Front Suspension Frame, Stabilizer Bar and/or Bushing Removal and Installation

Front Suspension Frame, Stabilizer Bar and/or Bushing Removal and Installation

Front Suspension Frame, Stabilizer Bar and/or Bushing Components

Removal

1) Hoist vehicle and remove wheels (right & left).
2) Remove engine under cover and engine splash cover.
3) Remove suspension control arm. Front Suspension
4) Remove right side and left side front drive shaft assembly (if equipped).
5) Remove stabilizer joints (1). When loosening joint nut, hold stud with hexagon wrench.





6) For headlight auto leveling model, detach front fender lining clip (1).






7) For headlight auto leveling model, disconnect front height sensor connector (1) and then detach clip (2).





8) Disconnect steering lower shaft from pinion shaft. P/S Gear Case Assembly Removal and Installation
9) Detach low pressure return hose (2) from low pressure return pipe (3) and then disconnect pipe bracket (1).





10) Remove gear box union bolt (1).





11) Remove engine splash cover (2) from front suspension frame (1) (if equipped).






12) Remove front propeller shaft (if equipped). Propeller Shaft Removal and Installation
13) Fix radiator (2) to body with rope (1) to avoid the radiator (2) fall off when front suspension frame lowered.





14) Remove engine hood if necessary. Hood Removal and Installation
15) Support engine assembly by using chain hoist or engine crane.
16) Support suspension frame at the specified positions (1) indicated in figure.

WARNING:
If the front suspension frame is not stably supported on a transmission jack or other supporting equipment during its removal, the frame could drop and cause personal injury.

Make sure that the weight of the front suspension frame is supported at the frame's center and that the frame is well-balanced on the support.





17) Remove engine front body side mounting nuts (1).
18) Remove suspension frame mounting bolts (2), and then lower suspension frame (3) with stabilizer bar, P/S gear box assembly and front differential assembly (if equipped).





19) Remove P/S gear case assembly (1) and front differential assembly (2) (if equipped).
- P/S gear case assembly: P/S Gear Case Assembly Removal and Installation
- Front differential assembly:





20) Remove stabilizer bar (1) and bushing (2) from suspension frame (3).






Installation

Front Suspension Frame Check
1) When installing stabilizer, loosely assemble all components while insuring that stabilizer is centered, side-to-side.
2) Install stabilizer bar (1), stabilizer bushing (2) and stabilizer mounting bracket (3) to suspension frame.

NOTE:
- For correct installation of stabilizer bar, side-to-side, be sure that stopper ring (5) on stabilizer bar aligns with stabilizer bushing, both right and left, as shown in figure.
- Install stabilizer bushing so that a cut (6) becomes forward.

3) Tighten stabilizer bar mounting bracket bolts (4) to specified torque.

Tightening torque
Stabilizer bar mounting bracket bolt (a): 50 Nm (5.0 kgf-m, 36.5 lbf-ft)





4) Install P/S gear box assembly (1) and front differential assembly (2) (if equipped) referring to P/S Gear Case Assembly Removal and Installation P/S Gear Case Assembly Removal and Installation
and Front Differential Dismounting and Remounting:Front.






5) Install suspension frame.

WARNING:
If the front suspension frame is not stably supported on a transmission jack or other supporting equipment during its installation, the frame could drop and cause personal injury.

Make sure that the weight of the front suspension frame is supported at the frame's center and that the frame is well-balanced on the support.

NOTE:
Lug (2) in suspension frame (1) must be mated to the corresponding hole in body. And also engine front body side mounting bolts (3) must be mated to the corresponding holes (4) in suspension frame.





6) Tighten suspension frame mounting bolts (1) and engine front body side mounting nuts (2) to specified torque.

NOTE:
The front suspension frame mounting bolts are pre-coated with friction stabilizer. If these bolts are reused, they may work loose.

Be sure to replace the front suspension frame mounting bolts with new ones whenever they are removed.

Tightening torque
Suspension frame mounting bolt (a): 128 Nm (13.1 kgf-m, 94.5 lbf-ft)
Engine front body side mounting nut (b): 55 Nm (5.5 kgf-m, 40.0 lbf-ft)





7) Install engine splash cover (2) from front suspension frame (1) (if equipped).






8) Remove chain hoist from engine and the rope (1) from the radiator (2).





9) Install engine hood. Hood Removal and Installation
10) Install front propeller shaft (if equipped). Propeller Shaft Removal and Installation
11) Tighten pipe bracket bolts (1) to specified torque and then connect low pressure return hose (2) to low pressure return pipe (3).

Tightening torque
Pipe bracket bolt 11 Nm (1.1 kgf-m, 8.5 lbf-ft)





12) Tighten union gear box bolt (1) to specified torque.

Tightening torque
Union gear box bolt (a): 35 Nm (3.5 kgf-m, 25.5 lbf-ft)





13) Connect steering lower shaft from pinion shaft steering. P/S Gear Case Assembly Removal and Installation
14) For headlight auto leveling model, attach front fender lining clip (1).





15) For headlight auto leveling model, connect front height sensor connector (1) and then attach clip (2).





16) Install stabilizer joints (1), and tighten nuts to specified torque. When tightening, hold stud with hexagon wrench.

Tightening torque
Stabilizer joint nut (a): 60 Nm (6.0 kgf-m, 43.5 lbf-ft)





17) Install right side and left side front drive shaft assembly (if equipped).
18) Install suspension control arm. Front Suspension
19) Install engine under cover and engine splash cover.
20) Install front wheels and tighten wheel nuts to specified torque. Removal and Replacement
21) After installation, be sure to fill specified power steering fluid and bleed air. Service and Repair
22) Check front wheel alignment adjust it as necessary. Front Suspension