Frame Bracket Knockout Removal

Knockout Removal:

As originally installed, the upper control cannot be adjusted for caster and camber. However, if the caster or camber is measured and found to be out of tolerance, the caster and camber can be set to the proper specifications.

Remove or Disconnect

Tools Required:
J 36202 Torsion Bar Unloading Tool
J 35794 Knockout Removal Tool

^ Raise and support the vehicle.
^ Support the lower control arms with jack or jack stands.
1. Tire and wheel assembly.
2. Adjustment assembly on torsion bar.
^ Mark the adjustment bolt setting
^ Increase the tension on the adjustment arm using J 36202
^ Remove the adjuster bolt.
^ Relax tension on torsion bar.

Important
^ The jack or stand must remain under the lower control arm torsion bar seat during the removal and installation procedure in order to retain the lower control arm position.

3. Nuts (50), cams (49), and bolts (48) from the upper control arm bracket (44).
4. Lift upper control arm (45) up and to the side to gain access to the inner portion of the frame bracket.

Knockout Tool Components:

5. Frame bracket knockout using tool J 38794.
^ Do not distort the frame bracket when removing the knockout.
^ Apply extreme pressure lubricant to the threads of the T-bolt and insert the bolt through the knockout hole in the bracket support.

Knockout Too Intalled Inside Bracket:

^ Install bridge onto the T-bolt. The forward bracket requires the bridge to be installed between the legs of the bracket due to access problems.
^ Assemble the bridge, bearing (chamfered side out), washer, and nut in order.
^ The T-bolt head and bridge must line up horizontally with the knockout; the bridge should span the knockout without interfering with the knockout procedure.
^ Tighten the T-bolt head against the knockout by turning the nut at the opposite end using a socket and torque wrench.
^ An open end or adjustable wrench may be needed to prevent the T-bolt from losing horizontal alignment with the knockout.

NOTICE: Do not subject the tool to more than 100 N.m (75 lbs. ft.) torque. Exceeding the recommended torque may damage the tool and/or the bracket.

^ If the torque limit on the T-bolt is met and the knockout does not break free, use a die grinder of appropriate size. Using the stamped outline as a guide, remove the knockout. (Remove the wax coating in the knockout area to make the perforation lines more visible).
^ If the outline is not visible, use the T-bolt head installed horizontally, as a template, and scribe the frame bracket.
^ Repeat the procedure on the other upper control arm frame bracket.

Install or Connect

1. Upper control arm (45) into frame brackets (44).
2. Bolts (48) and cams (49) through frame brackets (44), and control arm (45)
3. Cams (49) and nuts (50).
^ Install cams with radius toward frame brackets.
4. Partially tighten nut (50).
5. Front wheel assemblies.
A. Adjustment assembly on torsion bar.
^ Increase the tension on the adjustment arm using J 36202.
^ Adjuster bolt to adjustment mark.
^ Relax tension on torsion bar.
6. Alignment machine heads.

Alignment Specifications:

Important
^ Check "Front Wheel Alignment Specifications" in the illustration for special requirements and alignment adjustments. Check trim height "Z" and "D." Verify alignment specifications before proceeding.

Adjust
^ Caster and camber to the correct specifications by rotating the bolt head installed through adjuster cam.

Tighten
A. Front upper control arm nuts (50) to 190 N.m (140 lbs. ft.).
E. Rear upper control arm nuts (50) to 190 N.m (140 lbs. ft.).

^ Set steering wheel on center, with wheels straight, and loosen adjuster sleeve nuts.

Adjust
^ Toe-in, refer to the illustration.

Tighten
^ Tie rod adjuster sleeve nuts to 19 N.m (14 lbs. ft.).

^ Position clamps properly.
^ Recheck alignment specifications.
^ Lower the vehicle.