Replacement

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, No. MB990635 or equivalent, disconnect tie rod from knuckle.
9. Using tools, No. MB990635 and No. MB990809 or equivalent, 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 the upper arm assembly, retaining camber adjusting shims.
13. Remove lower arm assembly.
14. Reverse procedure to install, noting the following:

Fig. 6 Upper Arm To Crossmember Bolt Installation:

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. 6, and tighten to specification.
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 tighten to specification.
d. Attach shock absorber to arm post of side frame with double nuts. Tighten first nut, ensuring distance between bottom of nut and end of strut is 0.81 inch, then tighten to specification.
e. Apply suitable grease to torsion bar serrations, anchor arms serrations, 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. 7 Torsion Bar & Anchor Arm Installation:

h. When torsion bar and anchor arm are assembled, and rebound stop is in contact with side frame, dimension "A", Fig. 7, should be 5.52-5.82 inches 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. 5 Assembling Torsion Bar & Anchor Arm (W/4WD):

i. Tighten adjusting nut, ensuring dimension, Fig. 8, is 3.0 inches for left side and 2.7 inches for right side on Pickup, and 2.17 inches for left side and 2.68 inches for right side on Montero.
j. Install stabilizer bar to lower arm, ensuring distance between bottom of nut and end of bolt is 0.63-0.71 inch
k. Install front hub and caliper assemblies, then inspect driveshaft play in axial direction. Install wheel.
l. With vehicle lowered to ground, tighten to specification.

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

m.Measure distance "A" Fig. 9. If distance is not 3.1 inches, tighten adjusting nut of anchor bolt to obtain correct distance. When tightening adjusting nuts, ensure anchor bolt protrusion does not exceed 3.5 inches on left side or 3.3 inches on right side.