With 4 Wheel Drive

Replace

1. Raise and support vehicle.
2. Detach dust covers from anchor arm assembly and anchor arm.
3. Scribe alignment mark on torsion bar to line up with mark on anchor arm.
4. Loosen adjusting nut and remove torsion bar from anchor arm. It may be necessary to remove anchor arm assembly to remove torsion bar.
5. Detach stabilizer bar from lower arm.
6. Remove shock absorber.
7. Remove cotter pin and slotted nut from tie rod end and upper and lower ball joint studs.
8. Using tool MB990635 or equivalent, disconnect tie rod from knuckle.
9. Using tools MB990635 and MB990809 or equivalents, loosen connection between ball joint and knuckle, tapping knuckle with plastic mallet.
10. After upper ball joint has been removed from knuckle, disconnect lower ball joint. Slotted nut should be temporarily tightened to upper ball joint. When knuckle is removed, be careful not to damage Birfield joint boots.
11. Disconnect knuckle from ball joint.
12. Remove bolts connecting upper arm shaft to arm post of side frame, then remove upper arm assembly, retaining camber adjusting shims.
13. Remove lower arm assembly.
14. Reverse procedure to install, noting the following:

Fig. 18 Installing upper arm to crossmember bolts:

a. Install camber adjusting shims between upper arm shaft and arm post of side frame, then install bolt connecting upper arm shaft to arm post of side frame as shown, Fig. 18, and torque to 73-86 ft. lbs.
b. Assemble lower arm to bracket of side frame. Do not tighten at this time.
c. Assemble knuckle to upper and lower ball joints, then torque upper knuckle to ball joint to 44-65 ft. lbs. and lower knuckle to ball joint to 87-130 ft. lbs.
d. Attach shock absorber to arm post of side frame with double nuts. Tighten first nut so that distance between bottom of nut and end of strut is .81 inch, then torque second nut to 9-13 ft. lbs. Torque shock absorber to lower arm attaching nuts to 6-8 ft. lbs.
e. Apply suitable grease to torsion bar serrations, serrations of anchor arms, inside of dust boot, and anchor bolt thread.
f. Left and right torsion bars are marked for identification.
g. Face end of torsion bar with identification mark forward and align mark on anchor arm with mating mark on torsion bar when torsion bar is inserted in anchor arm. If installing new torsion bar, align serration painted white with mark on anchor arm.

Fig. 5 Assembling Torsion Bar & Anchor Arm (W/4WD):

h. When torsion bar and anchor arm are assembled, and rebound stop is in contact with side frame, dimension ``A,'' Fig. 19, should be 5.52-5.82 inch for left side and 5.32-5.62 inch for right side on Pickup or 5.43-5.73 inches for left side and 5.04-5.35 inches for right side on Montero.

Fig. 20 Tightening torsion bar adjusting nut, with 4 wheel drive:

i. Tighten adjusting nut so that dimension, Fig. 20, is 2.8 inches for left side and 2.7 inches for right side on Pickup with 4-122 engine; 3.0 inches for left side and 2.7 inches for right side on Pickup with 4-156 engine; 3.2 inches for left side and 3.1 inches for right side on Pickup with diesel engine; or 2.17 inches for left side and 2.68 inches for right side on Montero.
j. Install stabilizer bar to lower arm so that distance between bottom of nut and end of bolt is .63-.71 inch
k. Install front hub and caliper assemblies.
l. Check driveshaft play in axial direction.
m. Install wheel.
n. With vehicle lowered to ground, torque lower arm to bracket of side frame to 102-115 ft. lbs.

Fig. 7 Measuring Distance Between Bump Stop & Bump Stop Bracket:

o. Measure distance ``A,'' Fig. 21, and if not 2.8 inch on 1984-86 models or 3.1 inch on 1987-88 models, tighten adjusting nut of anchor bolt to obtain correct distance. When tightening adjusting nuts, ensure that anchor bolt protrusion does not exceed 3.5 inch on left side or 3.3 inch on right side.
p. Torque anchor bolt jam nut to 29-36 ft. lbs.

Service

Fig. 22 Exploded view of front suspension with 4 wheel drive:

1. Remove knuckle oil seal and take out spacer, Fig. 22.
2. Drive out needle bearing by tapping needles uniformly.
3. Remove rebound stop.
4. Remove ring, dust cover, and snap ring from upper ball joint.
5. Using tools MB990799 and MB990800 or equivalents, remove upper ball joint.
6. Remove lower ball joint from lower arm.
7. Remove ring and dust cover from lower ball joint.
8. Using tools MB990883 and MB990957 or equivalents, remove bushing ``B'' from lower arm.
9. Using tool MB990958 or equivalent, remove bushing ``A'' from front suspension crossmember bracket. When removing left hand bushing, detach differential carrier.
10. Inspect all components, replacing as necessary.
11. Apply suitable grease to roller surface of needle bearing.
12. Using tool MB990956 or equivalent, press in needle bearing until it is flush with knuckle end face.
13. Install spacer into knuckle with smaller inside diameter side toward needle bearing.
14. Using tool MB990985 or equivalent, press in oil seal.
15. Pack suitable grease inside oil seal and on lip.
16. Line up mating marks on upper ball joint with that on upper arm.
17. Using tools MB990799 and MB990800 or equivalents, press ball joint into upper arm.
18. Insert snap ring into groove in ball joint case. If snap ring is loose, replace it.
19. Install dust cover and ring and fit to groove of ball joint.
20. Assemble ball joint to lower arm and torque bolts to 87-130 ft. lbs.
21. Install dust cover with embossed portion facing forward, then install ring into groove of ball joint case.
22. Coat bushing ``B'' and lower arm with soap solution, then press bushing into lower arm, using tools MB990883 and MB990957 or equivalents. Press in bushing so that both ends of bushing protrude from lower arm by same amount.
23. Using tool MB990958 or equivalent, press in busing ``A'' with collar of bushing facing forward.