Front Brake System Repair - Assembly

Figure 3:

1. Spindle carrier installation.

a. Insert the spindle carrier lever (T85M-3206-A) into the new spindle carrier slot, Figure 3.

b. Rotate the spindle carrier lever 90~.

c. Slide the spindle carrier assembly onto the strut.

d. Align the bolt hole and install a new pinch bolt.

e. Tighten the pinch bolt to 59-66 ft.lbs. (80-90 N-m).

Figure 4:

2. Using a control arm bushing remover (T88M-5493-A) or equivalent, carefully remove the stabilizer bar bushings from the lower control arm, Figure 4.
3. Position the lower control arm in a vise.

4. Install the bushings.

a. Position one bushing on the lower control arm.

Figure 5:

b. Install the control arm to bushing replacer (T88M-5493-B) or equivalent, Figure 5.

c. Tighten the screw to seat the bushing in the lower control arm.

5. Turn the lower control arm over in the vise and install the other bushing following the procedure in Step # 4.

Figure 6:

6. Install the rear washer and the washer cover on the stabilizer bar. Slide the control arm on the stabilizer bar, Figure 6.

NOTE: THE REAR WASHER HAS A SHALLOWER DISH THAN THE FRONT WASHER. WHEN THE WASHER IS INSTALLED, MAKE SURE THE PLASTIC COVER IS IN PLACE BETWEEN THE DISHED STEEL WASHER AND THE BUSHING. THE DISHED SIDE OF THE STEEL WASHER FACES AWAY FROM THE BUSHING.

7. Install the front washer, the front washer cover and the nut. Do not tighten the nut at this time.

NOTE: THE STABLIZER BAR NUTS MUST BE TORQUED WITH THE CAR OFF THE HOIST. A STEERING WHEEL NIBBLE CONDITION MAY BE CREATED IF THE NUTS ARE NOT TORQUED CORRECTLY.

8. Install the control arm ball joint.

a. Position the control arm ball joint into the spindle carrier.

b. Install the attaching nut.

c. Tighten the nut to 48-63 ft.lbs. (65-85 N-m).

d. Install a new cotter pin.
9. Grip the bottom of the strut or spindle/carrier assembly and pull inward until the control arm enters the crossmember and aligns with the bolt holes. Use a drift punch to hold the arm in alignment while installing the attaching bolt.

10. Install the control arm pivot bolt, washer and attaching nut. Snug the attaching nut, but do not tighten it at this time.

11. Install the tie rod end to the spindle carrier.

a. Install the attaching nut.

b. Tighten the attaching nut to 15-23 ft.lbs. (20-32 N-m).

c. Install a new cotter pin.

12. Install a new rotor and the rotor retaining clip.

13. Position the anchor bracket to the spindle carrier.

a. Install the retaining bolts.

b. Tighten the bolts to 43-44 ft.lbs. (51-61 N-m).

14. Install the new brake pads in the caliper.

15. Position the caliper over the rotor.

a. Install the caliper to anchor plate bolts.

b. Tighten the bolts to 18-23 lb.ft. (25-30 N-m).

Figure 7:

16. Connect the brake pad wear sensor and make sure it is properly routed, Figure 7.

17. Install the wheel and tire assemblies. Torque the wheel nuts evenly to 55-70 ft.lbs. (70-100 N-m) per the shop manual. Lower the car.

18. Bounce the car to settle the suspension.

19. With the vehicle weight on the tires, tighten the lower control arm pivot bolt to 11 ft.lbs. (15 N-m), then make an additional 1/4 turn.

20. Tighten the stabilizer bar to control arm attaching nut to 52-81 ft.lbs. (70-110 N-m). Make sure the front washer does not rotate with the nut during tightening.
21. Pump the brake pedal before moving the vehicle to position the new brake pads.