e b ol ted t o t h e a x le

spring bracket.

Coil Springs: The springs control ride quali ty andmaintain proper ride height. The coil springs mount

u p i n t h e f e n d e r s h i e l d t o a br a c k e t w h i c h i s p a r t o f

t h e u n it i zed b od y. A r ub ber i sol a t or i s l oca t e d

between the top of the spring and the body. The bot-

t o m o f t h e s p r i n g s e a t s o n a a x l e p a d a n d i s r e t a i n e d

w i t h a c l i p .

Upper & Lower Suspension Arms: The suspen-

s ion a r m s a r e d if fe ren t l en g t h s, w i t h b u sh i ng s a tbo t h e n d s . T h e y bo l t t h e a x l e a s s e m bl y t o t h e bo d y .

Th e l ow e r a r m s u se s hi ms a t t h e b od y m ou n t t o

a l l ow f or a d ju st m e n t of ca s t e r a n d d r i ve s h a f t p in i on

angle. The suspension arm travel is l imited through

the use of jounce bumpers in compression and shocks

absorbers in rebound.

Stabilizer Bar: The stabil izer bar is used to min-imize vehicle body roll during turns. The spring steel

bar helps to control the vehicle body in relationship

t o t h e s u s p e n s i o n . T h e ba r e x t e n d s a c r o s s t h e f r o n t

u n d er s id e of t h e ch a s s is a n d con n ect s t o t h e b od y

r a i l s . L i n k s a r e c o n n e c t e d f r o m t h e b a r t o t h e a x l e

br a c k e t s . St a bi l i z e r ba r m o u n t s a r e i s o l a t e d by r u b-ber bushings.

Track Bar: Th e t r a c k b a r i s u s e d t o l oca t e t h ea x le l a t er a ll y. Th e b a r i s a t t a c hed t o a b od y r a i l

br a c k e t w i t h a ba l l s t u d a n d i s o l a t e d w i t h a bu s h i n g

a t t h e a x l e br a c k e t .

CAUTION: Components attached with a nut andcotter pin must be torqued to specification. Then if

the slot in the nut does not line up with the cotterpin hole, tighten nut until it is aligned. Never loosenthe nut to align the cotter pin hole.

CAUTION: Suspension components with rubber/urethane bushings (except stabilizer bar) should betightened with the vehicle at normal ride height. It isimportant to have the springs supporting the weightof the vehicle when the fasteners are torqued. If

springs are not at their normal ride position, vehicle

ride comfort could be affected and premature bush-ing wear may occur.

NOTE: Periodic lubrication of the front suspension/

steering system components may be required. Rub-ber bushings must never be lubricated. Refer toGroup 0, Lubrication And Maintenance for the rec-ommended maintenance schedule.


SHOCK DIAGNOSISA knocking or rat t l ing noise from a shock a bsorber

m a y b e ca u s ed b y m ov em en t b et w e en m ou n ti ng

b u sh i ng s a n d m et a l b r a ck et s or a t t a ch i ng com po-

nents. These noises can usually be stopped by t ight-

en in g t h e a t t a ch in g n ut s. I f t h e n oi se per si st s,

i n s p e c t f o r d a m a g e d a n d w o r n bu s h i n g s , a n d a t t a c h -

i n g c o m p o n e n t s . R e p a i r a s n e c e s s a r y i f a n y o f t h e s e

conditions exist.

A squeaking noise from the shock absorber may be

ca u s e d by t h e h y d r a u l i c va l v i n g a n d m a y be i n t er m i t -

t e n t . Th i s c on d i t i on i s n o t r e pa i r a bl e a n d t h e s h ock

absorber must be replaced.

Th e s h ock a bs or ber s a r e n ot r e fi ll a bl e o r a d ju st -

a b l e. I f a m a l fu n ct i on occu r s, t h e s h ock a b s or b er

must be replaced. To test a shock a bsorber, hold it in

an upright position and force the piston in and out of

the cylinder four or five times. The action throughout

each stroke should be smooth and even.

Th e s h ock a bs or ber bu sh i n g s d o n o t r e q u ir e a n y

t y p e o f l u br ica t i o n . Do n ot a t t e m pt t o s t o p bu s h i n g

n oi se b y l ub r ica t i n g t h e m. G r e a s e a n d m i ne ra l oi l-

ba s e l u br i ca n t s w i l l d e t e r i or a t e t h e bu s hi n g .


DESCRIPTION AND OPERATION (Continued)


9/18

REMOVAL AND INSTALLATION

SHOCK ABSORBER

REMOVAL(1) R em ov e t h e n u t , r e t a i n er a n d g r om m e t f r om

the upper stud in the engine compartment (Fig. 2).(2) Remove the lower nuts and bolts from the axle

bracket.

(3) Remove the shock absorber.

INSTALLATION(1) Position the lower retainer and grommet on the

s h ock s t u d. I n s er t t h e s h ock a b s or b er t h r ou g h t h e

shock tower hole.

(2) I n s t a l l t h e l ow e r bol t s a n d n u t s . Ti g h t en n u t s

to 23 Nm (17 ft . lbs.).

(3 ) I n s t a l l t h e u p p e r g r o m m e t a n d r e t a i n e r o n t h e

s t ud . I n st a l l t h e n u t a n d t ig h ten t o 1 0 N m ( 8 f t .

lbs.).

COIL SPRING/JOUNCE BUMPER

REMOVAL(1) R a i se a n d s upp or t t h e v eh icl e. P os it ion a

h y d r a u l i c ja c k u n d e r t h e a x le t o s u p por t i t .

(2) Remove the wheel and t ire assemblies.

(3) Mark an d disconnect the front propeller shaft

from the axle.

(4) Remove lower suspension arms mounting nuts

and bolts from the axle (Fig. 2).

(5) R em ov e t h e s t a bi li zer b a r l in k a n d s hock

absorber from the axle.

(6) R em ove t h e t r a ck b a r f rom t h e b od y r a il

bracket.

(7 ) R e m o v e t h e d r a g l i n k f r o m t h e p i t m a n a r m .

(8) Lower the axle unti l the spring is free from the

upper mount. Remove the coil spring clip and removethe spring.

(9) Pull jounce bumper out of mount.

INSTALLATION(1) Instal l jounce bumper into mount.

(2) Position the coil spring on the axle pad. Instal l

the spring cl ip a nd bolt . Tighten bolt to 21 Nm (16

ft. lbs.).

(3) R a i s e t h e a x l e i n t o p os it i on u n t il t h e s pr i ng

s e a t s i n t h e u p p e r m o u n t .

(4) I n st a l l t h e s t a bi li zer b a r l in ks a n d s hock

a bs or ber s t o t h e a x l e br a ck et .

(5 ) I n s t a l l t h e t r a c k ba r t o t h e bo d y r a i l br a c k e t .(6 ) I n s t a l l t h e l o w e r s u s p e n s i o n a r m s t o t h e a x l e .

I n s t a l l m o u n t i n g bo l t s a n d n u t s f i n g e r t i g h t .

(7) I n s t a l l t h e f r on t p r op el le r s h a f t t o t h e a x le .

(8) I n s t a l l t h e w h e e l a n d t i r e a s s em bl ie s.

(9) Remove the supports and lower the vehicle.

(10) Ti g h t en l ow e r s u s pe n si on a r m s n u t s t o 115

Nm (85 ft. lbs.).

STEERING KNUCKLEFor service procedures on the steering knuckle and

ba l l joi n t s r e fe r t o Gr o u p 3 Di f f er e n t ia l s An d Dr i v -

eline.

Fig. 2 Coil Spring & Shock Absorber



10/18

LOWER SUSPENSION ARM

REMOVAL(1) Raise and support the vehicle.

(2) Remove the lower suspension arm nut and bolt

from the axle bracket.

(3) Remove the nut and bolt from the rear bracketand remove the lower suspension arm (Fig. 3).

INSTALLATION(1 ) P o s i t i o n t h e l o w e r s u s p e n s i o n a r m a t t h e a x l e

br a c k e t a n d r e a r br a c k e t .

(2 ) I n s t a l l t h e bo l t s a n d f i n g e r t i g h t e n t h e n u t s .

(3) Remove support and lower the vehicle.

(4) Tighten the front and rear nuts to 115 Nm (85

ft. lbs.).

UPPER SUSPENSION ARM


(2) Remove the upper suspension ar m n ut an d bolta t t h e a x l e br a c k e t .

(3 ) R e m o v e t h e n u t a n d bo l t a t t h e f r a m e r a i l a n d

remove the upper suspension arm (Fig. 3).

INSTALLATION(1 ) P o s i t i o n t h e u p p e r s u s p e n s i o n a r m a t t h e a x l e

a n d f r a m e r a i l .

(2 ) I n s t a l l t h e bo l t s a n d f i n g e r t i g h t e n t h e n u t s .


(4) Ti g h t en t h e n u t a t t h e a x l e t o 7 5 N m (55 f t .

lbs.). Tighten th e nut at the fra me bracket to 90 Nm

(66 ft. lbs.).

FRONT AXLE BUSHING

REMOVAL(1) Remove the upper suspension arm from axle.(2) P osition Spacer 7932-3 over the axle bushing

on a 4x2 vehicle and right side on a 4x4 vehicle.

(3) P lace R eceiver 7932-1 over flanged end of t he

bushing. (Fig. 4).

(4) P l a c e s m a l l e n d of R e mov er /I n s t a l l 7932-2

a g a i n s t o t h e r s i d e o f t h e bu s h i n g .

(5) Insta l l bolt 7604 through remover, bushing an d

receiver.

(6) Instal l Long Nut 7603 and t ighten nut too pull

bu s h in g ou t of t h e a x l e br a c k et .

(7) Remove nut, bolt , receiver, remover and bush-

ing.

NOTE: On 4x2 vehicle and right side of 4x4 vehicle,leave Spacer 7932-3 in position for bushing instal-

lation.

INSTALLATION

(1) P lace Receiver 7932-1on the other side of theaxle bracket.

(2) P os i t ion n e w bu sh i n g u p t o t h e a x l e br a c k et ,

an d large end of Remover/Insta l l 7932-2 a gainst the

bushing (Fig. 5).

(3) Insta l l bolt 7604 th rough receiver, bushing an d

installer.

(4) I n s t a l l L o n g Nu t 7603 a n d t i g h t en n u t t o d r a w

t h e bu s h i n g i n t o t h e a x l e br a c k e t .

(5) Remove tools and instal l the upper suspension

a r m .

Fig. 3 Upper and Lower Suspension Arms

Fig. 4 Bushing Removal

2 - 1 0 SUSPENSI ON XJ

REMOVAL AND INSTALLATION (Continued)


11/18

STABILIZER BAR


(2) Remove nuts, retainers and grommets from the

links at the stabil izer bar (Fig. 6).

(3) R em ov e t h e l in k s m ou n t in g n u t s a n d b ol t s

from the axle brackets.

(4) Rem ov e t h e s t a b il iz er b a r cl a m ps f r om t h e

body rai ls . Remove the stabil izer bar.

INSTALLATION(1) Inspect st abil izer ba r bushings. Replace bush-

ings i f cracked, cut, distorted, or worn.

(2) P o s it i on t h e s t a bi li z er ba r on t h e bo d y r a i l a n d

i n s t a l l t h e b u s h i n g s a n d c l a m p s . E n s u r e t h e b a r i s

ce n t er e d w i t h e q u a l s p a ci n g on bot h s i de s. Ti g h t en

the bolts to 75 Nm (40 ft . lbs.).

(3 ) I n s t a l l t h e l i n k s a n d g r o m m e t s o n t o t h e s t a bi -

l i z e r ba r a n d a x l e br a c k e t s .

(4) Ti g h t en t h e l i n k n u t s a t t h e a x le br a c k et t o 9 5Nm (70 ft. lbs.).

(5) Tighten the l ink nuts at the sta bil izer bar to 36

Nm (27 ft. lbs.).


TRACK BAR


(2) R e m ov e t h e cot t e r p in a n d n u t f r om t h e b a l l

s t u d e n d a t t h e bo d y r a i l br a c k e t .

(3) U s e a u n i ve r sa l p u ll er t o ol t o s ep a r a t e t h e ba l l

s t u d f r o m t h e f r a m e r a i l br a c k e t .(4) R em ov e t h e b ol t a n d f la g n u t f r om t h e a x l e

shaft tube bracket (Fig. 7).

(5) Remove the track bar.

INSTALLATION(1) I ns ta l l t h e t r a ck b a r a t a x le t u be br a cket .

L o o s e l y i n s t a l l t h e r e t a i n i n g bo l t a n d f l a g n u t .

(2 ) I t m a y be n e c e s s a r y t o p r y t h e a x l e a s s e m bl y

ov er t o i n st a l l t h e t r a c k b a r a t t h e b od y r a i l. I n s t a l l

t r a c k ba r a t t h e bo d y r a i l br a c k e t . I n s t a l l t h e r e t a i n -

i n g n u t o n t h e s t u d .


(4) Ti gh t en t h e r et a i n in g b ol t a t t h e a x l e s h a f t

tube bracket to 100 Nm (74 ft . lbs.).

Fig. 5 Bushing Installation

Fig. 6 Stabilizer Bar (LHD)Fig. 7 Track Bar (LHD)

XJ SUSPENSION 2 - 11



12/18

(5) Ti gh t e n t h e b a l l s t u d n u t t o 81 N m (60 f t .

lbs.). Instal l a new cotter pin.

FRONT HUB BEARING


(2) Remove the wheel and t ire assembly.

(3) Remove the brake caliper, rotor a nd AB S wh eel

speed sensor, refer to Group 5 Brakes.

(4) R e m ov e t h e cot t e r p in , n u t r e t a i n er a n d a x l e

hub nut (Fig. 8).

(5) R e m ov e t h e h u b bea r i n g m ou n t i n g bol t s f r om

t h e ba c k o f t h e s t e e r i n g k n u c k l e . R e m o v e h u b be a r -

i n g f r o m t h e s t e e r i n g k n u c k l e a n d o f f t h e a x l e s h a f t .

INSTALLATION(1 ) I n s t a l l t h e h u b be a r i n g a n d br a k e d u s t s h i e l d

to the knuckle.

(2) I n s t a l l t h e h u b b ea r i n g t o k n uck le b ol t s a n d

tighten to 102 Nm (75 ft . lbs.).

(3) I n s t a l l t h e h u b w a s h er a n d n u t . Ti gh t en t h eh u b n u t t o 237 N m (175 f t . l bs .). I n s t a l l t h e n u t

r e t a i n e r a n d a n e w c o t t e r p i n .

(4 ) I n s t a l l t h e br a k e r o t o r , c a l i p e r a n d A B S w h e e l

speed sensor, refer to Group 5 Brakes.

(5) I n s t a l l t h e w h e el a n d t i r e a s s em bl y.

(6) Remove support and lower the vehicle.

WHEEL MOUNTING STUDS-FRONT

REMOVAL(1) Raise and support vehicle.

(2) Remove wheel and t ire assembly.

(3) Remove brake caliper and rotor, refer to Group

5 Brakes for procedure.

(4) Remove stud from hub with Remover C-4150A

(Fig. 9).

INSTALLATION(1 ) I n s t a l l n e w s t u d i n t o h u b f l a n g e .

(2) I n s t a l l t h r ee w a s h e r s on t o s t u d, t h en i n st a l l

l ug n ut w it h t h e f la t s id e of t h e n u t a g a in st t h e

w a s h e r s .

Fig. 8 Hub Bearing & Knuckle

Fig. 9 Wheel Stud Removal




13/18

(3) Ti gh t e n l ug n u t u n t il t h e s t u d i s p ul le d i n t o

t h e h ub f la n g e. Ver if y t h a t t h e s t ud i s p roper ly

s e a t e d i n t o t h e f l a n g e .

(4 ) R e m o v e l u g n u t a n d w a s h e r s .

(5) I n st a l l t h e b r a k e r ot or a n d ca l i per, r ef er t o

Group 5 Brakes for procedure.

(6) I n s t a l l w h e el a n d t i r e a s se mb ly, u s e n e w l ugn u t o n s t u d o r s t u d s t h a t w e r e r e p l a c e d .

(7) Remove support and lower vehicle.

SPECIFICATIONS

TORQUE CHART

DESCRIPTION TORQUE

Shock Absorber

Upper Nut . . . . . . . . . . . . . . . . . 11 Nm (8 ft . lbs.)

Lower Nut . . . . . . . . . . . . . . . . 23 Nm (17 ft . lbs.)

Suspension Arm UpperFr on t Nu t . . . . . . . . . . . . . . . . 74 N m (55 f t . l bs.)

Rear Nut . . . . . . . . . . . . . . . . . 89 Nm (66 ft . lbs.)

Suspension Arm Lower

Front Nut . . . . . . . . . . . . . . . 115 Nm (85 ft . lbs.)

Rear Nut . . . . . . . . . . . . . . . . 115 Nm (85 ft . lbs.)

Stabilizer Bar

C l a m p B ol t . . . . . . . . . . . . . . . 54 N m (40 f t . l bs.)

L i n k U p p er Nu t . . . . . . . . . . . 36 N m (27 f t . l bs .)

L i n k L ow e r Nu t . . . . . . . . . . . 95 N m (70 f t . l bs .)

Track Bar

B a l l St u d Nu t . . . . . . . . . . . . . 81 N m (60 f t . l bs.)

Axle Bra cket B olt . . . . . . . . . 100 Nm (74 ft . lbs.)Track Bar Bracket

B olts . . . . . . . . . . . . . . . . . . . 125 Nm (92 ft . lbs.)

Nut . . . . . . . . . . . . . . . . . . . . 100 Nm (74 ft . lbs.)

Support B olts . . . . . . . . . . . . . 42 Nm (31 ft . lbs.)

Hub/Bearing

B olts . . . . . . . . . . . . . . . . . . . 102 Nm (75 ft . lbs.)

Axle Nut . . . . . . . . . . . . . . . 237 Nm (175 ft . lbs.)

SPECIAL TOOLS

FRONT SUSPENSION

Nut, Long 7603

Bolt, Special 7604

Remover C-4150A

Remover Tie Rod End MB-990635

Remover/Installer Suspension Bushing 7932




14/18

REAR SUSPENSION

INDEX

page page

DESCRIPTION AND OPERATIONSUSPENSION COMPONENT . . . . . . . . . . . . . . . 14


SPRING AND SHOCK DIAGNOSIS . . . . . . . . . . . 14REMOVAL AND INSTALLATION

SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . 15

STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . 15LEAF SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . 16

LEAF SPRING AND SHACKLE BUSHING . . . . . . 16SPECIFICATIONS

TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 17

DESCRIPTION AND OPERATION

SUSPENSION COMPONENTThe rear suspension is comprised of:

Drive Axle L e a f Sp r i n g s

Dual-Action Shock Absorbers

Stabil izer Bar (optional)

J ounce Bumpers

Leaf Springs: The rear suspension system uses amulti-leaf springs and a solid drive axle. The forward

end of the springs are mounted to the body rai l hang-

e r s t h r o u g h r u bbe r bu s h i n gs . Th e r e a r w a r d e n d o f

t h e s p r i n g s a r e a t t a c h e d t o t h e b o d y b y t h e u s e o f

shackles. The spring and shackles use rubber bush-

i n g s. Th e bu s h in g h e lp t o i s ol a t e r oa d n oi s e. Th e

s h a c k l e s a l l o w t h e s p r i n g s t o c h a n g e t h e i r l e n g t h a s

the vehicle moves over various r oad conditions.Shock Absorbers: R i d e con t r o l i s a c com p li s h ed

through the use of dual-action shock absorbers. The

shocks da mpen the jounce and rebound as the vehicle

tra vels over va rious road conditions. The t op of the

shock absorbers are bolted to the body crossmember.

Th e b ot t om of t h e s hock s a r e b ol ted t o t h e a x le

bracket.

Stabilizer Bar: The stabil izer bar is used to min-imize vehicle body roll . The spring steel bar helps to

con t r o l t h e v eh i cl e bo d y i n r e la t i on s h i p t o t h e s u s -

pension. The bar extends across the underside of the

v e h i c l e a n d i s bo l t e d t o t h e a x l e . L i n k s a t t h e e n d o f

t h e ba r a r e bo l t e d t o t h e f r a m e .

J ounce Bumpers: The jounce bumpers are usedto l imit the spring and axle travel . They are bolted to

t h e f r a m e r a i l a bo v e t h e a x l e .

CAUTION: Suspension components with rubber/

urethane bushings (except stabilizer bar) should betightened with the vehicle at normal ride height. It isimportant to have the springs supporting the weight

of the vehicle when the fasteners are torqued. If

springs are not at their normal ride position, vehicleride comfort could be affected and premature bush-ing wear may occur.


SPRING AND SHOCK DIAGNOSISA knocking or rat t l ing noise from a shock a bsorber

m a y b e ca u s ed b y m ov em en t b et w e en m ou n ti ng

b u sh i ng s a n d m et a l b r a ck et s or a t t a ch i ng com po-

nents. These noises can usually be stopped by t ight-

en in g t h e a t t a ch in g n ut s. I f t h e n oi se per si st s,

i n s p e c t f o r d a m a g e d a n d w o r n bu s h i n g s , a n d a t t a c h -

i n g c o m p o n e n t s . R e p a i r a s n e c e s s a r y i f a n y o f t h e s e

conditions exist.

A squeaking noise from the shock absorber may be

ca u s e d by t h e h y d r a u l i c va l v i n g a n d m a y be i n t er m i t -

t e n t . Th i s c on d i t i on i s n o t r e pa i r a bl e a n d t h e s h ock

absorber must be replaced.

Th e s h ock a bs or ber s a r e n ot r e fi ll a bl e o r a d ju st -

a b l e. I f a m a l fu n ct i on occu r s, t h e s h ock a b s or b er

must be replaced. To test a shock a bsorber, hold it in

an upright position and force the piston in and out of

the cylinder four or five times. The action throughout

each stroke should be smooth and even.

The spring eye a nd shock a bsorber bushings do not

r eq u ir e a n y t y p e of l ub r ica t i on . D o n ot a t t e m pt t o

s t op s pr in g b us hi ng n oi se b y l ub ri ca t i ng t h em .G r e a s e a n d m i n er a l oi l -ba s e l u br i ca n t s w i l l d e t er i o-

r a t e t h e bu s h i n g r u bbe r.

If the vehicle is used for severe, off-road operation,

the springs should be examined periodically. Check

for broken and shifted leafs, loose and missing cl ips,

a n d br o k e n c e n t e r bo l t s . R e f e r t o Sp r i n g a n d Sh o c k

Absorber Diagnosis chart for additional information.



15/18

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 bushings.

3. Worn or missing spring tip inserts. 3. Replace spring tip inserts.

SHOCK NOISE 1. Loose mounting fastener. 1. Tighten to specification.

2. Worn bushings. 2. Replace shock.

3. Leaking shock. 3. Replace shock.

REMOVAL AND INSTALLATION

SHOCK ABSORBER

REMOVAL(1) R e m ov e t h e s h ock a bs or ber u p pe r bol t s f r om

the body bracket (Fig. 1).

(2) R e m ov e l ow e r a t t a c h i n g n u t a n d w a s h er f r om

the bracket stud. Remove the shock absorber.

INSTALLATION

(1) I n s t a l l t h e s h ock a b s or b er l ow e r e ye on t h es p ri n g br a ck et s t u d . I n s t a l l t h e s h ock a bs or ber a n d

upper bolts on the body bracket.

(2) Tighten the lower nut to 62 Nm (46 ft . lbs.).

(3) Tighten th e upper bolts to 23 Nm (17 ft. lbs.).

STABILIZER BAR


Fig. 1 Rear Suspension Components


DIAGNOSIS AND TESTING (Continued)


16/18

(2) D is con n ect s t a b il iz er b a r l in k s f r om s pr i ng

brackets (Fig. 2).

(3) Disconnect the stabil izer bar brackets from the

bod y r a i l s . R e m ov e t h e s t a bi l iz er ba r a n d l in k s .

INSTALLATION(1) P os i t ion t h e s t a bi l iz er ba r l i nk s a t t h e s pr i n g

b ra ck et s . I n st a l l t h e a t t a c hi ng b ol ts a n d n u ts a n d

tighten to 74 Nm (55 ft . lbs.).

(2) Attach the stabil izer bar to the body rai l brack-ets w ith the bolts. Tighten to 54 Nm (40 ft . lbs.).


LEAF SPRING

REMOVAL(1) Raise vehicle at body rai ls .

(2) Remove the wheel and t ire assemblies.

(3) Support axle with hydraulic jack to relieve axle

weight.

(4) D is con n ect t h e s t a b il iz er b a r l in k f r om t h e

spring bracket stud.

(5) Remove nuts, U-bolts and spring bracket from

axle.

(6) Remove nut and bolt attaching spring front eye

to shackle.

(7) Remove nut and bolt from spring rear eye.

(8) Remove spring from vehicle.

INSTALLATION(1) P os it i on t h e s pr i ng f r on t e ye i n t h e b r a ck et .

L oos el y i n st a l l t h e a t t a ch i ng b ol t a n d n u t . D o n ot

t i g h t e n a t t h i s t i m e .

(2) P os it i on t h e r ea r e ye i n t h e s h a ck le b r a ck et .

L oos el y i n st a l l t h e a t t a ch i ng b ol t a n d n u t . D o n ot

t i g h t e n a t t h i s t i m e .

(3) P os it i on t h e a x le . I n s t a l l t h e s pr i ng b r a ck et ,

U-bolts a nd nuts. Tighten t he nut s t o 70 Nm (52 ft .

lbs.).

(4) C o n ne ct t h e s t a b il iz er b a r l in k t o t h e s pr i ngbracket.

(5) Remove the hydraulic jack.

(6) Lower the vehicle.

(7) Tighten t he spring front eye at ta ching bolts t o

156 Nm (115 ft. lbs.).

(8) Ti g h t en t h e s pr i n g r e a r e y e a t t a ch i n g bo lt s t o

108 Nm (80 ft. lbs.).

(9) Tighten t he st abil izer bar l ink to 74 Nm (55 ft .

lbs.).

LEAF SPRING AND SHACKLE BUSHINGF or f ron t b us hin gs b en d t a b s D OWN bef or e

removal . Use an appropriate driver tool and force theoriginal bushing out of the spring eye.

(1) Assemble t ools shown (Fig. 3). Tighten nut at

t h e s o c k e t w r e n c h e n d o f t h e t h r e a d e d r o d u n t i l t h e

bushing is forced out.

(2) As se mb le a n d a l i gn t h e b u sh i ng i n st a l l a t i on

tools.

(3) Al ig n t h e b us hi ng w i t h t h e s pr in g ey e or

s h a c kl e e ye a n d t i g h t en t h e n u t a t t h e s o ck et w r e n ch

end of the t hreaded rod. Tighten unt i l the bushing is

forced into the spring eye.

Fig. 2 Stabilizer Bar

Fig. 3 Spring Eye Bushing Removal




17/18

NOTE: The bushing must be centered in the springeye. The ends of the bushing must be flush orslightly recessed within the end surfaces of thespring eye.

(4 ) Fo r f r o n t bu s h i n g s be n d t a bs u p a f t e r i n s t a l l a -

tion.

SPECIFICATIONS

TORQUE CHART

DESCRIPTION TORQUE

Shock Absorber

U p p er B ol t . . . . . . . . . . . . . . . 23 N m (17 f t . l bs.)

Lower Nut . . . . . . . . . . . . . . . . 62 Nm (46 ft . lbs.)

Stabilizer Bar

C l a m p B ol t . . . . . . . . . . . . . . . 54 N m (40 f t . l bs.)

Link U pper B olt . . . . . . . . . . . . 12 Nm (9 ft . lbs.)

Link Lower Nut . . . . . . . . . . . 74 Nm (55 ft . lbs.)

Spring

U-B olt Nut . . . . . . . . . . . . . . . 70 Nm (52 ft . lbs.)

Front P ivot B olt . . . . . . . . . 156 Nm (115 ft . lbs.)

Upper Sh ackle Bolt . . . . . . . 156 Nm (115 ft . lbs.)

Lower Sh ackle Bolt . . . . . . . . 108 Nm (80 ft . lbs.)




18/18

Documents

EXJ_299 jeep xj service manual