Service Procedure
Preliminary Steps1. Record all radio station presets.
2. Disconnect the negative battery cable.
3. Raise the vehicle on a hoist.
NOTE:
Make sure you release the parking brake.
Remove Rear Wheels/Brake Calipers
4. Remove both rear wheels/tires.
5. Remove both brake calipers and hang them from the brake line supports with wire (see Figure 2).
Remove Center Exhaust Tube/Rear Muffler
6. Remove the exhaust system ground strap from the muffler stud/nut (see Figure 3).
7. On the passenger (RH) side:
remove two bolts and one clip and remove the rear plastic under cover (see Figure 4).
8. Below the plastic cover you just removed: remove three bolts and remove the rear metal cover (see Figure 5).
9. On the driver's (LH) side: remove two nuts and one clip and remove the rear plastic under cover (see Figure 6).
10. Below the plastic cover you just removed: remove two bolts and one clip and remove the rear metal cover (see Figure 7).
11. Remove nuts and bolts and remove the tunnel stay side covers and the tunnel "stay" bracket (see Figure 8).
12. Remove the nut that holds the center muffler mount bracket (see Figure 9).
13. Remove the bolt that holds the passenger (RH) side rear muffler mount bracket (see Figure 10).
14. Remove the exhaust system center tube front nuts (see Figure 11).
15. Support the rear muffler (see Figure 12).
16. Remove the rear muffler bracket bolts (see Figure 13a and 13b).
17. Carefully remove the exhaust center tube/rear muffler and place it in a safe location (see Figure 14).
Remove Propeller Shaft
18. Apply an "index" (line up) mark across the propeller shaft and differential pinion flange for correct re-assembly (see Figure 15).
19. Remove four nuts and bolts and carefully remove the propeller shaft and place it in a safe location.
CAUTION:
Avoid propeller shaft damage. Do NOT scratch, chip, ding, or dent the propeller shaft.
Disconnect Parking Brake Cables
20. Disconnect the parking brake cables as follows:
a. Remove the nuts that hold the parking brake cable brackets to the rear suspension member (see Figure 16).
b. Remove the cables from the metal support brackets (see Figure 17).
C. Remove the nuts that hold the parking brake cables to the vehicle body (see Figure 18).
d. Disconnect the cables from the front equalizer (see Figure 18).
Disconnect ABS Harness Connector/Remove Tie Wrap
21. Disconnect the ABS harness connector (see Figure 19a). Then remove the tie wrap from the suspension member using a pair of needle-nose pliers (see Figure 19b).
^ If you accidentally break the tie wrap, install a new one at re-assembly. The tie wrap part number is 24225-89960.
Disconnect Shock Absorber From Knuckle
22. Place a support jack under the rear lower link. Then remove the bolt that holds the shock absorber to the knuckle (see Figure 20).
NOTE:
Do NOT disconnect the shock absorber from the body at the top of the wheel well.
23. Place an index mark across the bushing and cross bar for proper re-assembly (see Figure 22).
Install Jack Adapter Tool # J-47441 To Differential
24. Install the jack adapter tool # J-47441 to the differential pinion flange and suspension member as follows:
a. Install part "A" of the adapter tool onto the pinion flange. Make sure both pins on the tool are inserted into the pinion flange bolt holes (see Figure 23).
b. Slide part "B" of the adapter tool over the rear of part 'A". Then, insert the locator pins at the upper corners of the tool into the rear suspension member (see Figure 24).
Remove Rear Suspension Member
25. Use bolts to attach a transmission jack to the adapter tool (see Figure 25).
26. Place an additional support jack under the front suspension member to help stabilize the vehicle on the lift (see Figure 26).
27. Place an index mark across the coil spring and upper spring seat for proper re-installation (see Figure 27).
28. Place a support jack under the rear suspension member.
^ Then remove the bolts and nuts that hold the suspension member "stay" brackets (both passenger and drivers side brackets). See Figure 28.
^ Slowly lower the support jack and remove the stay brackets.
NOTE:
The larger nuts hold the suspension member.
29. Remove the bolts and nuts and remove the rear stay bracket (see Figure 29).
30. Carefully lower the suspension member (see Figure 30) and place it in a safe location away from "Traffic".
Install Fuel Hoses
CAUTION:
Make sure the fuel tank is less than 1/4 full before you perform this procedure.
31. Remove three nuts and remove the evaporative canister shield (see Figure 31).
32. Remove and replace the four fuel hoses (provided in the kit). See Figure 32.
^ Replace hoses one at a time, making sure they are correctly positioned and secured.
^ Tighten the fuel filler hose clamps so that the distance between the bolt head and metal plate is set to the proper dimension (see Figure 32).
Re-Assembly
33. Re-install all components in the reverse order of removal, making sure of the following:
A. Make sure the additional support jack under the center of the front suspension member is in place and contacting the front suspension member. (see Figure 36A)
B. Raise the rear suspension assembly on the studs until approximately 1.0 inch/25.4 mm of the rear stud and approximately 1.25 inch /31.7 mm of the front stud is sticking through the mount.
C. Use a single nut on each side to hold the front suspension stay bracket in place.
D. Use a single nut on each side to hold the rear suspension bracket in place.
E. Use a support jack to raise one corner of the rear suspension assembly until the bushing assembly is flush to the body. Tighten the nut until the nut contacts the bushing inner sleeve.
F. Repeat the same procedure on the other side.
C. Use a support jack to raise one corner of the front suspension assembly until the assembly is flush to the body. Tighten the nut until the nut contacts the bushing inner sleeve.
H. Repeat the same procedure on the other side.
I. Torque the front and rear suspension mounting nuts to 110 Nm (11 kg-m, 81 ft-lb.)
^ All suspension fasteners are tightened to the proper torque specification (see Figure 33).
^ All "index" marks that you made are lined up.
^ Use new nuts/bolts (provided in the kit) for securing the propeller shaft to the differential pinion flange. Tighten the nuts to: 69 - 78 Nm (7.0 - 8.0 kg-m, 51 - 58 ft-lb).
^ Use a new gasket (see Parts Information) between the front and center exhaust tubes.
34. Re-connect the negative battery cable.
35. Re-program all radio station pre-sets.