Front Suspension Page 3–1

Page 3-1

Section 3

Front Suspension

ATTENTION

Before performing any Service Operation or other procedure described in this Section, refer to Section 00

Warnings, Cautions And Notes for correct workshop practices with regard to safety and/or property damage.

1 General Description............................................................................................................................... 3

2 Wheel Alignment.................................................................................................................................... 5

2.1 Steering Geometry.................................................................................................................................................5

Caster......................................................................................................................................................................5

Camber....................................................................................................................................................................6

Wheel Toe ...............................................................................................................................................................6

Steering Axis Inclination........................................................................................................................................7

Scrub Radius..........................................................................................................................................................7

Included Angle........................................................................................................................................................8

Toe-Out On Turns...................................................................................................................................................8

2.2 Wheel Alignment Checking and Adjustment.......................................................................................................9

Preliminary Inspection...........................................................................................................................................9

Caster Adjustment .................................................................................................................................................9

Camber Adjustment...............................................................................................................................................9

Toe Adjustment....................................................................................................................................................11

2.3 Jacking Precautions ............................................................................................................................................12

2.4 Front Wheel Hub Assembly – End Float Checking Procedure.........................................................................13

3 Service Operations.............................................................................................................................. 14

3.1 Service Notes And Cautions ...............................................................................................................................14

3.2 Suspension and Trim Height, Check..................................................................................................................15

3.3 Front Wheel Hub Assembly, Brake Rotor and/or Brake Shield........................................................................16

Remove .................................................................................................................................................................16

Inspect...................................................................................................................................................................18

Reinstall ................................................................................................................................................................19

3.4 Front Wheel Hub Studs........................................................................................................................................21

Replace .................................................................................................................................................................21

3.5 Front Strut Assembly...........................................................................................................................................23

Remove .................................................................................................................................................................23

Reinstall ................................................................................................................................................................25

3.6 Upper Strut Support Bearing and Mount............................................................................................................27

Remove .................................................................................................................................................................27

Reinstall ................................................................................................................................................................28

3.7 Front Spring..........................................................................................................................................................29

Remove .................................................................................................................................................................29

Reinstall ................................................................................................................................................................29

3.8 Front Strut Unit.....................................................................................................................................................30

Replace .................................................................................................................................................................30

3.9 Steering Knuckle..................................................................................................................................................31

Remove .................................................................................................................................................................31

Reinstall ................................................................................................................................................................34

3.10 Front Control Arm Ball Joint Assembly .............................................................................................................36

Inspect...................................................................................................................................................................36

Replace .................................................................................................................................................................36

Techline

Front Suspension Page 3–2

Page 3-2

3.11 Front Control Arm ................................................................................................................................................37

Remove .................................................................................................................................................................37

Reinstall ................................................................................................................................................................39

3.12 Front Control Arm Rear Bushing........................................................................................................................41

Replace .................................................................................................................................................................41

3.13 Front Control Arm Front Isolating Bushing.......................................................................................................43

Inspect...................................................................................................................................................................43

Replace .................................................................................................................................................................43

3.14 Front Suspension Crossmember Cradle............................................................................................................46

Remove .................................................................................................................................................................46

Reinstall ................................................................................................................................................................49

3.15 Stabiliser Bar Link................................................................................................................................................51

Replace .................................................................................................................................................................51

3.16 Stabiliser Bar Isolator Bushes ............................................................................................................................53

Replace .................................................................................................................................................................53

3.17 Stabiliser Bar........................................................................................................................................................54

Remove .................................................................................................................................................................54

Reinstall ................................................................................................................................................................55

4 Diagnosis.............................................................................................................................................. 56

4.1 General..................................................................................................................................................................56

Strut Diagnosis.....................................................................................................................................................56

Acceptance Criteria..............................................................................................................................................56

4.2 Diagnosis Guide...................................................................................................................................................57

Hard or Heavy Steering........................................................................................................................................57

Excessive Play or Looseness in Steering..........................................................................................................57

Erratic Steering on Application of Brakes..........................................................................................................58

Vehicle Pulls to One Side....................................................................................................................................58

Front or Rear Wheel Tramp.................................................................................................................................59

Road Shocks.........................................................................................................................................................59

Scuffed Tyres........................................................................................................................................................59

Cupped Tyres .......................................................................................................................................................60

Front Wheel Shimmy............................................................................................................................................60

Vehicle Wanders...................................................................................................................................................61

5 Specifications....................................................................................................................................... 62

Suspension Travel ...............................................................................................................................................62

Front Spring Details.............................................................................................................................................62

Front Stabiliser Bar Details .................................................................................................................................62

Front Strut Details................................................................................................................................................63

Front Control Arm Details....................................................................................................................................63

Front Control Arm Ball Joint...............................................................................................................................63

Front Wheel Bearings..........................................................................................................................................63

Wheel Bearing Angular 'Float'.............................................................................................................................63

Suspension Trim Height Specifications.............................................................................................................64

Front Wheel Alignment Specifications...............................................................................................................65

6 Torque Specifications ......................................................................................................................... 66

7 Special Tools........................................................................................................................................ 67

Front Suspension Page 3–3

Page 3-3

1 General Description

The front suspension fitted to all MY 2004 AWD Wagon Models operates on the McPherson strut principle. The

assembly consists of the front suspension crossmember cradle, lower control arms, stabiliser bar and heavy duty strut

assemblies (Refer to Figure 3-1).

The front suspension crossmember cradle is bolted to both longitudinal frame side members. The front suspension

crossmember cradle to side member attaching bolts incorporate a tapered boss near the head of the front two bolts to

assist in crossmember to body alignment during assembly. The lower control arm pivots are rubber bushed at the inner

ends and are attached to the crossmember by a micro-encapsulated bolt at the front and a bolt at the rear. The outer end

of each front control arm is connected to the steering knuckle through a front control arm ball joint assembly.

The strut assembly incorporates a hydraulic wet sleeve type damper inside the strut tube, a rubber front strut dust shield

assembly with air filter and compression rubber, a coil type suspension spring mounted between the strut housing and

upper spring seat collar, a bearing assembly and an upper strut support.

The strut assembly is located at the upper end to the body structure by an upper strut support and secured by a self-

locking nut and locating disc. The lower end of the strut tube is fastened to the steering knuckle by two bolts and nuts.

A stabiliser bar is mounted to the side me mber s of the front suspe nsi on cro ss mem ber crad l e by two brackets and

insulating rubbers, and attaches to each strut tube by a spacer stud, insulators, retainers and attaching nuts. The lower

end of the stabiliser bar spacer stud is connected to the stabiliser bar with a socket stud and nut.

To increase body rigidity, a strut brace is attached to each strut tower by two nuts on each side. For service procedures

relating to this strut brace, refer to Section 1A1 Body, in the MY 2004 AWD Wagon Service Information.

Legend for Figure 3 – 1

1 Nut (2 Places)

2 Washer (2 Places

3 Insulator (2 Places)

4 Seat (2 Places)

5 Insulator (2 Places)

6 Washer (2 Places)

7 Stabiliser Bar Stud (2 Places)

8 Nut (2 Places)

9 Flanged Nut (4 Places)

10 Bracket (2 Places)

11 Insulator (2 Places)

12 Bar – Stabiliser

13 Nut (2 Places)

14 Drives haf t - Front (2 Places)

15 Front Suspension Crossm ember Cradle

16 Bol t (2 Plac es)

17 Front Control Arm (2 Places)

18 Bolt (2 Places)

19 Bol t – Front, Flanged (2 Places)

19a Bolt – Rear, Plain (2 Places)

20 Cover – Dust (2 Places)

21 Nut (2 Places)

22 Locating Disc (2 Places)

Stud to be held while nuts are torqued to specification

Fasteners must be new and assembled dry.

Front Suspension Page 3–4

Page 3-4

Figure 3 – 1

Front Suspension Page 3–5

Page 3-5

2 Wheel Alignment

ATTENTION

All front suspension fasteners are important attaching parts as they affect the performance of vital components

and/or could result in major repair expense. Where specified in this section, fasteners MUST be replaced with

parts of the same part number or an approved equivalent. Do not use fasteners of an inferior quality or

substitute design.

Torque values must be used as specified during reassembly to ensure proper retention of all rear suspension

components.

Throughout this section, fastener torque wrench specifications may be accompanied with the following

identification marks:

! Fasteners must be replaced after loosening.

" Vehicle must be at curb height before final tightening.

# Fasteners either have micro encapsulated sealant applied or incorporate a mechanical thread lock and

should only be re-used once. If in doubt, replacement is recommended.

If one of these identification marks is present alongside a fastener torque wrench specification, the

recommendation regarding that fastener must be adhered to.

2.1 Steering Geometry

To achieve the desired handling characteristics of a vehicle under various operating conditions, modern steering

geometry relates to both front and rear suspension systems. It must also be realised that the various, measurable angles

that can be checked while the vehicle is stationary, are no real indication of the changes that occur in a dynamic

situation, when the vehicle is required to have directional stability, during normal manoeuvres, such as straight ahead

driving, cornerin g or braking.

Even though some of the following descriptions of front wheel alignment angles are not normally measurable and (in

some instances) not adjustable, each is an inherent part of the vehicle's dynamic suspension tuning that has been

developed over an extended testing program.

Caster

It is usual to describe this front wheel alignment angle as the

tilting of the steering axis either forward or backward (1)

from the vertical (2) when viewed from the side of the

vehicle. A backward tilt at the top steering axis point is said

be positive (+) and a forward tilt is said to be negative (–).

Measurement is usually expressed as an angle in degrees

and minutes. Figure 3-2 shows the usual practice where the

vertical and steering axis centrelines both pass through the

wheel centre (3).

This results in a caster distance (4), which can be described

as being the distance in side view, between the point where

the steering axis contacts the ground and the centre of the

tyre’s footprint contact.

Figure 3 – 2

Front Suspension Page 3–6

Page 3-6

The amount of caster angle (1) will determine the ability of

the steering to return to the straight ahead position after a

cornering manoeuvre. Too high an angle though, can result

in an excessive steering effort with associated ‘wheel fight'

and ‘kickback'. To optimise vehicle handling and control

during cornering and to maintain the benefits of positive

caster, MY 2004 AWD Wagon models have a 32.1 mm

caster trail (2) incorporated into the suspension design.

This is achieved by moving the wheel spindle centreline (3)

forward (in this instance, by 32.1 mm), which will effectively

reduce the caster distance by that amount (Refer to Figure

3-3). This action reduces the undesirable effects of a high

caster angle but maintains the directional stability, increased

front axle lateral grip and steering feel that a high caster

angle normally provides.

Figure 3 – 3

Camber

This angle is the tilting of the wheels from the vertical (1)

when viewed from the front of the vehicle. When the wheels

tilt outward at the top, the camber (2) is said to be positive

(+). When the wheels tilt inward at the top, camber is said to

be negative (–). The amount of tilt is measured in degrees

from the vertical and this measurement is called the camber

angle.

While unequal camber may result in unstable steering or

wander, unequal and/or excessive camber can also cause

rapid tyre wear.

Figure 3 – 4

Wheel Toe

Wheel Toe (Refer to Figure 3-5), is the turning in (or out) of

the wheels when viewed from the overhead position. The

actual amount of toe is normally only a few minutes of one

degree. The purpose of a static toe specification is to ensure

parallel rolling of the wheels, once the vehicle is in a

dynamic state.

Excessive toe-in or toe-out may increase tyre wear. With

rear wheel drive vehicles, a slight amount of toe-in,

measured statically with the vehicle at rest, is required to

off-set the small deflections due to rolling resistance and

brake applications which tend to turn the wheels outward,

when the vehicle is in mot ion.

Figure 3 – 5

Front Suspension Page 3–7

Page 3-7

Steering Axis Inclination

When viewed from the vehicle front, Steering Axis

Inclination (1) can be described as being the angle formed

between the steering axis (2) and the true vertical (3), where

the steering axis is the imaginary centreline through the

upper strut support bearing and the lower control arm ball

joint assembly, both components being the pivot points of

the strut assembly.

The Steering Axis Inclination angle is an important factor in

determining steering effort and directional stability of the

vehicle, by assisting caster in keeping the front wheels in a

central position. Steering Axis Inclination also provides a

self-centring eff ect after corn er ing.

While not an adjustable angle, the steering axis inclination

on the MY 2004 AWD Wagon, is 13.3 degrees.

Figure 3 – 6

Scrub Radius

This term refers to the distance (4) that two imaginary points

are apart, at the road surface (1). These two imaginary

points are;

a. The intersection of the steering axis (2) and the road

surface (1).

b. The centreline of the tyre (3) at the road surface (1).

As road wheel offset will affect scrub radius (4), in the

interests of vehicle handling and safety, non-standard road

wheels are not to be fitted to any MY 2004 AWD Wagon

vehicle.

With rear wheel drive vehicles, it is usual practice to

maintain a positive scrub radius (as shown in Figure 3-7) to

make the steering more responsive and direct, thereby

providing the driver with a more positive sense of the tyre

and road surface interaction.

Figure 3 – 7

Front Suspension Page 3–8

Page 3-8

Included Angle

When both the Steering Axis Inclination angle (1) and

Camber angle (3) are combined, the resulting angle is

referred to as the Included Angle (2). This information can

be effectively used to determine if a component is damaged

or whether an adjustment is responsible for an out-of-

specificat ion con dition occurri n g.

While Figure 3-8 shows a positive camber angle, this has

only been used to clarify the term ‘Included Angle'.

Figure 3 – 8

To e -Ou t On T u rn s

During cornering operations, a vehicle's road wheels all turn

about a common turning point, causing the outer wheels to

try and turn through a greater radius than the inner. To

overcome the tendency for wheel slip when cornering, the

outer wheel is commonly caused to toe-out, to compensate

for this increased turning circle.

The amount of toe-out during cornering, is governed by the

angle of the steering arms, which are an inherent part of the

steering knu ckle.

Figure 3 – 9

Front Suspension Page 3–9

Page 3-9

2.2 Wheel Alignment Checking and

Adjustment

LT Section No. – 06-212

ATTENTION

The following fasteners MUST be replaced when performing these operations:

! Steering knuckle to strut attaching bolts and nuts.

Preliminary Inspection

Before any attempt is made to check camber, caster or toe-in, these preliminary checks should be carried out.

1 Check tyre and tyre mountings. Always check camber and toe-in at the mean run-out position on the tyre or rim.

2 Check and adjust tyre pressures to recommended values.

3 Front wheel bearing end float is to be checked to ensure it is within specification, refer to 2.4 Front Wheel Hub

Assembly – End Float Checking Procedure, in this Section.

4 Front lower control arm socket assembly and pivot bushing should be checked for wear, refer to 3.10 Front Control

Arm Ball Joint Assembly, in this Section.

5 Check steering gear mounting bolts for tightness and steering linkage outer tie rod sockets for wear, refer to

Section 9 Steering in the MY 2004 AWD Wagon Service Information, for the procedures.

6 The vehicle should be at curb weight, fuel tank full, without driver, passengers or luggage etc.

7 Check for improperly operating front struts or rear shock absorbers.

8 Check for loose or missing stabiliser bar or spacer stud to strut tube attachments.

9 Before checking the front wheel alignment, refer to 2.7 Rear Wheel Alignment Checking in Section 4A Rear

Suspension in the MY 2004 AWD Wagon Service Information, for wheel alignment details.

Caster Adjustment

No provision for caster adjustment is provided with the front suspension design utilised for the MY2004 AWD Wagon

se ries of vehicles.

Camber Adjustment

1 Raise the front of the vehicle and support on safety stands under the front side members. Refer to 2.3 Ja cki ng

Precautions in this Section.

2 Remove the decorative centre wheel cap and mark the relationship of the wheel to the hub stud, using a felt tipped

pen or similar.

3 Loosen, then remove the road wheel attaching nuts, working in a 'star' pattern. Refer to Section 10, Wheels and

Tyres, in the MY 2003 VY and V2 Series Service Information, for detailed information. Remove the road wheel.

NOTE

Steps 2 and 3 are necessary to maintain

component relationships and to avoid brake rotor

distortion and the creation of brake shudder, after

the vehicle is placed back in service.

Front Suspension Page 3–10

Page 3-10

4 Loosen, remove and discard the two lower strut

attaching bolts and nut s (1).

Install NEW lower strut attaching bolts and nuts but do

not tighten fully to specification until after the camber

has been adjusted to the recommended specification.

5 Reinstall the road wheel, aligning the previously made

marks. Tighten the road wheel attaching nuts to

correct torque specification, working in a ‘star’ pattern.

Refer to Section 10 Wheels and Tyres, in the MY 2003

VY and V2 Series Service Information, for detailed

information regarding installation procedure for the

road wheels.

Road wheel attaching nut

torque specific atio n ............................................125 Nm

6 Lower the vehicle to the ground and bounce several

times to settle the suspension, then check the camber

angle.

Figure 3 – 10

7 If required, adjust the camber by turning the camber adjusting screw ('2' in Figure 3-10) in the required direction;

clockwise to reduce negative camber, anti-clockwise to reduce positive camber.

NOTE

The camber adjusting screw has thread sealant

applied in the form of micro-encapsulation and

does not require a lock nut.

8 Raise vehicle once again, support on safety stands and remove the front road wheels.

9 Tighten both steering knuckle attaching nuts to the correct torque specification.

( ! ) Steering knuckle to strut

attaching nut torque specification............Stage 1 85 Nm

Stage 2 100 Nm

Stage 3 Turn through 90 °

10 Install the road wheels, aligning the marks made prior to removal.

11 Remove the jack stands and lower the vehicle.

12 Tighten the road wheel attaching nuts to the correct torque specification, working in a ‘star’ pattern. Refer to

Section 10 Wheels and Tyres, in the MY 2003 VY and V2 Series Service Information, for detailed information

regarding installation procedure for the road wheels.

Road wheel attaching nut

torque specific atio n ............................................125 Nm

13 Install the decorative centre wheel cap.

14 Check the camber angle again to ensure that it is still within specification.

Front Suspension Page 3–11

Page 3-11

Toe Adjustment

Toe of both front wheels, is checked with the wheels in the

straight ahead position.

djustment is achieved by winding the steering linkage inner

tie rod into or out from the outer tie end, thus increasing or

decreasing the linkage length and thereby altering the toe-in

setting.

1 Set steering gear and wheels in straight ahead

position.

2 To check if steering gear is in straight ahead position

(on-centre), the pinion (inp ut) shaft (1) should be

aligned as show n.

Figure 3 – 11

3 Before adjusting the steering linkage inner tie rods (1),

disconnect the steering gear outer boot clips (2).

4 Loosen the lock nut (3) at the end of each steering

linkage outer tie rod end.

5 Turn each steering linkage inner tie rod as required,

until the correct toe is obta ined .

NOTE

During the toe adjustment, ensure that the

steering wheel is held in the straight ahead

position.

6 Tighten the lock nuts to the correct torque

specification, ensuring that the steering linkage outer

tie rod ends are in alignment with their ball studs.

Figure 3 – 12

Steering linkage tie rod to outer

tie rod end lock nut torque specification...............65 Nm

7 Tighten the outer boot clips securely, making sure that the convolutions of the boots are not distorted.

8 With the steering gear in the straight ahead position, ensure that the steering wheel is centralised. If not, remove

and reposition the steering wheel, refer to Section 9 Steering, in the MY 2003 VY and V2 Series Service

Information.

Front Suspension Page 3–12

Page 3-12

2.3 Jacking Precautions

When raising the front of the vehicle with a jack (1), the jack

should be placed under the centre of the front suspension

crossmember cradle (2). THE WEIGHT OF THE VEHICLE

MUST NOT BE LIFTED UNDER THE CONTROL ARMS.

When the vehicle is raised on the jack, it must be firmly

supported on safety stands located under the frame side

members before any work is attempted. If a vehicle is not

correctly supported by safety stands, serious injury can

result if the vehicle should slip off the jack.

For further information relating to the location of jacking and

support points, refer to Section 0A General Information, in

the MY 2003 VY and V2 Series Service Information.

Figure 3 – 13

Front Suspension Page 3–13

Page 3-13

2.4 Front Wheel Hub Assembly – End Float

Checking Procedure

LT Section No. – 06-212

1 Raise the front of the vehicle and place on safety stands. Refer to 2.3 Jacking Precautions in this Section.

2 Remove the decorative wheel nut caps.

3 Loosen, then remove the road wheel attaching nuts, working in a 'star' pattern. Refer to Section 10, Wheels and

Tyres, in the MY 2003 VY and V2 Series Service Information, for detailed information. Remove the road wheel.

NOTE

Steps 2 and 3 are necessary to maintain

component relationships and to avoid brake rotor

distortion and the creation of brake shudder, after

the vehicle is placed back in service.

4 Temporarily install three, reversed wheel nuts with a

flat washer under each nut, to prevent damage to the

nut thread.

5 Mount a dial indicator on to a suitable magnetic stand

and attach to the front strut tube. Position the dial

indicator pointer at the outer diameter of the rotor, as

shown.

NOTE

The dial indicator gauge must be mounted at

right-angles (90°) to the brake rotor friction

surface.

6 Apply an outward, 10 kg force to the outer brake rotor

diameter, in an opposite position (180°) to the dial

indicator. To maintain consistency, a spring balance

capable of measuring this force, MUST be used. W ith

the force applied, zero the dial indicator.

7 Apply an inward, 10 kg force to the outer brake rotor

diameter and note the dial indi cator read ing.

8 The reading obtained is the angular movement (not to

be confused as end float). To deter mine the bearing’s

serviceability, compare the measured result with the

following spe cif ica t io ns.

Figure 3 – 14

Wheel Bearing Angular ‘Float’ Specification

New Bearing 0.106 mm Maximum

Used Bearing 0.213 mm Maximum

9 Should this inspection show that the wheel bearing assembly is outside the specified, angular ‘float’ dimension,

then the hub must be replaced. Refer to 3.3 Front Wheel Hub Assembly Brake Rotor and/or Brake Shield in this

Section.

10 Remove the dial indicator and stand, and the three wheel nuts and flat washers.

11 Install the road wheel, aligning the marks made prior to removal and secure with attaching nuts.

12 Raise the vehicle, remove the safety stands and lower vehicle to the ground. Tighten road wheel attaching nuts to

correct torque specification, working in a ‘star’ pattern. Refer to Section 10 Wheels and Tyres in the MY 2003 VY

and V2 Series Service Information, for detailed information regarding the installation procedure for the road wheels.

Road wheel attaching nut

torque specific atio n ............................................125 Nm

13 Reinstall the decorative wheel nut caps.

Front Suspension Page 3–14

Page 3-14

3 Service Operations

ATTENTION

All fasteners are important attaching parts as they affect the performance of vital components and/or could

result in major repair expense. Where specified in this section, fasteners MUST be replaced with parts of the

same part number or an approved equivalent. Do not use fasteners of an inferior quality or substitute design.

Torque values must be used as specified during reassembly or reinstallation of all components to ensure

correct retention.

Throughout this section, fastener torque wrench specifications may be accompanied with the following

identification marks:

! Fasteners must be replaced after loosening.

" Vehicle must be at curb height before final tightening.

# Fasteners either have micro encapsulated sealant applied or incorporate a mechanical thread lock and

should only be re-used once. If in doubt, replacement is recommended.

If one of these identification marks is present alongside a fastener torque wrench specification, the

recommendation regarding that fastener must be adhered to.

3.1 Service Notes And Cautions

CAUTION

Whenever any component that forms part of

the ABS (if fitted) is disturbed during Service

Operations, it is vital that the complete ABS

system be checked, using the procedure as

detailed in the MY2004 AWD Wagon Service

Information, Section 5B ABS & TCS Function

Check.

NOTE

Whenever a road wheel and/or brake disc

is removed from or installed to a MY2004

AWD Wagon vehicle, it MUST be done in

accordance with the procedure provided in the

VY Series and V2 Series Service Information,

Section 10, Wheel Removal And Reinstallation.

NOTE

To ensure proper retention of the control arm, the

ball joint stud and the corresponding tapered hole

in the control arm must be cleaned of dirt and

foreign matter prior to reinstallation.

Front Suspension Page 3–15

Page 3-15

3.2 Suspension and Trim Height, Check

Good judgement must be exercised before

replacing a spring or springs from a vehicle

whose height is within the limits quoted. Even

if a vehicle's dimensions should prove to be

slightly outside these tolerances, the vehicle

could well be in a serviceable condition.

Spring replacement under conditions of

excessive weight due to non-standard fittings,

undercoating, road dirt, etc; will assist very

little in restoring the vehicle to its specified

height.

The vehicle trim height dimensions for standard vehicles with base equipment only, are provided in 5. Specifications in

this Section. The dimensions are for a new vehicle built to standard specification and only intended as a guide when

checking trim height dimensions at normal curb weight.

Normal curb weight is defined as a vehicle with a full tank of fuel, all fluids at the specified levels, spare tyre included,

tyre pressures as specified and no passengers. Accumulated dirt, distance travelled, etc., must also be taken into

consideration when checking vehicle heights.

The following procedure should be followed before checking any suspension or trim height.

1 All checks must be carried out on a LEVEL surface, after the vehicle's tyre pressures have been chec ked and it has

been confirmed that the vehicle has not been subjected to accident damage.

2 On average, all MY 2004 AWD Wagon models will sit approximately 4 mm lower at the right hand side front,

because of the vehicle battery weight.

3 Push the vehicle up and down several times at the front bumper bar with a decreasing force and then gently

remove hands, allowing vehicle to settle on its own. Carry out vehicle suspension front trim height check.

4 Push the vehicle up and down several times at the rear bumper bar with a decreasing force and then gently

remove hands, allowing vehicle to settle on its own. Carry out vehicl e rear trim and suspension height check.

As shown in the specification listing (refer to 5. Specifications in this Section), there is only the one set of dimensions that

must be checked and the location for the measurements to be taken is critical, to correctly establish a standard vehicle

condition.

NOTE

Excessive trim height variation may also be due

to any one or a combination of the following:

• Spring seat location on the suspension/body.

• Incorrect springs; Check spring identification

against the table shown in 5. Specificatio ns in

this Section.

• Non-standard, additional vehicle weight, such

as after-market equipment.

• Any combination of the above.

Front Suspension Page 3–16

Page 3-16

3.3 Front Wheel Hub Assembly, Brake Rotor

and/or Brake Shield

LT Section No. – 06-212

ATTENTION

The following fasteners MUST be replaced when performing these operations:

! Brake caliper anchor plate to steering knuckle retaining bolts.

NOTE

Apart from wheel stud replacement, there are no

serviceable items in the front wheel hub

assembly. As the unit is a 'sealed for life'

assembly, neither bearing adjustment nor

lubrication maintenance is required. Should a

non-standard condition develop, then the hub

assembly must be replaced as a complete unit.

NOTE

While the front wheel hub assembly is designed

to have zero axial free play or ‘end-float’, some

angular movement may be evident when a

rocking force is applied to the mounted wheel and

tyre assembly. Before a hub is replaced, refer to

2.4 Front Wheel Hub Assembly – End Float

Checking Procedure, in this Section.

Remove

1 Observing the jacking precautions – refer to 2.3 Jacking Precautions in this Section, raise the front of the vehicle

and support on safety stands.

2 Remove the decorative wheel nut caps, then mark the relationship of the road wheel to hub or brake rotor.

3 Loosen, then remove the road wheel attaching nuts, working in a 'star' pattern. Refer to Section 10, Wheels and

Tyres, in the MY 2003 VY and V2 Series Service Information, for detailed information. Remove the road wheel.

NOTE

Steps 2 and 3 are necessary to maintain

component relationships and to avoid brake rotor

distortion and the creation of brake shudder, after

the vehicle is placed back in service.

Front Suspension Page 3–17

Page 3-17

4 Attach holding tool KM-468 to the wheel hub with two

inverted wheel nuts. Support the tool outer end on a

safety stand (1).

5 Using a 36 mm socket and suitable socket equipm ent,

loosen then remove the driv es haft retain ing nut and

flat washer. Discard the removed nut.

Figure 3 – 15

6 Remove the Allen key headed screw (1) securing the

wheel speed sensor to the steering knuckle, grasp the

sensor and twist back and forth while pulling, to

remove. Secure sensor with tie wire or similar to

prevent sensor damage during the service procedure.

7 Remove the front driveshaft. Refer to 2.4 Driveshaft

Assembly, Remove, in Section 4B2 Fron t Final Drive,

Bearing Housing & Driveshafts, in the MY 2004 AWD

Wagon Service Information.

Figure 3 – 16

Front Suspension Page 3–18

Page 3-18

8 Remove the brake caliper retaining bolts and captive

washers (1), then lift the caliper assembly (2) from the

brake rotor. Position caliper in such a way that no

strain is placed on the brake hose. If necessary, tie

caliper to the suspension spring with a piece of wire.

THE CALIPER IS NOT TO HANG BY THE BRAKE

HOSE. Discard the removed caliper bolts as they must

be replaced on reassembly.

9 Even though the brake rotor to hub location is marked

in production, ensure that the rotor to hub position is

carefully marked, to ensure the correct relationship on

reassembly.

NOTE

This is necessary to overcome the possibility of

inducing a brake shudder condition after

reassembly.

10 Remove the brake rotor from the wheel hub assembly

and carefully set to one side.

11 Using a commercially available 10 mm Allen key

socket and suitab le soc ket eq uipm ent, loo sen each of

the three bolts (3) holding the wheel bearin g hub to the

steering knu ckle.

Figure 3 – 17

12 If the hub is a tight fit to the knuckle, it may be necessary to loosen the three bolts and tap on the heads. DO NOT

STRIKE THE HUB, NOR THE W HEEL BEARING.

13 Remove the three bolts and then the hub from steering knuckle.

14 Where removal of the brake shield is necessary,

Remove the three screws (1) securing the shield to the

steering knu ckle support, then remove the brake

shield from the steering knuckle.

Figure 3 – 18

Inspect

1 Check wheel studs are pressed firmly into the front wheel hub assembly and ensure threads are not damaged. If

one or more of the wheel studs require replacement, refer to 3.4 Front Wheel Hub Studs in this Section for details.

2 If a check be fore hub removal showed that the wheel bearing angular 'float' exceeded specification, if rotation of the

hub feels 'gritty' or rough, or if a grease leak is evident, then the hub and bearing assembly must be replaced as a

unit.

3 Examine the brake rotor for scores or damage. If either of these conditions exist, the brake rotor should be

machined or replaced. Refer to Section 5A, Service and Park Braking System, in the MY2003 VY and V2 Series

Service Information, for details.

4 Check for damage to the shield that may ca use fouling of any rotating parts and if suspect, the shield should be

replaced.

Front Suspension Page 3–19

Page 3-19

Reinstall

Installation of the front wheel hub assembly, brake rotor and brake shield is the reverse of removal procedures, except

for the following points:

1 If the brake shield has been removed, install the three

retaining screws and tighten to the correct torque

specification.

Brake shield retaining screw

torque specific atio n ..............................................10 Nm

2 Before reinstalling the hub, inspect both mating

surfaces to make sure that they are clean and free

from burrs that could prevent c orrect ali gnm ent of both

parts, once installed.

Figure 3 – 19

3 Install the hub assembly onto the steering knuckle.

NOTE

The holes will only align in one position.

4 Install the three attaching bolts (3) and tighten to the

correct torque specification.

Front wheel hub assembly to

steering knuckle attaching bolt

torque specific atio n ............................................108 Nm

5 Reinstall the front driveshaft. Refer to 2.4 Driveshaf t

Assembly, Reinstall, in Section 4B2 Front Final Drive,

Bearing Housing & Driveshafts in the MY 2004 AWD

Wagon Service Information, for the procedure.

6 Reinstall the wheel speed sensor to the steering

knuckle, reinstall the securing screw and tighten to the

correct torque specification.

Front wheel speed sen sor reta inin g

screw torque specificatio n....................................10 Nm

7 Install brake rotor, aligning the marks made before

removal.

Figure 3 – 20

NOTE

If the hub was replaced, then runout checks must

be carried out on the installed brake rotor. Refer

to Section 5A Service and Park Braking System,

in the MY 2003 VY and V2 Series Service

Information, for important information regarding

these checks.

8 Install the brake caliper (2) and new attaching bolts (1) and tighten to the correct torque specification.

( ! ) Brake caliper anchor plate

retaining bolts torque specification.......................85 Nm

then turn through 45°

Front Suspension Page 3–20

Page 3-20

9 Install the road wheel, aligning the marks made prior to removal and secure with the attaching nuts.

10 Remove the jack stands and lower the vehicle.

11 Tighten the road wheel attaching nuts to correct torque specification, working in a ‘star’ pattern, refer to

Section 10 Wheels and Tyres, in the MY 2003 VY and V2 Seri es Service Information.

Road wheel attaching nut

torque specific atio n ............................................125 Nm

12 Install the decorative wheel nut caps .

Front Suspension Page 3–21

Page 3-21

3.4 Front Wheel Hub Studs

LT Section No. – 06-212

ATTENTION

The following fasteners MUST be replaced when performing these operations:

! Brake caliper anchor plate to steering knuckle retaining bolt.

Replace

1 Remove the front wheel hub assembly. Refer to 3.3 Front Wheel Hub Assembly, Brake Rotor and/or Brake Shield,

Remove, in this Section.

NOTE

Hub removal is necessary, because there is

insufficient space behind the hub flange to

remove the stud with the hub assembly installed

to the steering knuckle.

Under no circumstances is a hammer to be

used in either stud removal or installation

operations. If a hammer is used, distortion of

the wheel hub flange will most probably

result.

2 Fabricate a piece of thick walled pipe (i.e. 25 mm

water pipe), removing a section, as indicated. As this

si ngle piece is used to both remove and install a new

stud, squaring the ends in a lathe is recommended.

Figure 3 – 21

Front Suspension Page 3–22

Page 3-22

3 Arrange the fabricated pipe (1) over the head of the

stud to be removed, with the flat of the cut-out section,

against the hub flange, then use a suitable drift (2) to

press the stud (3) from the wheel hub flange.

Figure 3 – 22

NOTE

Of the three wheel hub flanges, there is only one

(1) that provides sufficient clearance to allow

removal of the wheel stud.

Figure 3 – 23

4 Setup the wheel bearing hub with the pipe (1) under

the flange hole where the new stud is to be installed.

5 Use the same drift (2), press the stud into the wheel

hub flange, until fully installed.

NOTE

If the press effort was minimal during installation

or the stud is loose in the flange when installed,

then replace the front wheel bearing hub and

flange assembly.

6 Reinstall the front wheel hub assembly. Refer to

3.3 Front Wheel Hub Assembly, Brake Rotor and/or

Brake Shield, Reinstall, in this Section.

7 Reinstall the front driveshaft. Refer to 2.4 Front

Driveshaft Assembly, Reinstall, in Section 4B2 Front

Final Drive, Bearing Housing & Driveshafts in the

MY 2004 AWD Wagon Service Information.

Figure 3 – 24

Front Suspension Page 3–23

Page 3-23

3.5 Front Strut Assembly

LT Section No. – 06-212

ATTENTION

The following fasteners MUST be replaced when performing these operations:

! Upper strut locating plate retaining nut.

! Brake caliper anchor plate to steering knuckle retaining bolts.

! Steering knuckle to strut attaching nuts and bolts.

Remove

1 Observing the jacking precautions as outlined in 2.3 Jacki ng Precau tion s in this Section, raise the front of the

vehicle and support on safety stands.

2 Remove the decorative wheel nut caps.

3 Mark the relationship of the road wheel to hub or brake rotor. Loosen, then remove the road wheel attaching nuts,

working in a 'star' pattern. Refer to Section 10, Wheels and Tyres, in the MY 2003 VY and V2 Series Service

Information, for detailed information. Remove the road wheel.

NOTE

Step 3 is necessary to maintain part relationships

and to avoid brake rotor distortion and the

creation of brake shudder, after the vehicle is

placed back in service.

4 Position a suitable size open end spanner to hold the

stabiliser bar spacer stud (1) at ‘A’, then use another

spanner to loosen and remove the upper nut (2),

washer (3), insulator (4) and seat (5).

5 Disconnect the wheel speed sensor cable and

insulator from the strut bracket.

Figure 3 – 25

Front Suspension Page 3–24

Page 3-24

6 To avoid placing strain on the wheel speed sensor

cable, remove the Allen key headed screw (1)

securing the front wheel speed sensor to the steering

knuckle.

7 Grasp the sensor and twist back and forth while

pulling, to remove. Secure sens or with tie wire or

similar to prevent sensor damage during the service

procedure.

Figure 3 – 26

8 Remove the brake hose (1) from the strut housing

bracket (2) by turning the plastic sleeve (3) on the

hose until the flats on the sleeve align with the bracket

opening.

Figure 3 – 27

9 Remove the brake cali per retaining bolts and washers

(1), lift the caliper assembly (2) from the brake rotor

and support in such a way that no strain is placed on

the brake hose. THE BRAKE CALIPER IS NOT TO

HANG BY THE BRAKE HOSE. Discard removed bolts

as they must be replaced on reassembly.

10 Remove the brake rotor from the wheel hub assembly.

The brake rotor to hub relationship is marked during

production. To ensure this relationship is maintained,

ensure that the rotor to hub position is carefully

marked.

NOTE

• This is necessary to overcome the possibility

of inducing a brake shudder condition after

reassembly

• These two steps are primarily aimed at

reducing the weight of components that will

need to be supported after the strut to

knuckle bolts are removed.

Figure 3 – 28

11 Position a suitable floor jack fitted with a block of wood on the lift pad under the front control arm and raise it

enough to support the weigh t.

Front Suspension Page 3–25

Page 3-25

Unless the front wheel hub, knuckle and dust

shield are supported when the two strut to

knuckle bolts and nuts are removed, these

components will fall outward. Apart from the

risk of personal injury, the driveshaft inner

tripot joint will be separated, resulting in the

need to replace the joint and dust boot.

12 While supporting the front wheel hub, steering knuckle and dust shield, loosen, remove then discard the two lower

strut to knuckle attaching bolts and nuts.

13 While continuing to support the steering knuckle pull it clear from the strut.

14 Ensure that the steering knuckl e is maintained in a 'normal' attitude, by securing with wire to the brake pipe bracket .

15 Remove the dust cover (1) from the upper strut

support, in the engine compartment.

Support the strut assembly, while performing

the next step, to stop the strut falling free,

causing possible damage.

16 While holding the strut rod shaft (2) with a 10 mm

socket, remove the self-locking nut (3), using a 24 mm

ring spanner, then remove the locating disc (4).

Discard the strut rod nut.

17 Carefully lower the strut (5) from the tower, manipulate

the strut to remove the stabiliser stud from the bracket

on the strut and remove the assembly from the

vehicle.

Figure 3 – 29

Reinstall

The torque of the strut bearing retaining nut

MUST be checked for correct tightness

BEFORE installing the strut into the vehicle.

1 Use a 10 mm socket to hold the strut rod from turning, then tighten the strut bearing retaining nut (‘5’ in Figure

3-29) to the correct torque specification, using a 24 mm ring spanner with a torque wrench attached.

Upper strut bearing retaining

nut torque specification ........................................78 Nm

2 Manipulate the strut assembly so that the stabiliser bar stud is located in the strut bracket, then lo cate the strut

assembly into the spring strut tower.

3 After installing the locating disc, partially install a NEW upper nut to the strut rod. Do not tighten at this time.

Front Suspension Page 3–26

Page 3-26

4 While supporting the steering knuckle, hub and dust

shield asse mbly (1), remove the securing wire and

align the knuckle holes sufficiently to line up the bolt

holes in the steering knuckle and the lower end of the

strut assembly (2).

5 Install NEW retaining bolts (3) (from front to rear) and

nuts (4), and tighten to a preliminary torque of 85 Nm.

6 Use a 10 mm socket to hold the strut rod from turning,

then tighten the upper strut rod retaining nut (‘3’ in

Figure 3-29) to the correct torque specification, using a

24 mm ring spanner with a torque wrench attached.

( ! ) Upper strut locating plate

retaining nut torque specification .......................... 55 Nm

7 Install the brake hose to the strut bracket by turning

the plastic sleeve on the hose until the flats on the

sleeve align with the bracket opening.

Figure 3 – 30

8 Reinstall the brake rotor, aligning the marks made prior to removal.

9 Reinstall the brake caliper, tightening the NEW attaching bolts to specification.

( ! ) Brake caliper anchor plate

retaining bolts torque specification.......................85 Nm

then turn through 45°

10 Reinstall the wheel speed sensor to the steering knuckle, securing with the Allen key headed screw and tightening

to the correct torque specifi cat i on.

Front wheel speed sen sor atta chin g

screw torque specificatio n....................................10 Nm

11 Reinstall the sensor lead and insulator into the strut mounting bracket.

12 Reinstall the stabiliser bar spacer stud nut (1) after

ensuring that all the components are assembled as

shown. While holding the spacer stud (2) with a

suitable open end spanner at ‘A’, use another spanner

to tighten the upper retaining nut until the end of the

thread on the stud is conta cted.

NOTE

Do not use power tools for this tightening

operation, otherwise thread dam age will result.

13 Reinstall the road wheel, aligning the marks made

prior to removal.

14 Remove the safety stands and lower vehicle.

15 Tighten road wheel attaching nuts to the correct torque

specification, working in a ‘star’ pattern, refer to

Section 10, Wheels and Tyr es , in the MY 2003 VY

and V2 Series Service Information.

Road wheel attaching nut

torque specific atio n ............................................125 Nm

Figure 3 – 31

16 Install the decorative wheel nut caps .

17 Bounce the vehicle up and down several times to settle the suspension.

18 Check and correct the wheel alignment, as required. Refer to 2.2 W heel Alignment Checking and Adjustment, in

this Section.

Front Suspension Page 3–27

Page 3-27

3.6 Upper Strut Support Bearing and Mount

LT Section No. – 06-210

Remove

1. Remove the front strut (1), refer to 3.5 Fron t Strut

Assembly, in this Section.

2. Fit Tool No. 180 (or a commercially available

equivalent) to the front spring as shown. Compress the

spring (2) until the upper support bearing (4) has

clearance at the spring seat collar 3).

Figure 3 – 32

Do not attempt to remove the retaining nut (1)

from the strut rod shaft before compressing

the spring.

3. While holding the strut rod shaft with a 10 mm socket,

remove the upper strut bearing to strut rod retaining

nut (1), using a 24 mm ring spanner.

4. Remove the front suspension strut mount assembly

and the two washers (2) fitted to each side.

NOTE

The lower washer may be stuck to the lower

surface of the mount.

5. Remove the strut bearing (3) from the upper spring

seat collar, taking particular note of the bearing

orientation.

NOTE

• The upper support bearing is self-lubricated

and no servicing requirements are

necessary. If considered to be faulty, the

bearing is to be replaced as an assembly.

• Under no circumstances is the machined

surface of the piston rod section to be

gripped directly on its outer surface.

Figure 3 – 33

Front Suspension Page 3–28

Page 3-28

Reinstall

1. Loosely reinstall the strut rod nut, then pull the piston rod through the upper spring seat to its maximum length, then

remove the strut rod nut.

2. Install the upper bearing with the same orientation as noted on removal. Us ually, the coloured or narrow, outer

section, faces down to the upper spring seat collar.

3. While holding the strut rod extended and, after installing the first mount washer with the dished shape facing

downward (refer to item 2 in Figure 3-33), install the upper front suspension strut mount assembly over the bearing

and washer.

4. Install the second washer with the dished shape facing upward (refer to item 2 in Figure 3-33) and install the

retaining nut.

5. Using a 10 mm socket and a 24 mm ring spanner with a torque wrench attached, tighten the nut to the correct

torque specif ication.

Upper strut bearing retaining

nut torque specification ........................................78 Nm

6. Release the spring compressor and remove it from the spring.

7. Install the front strut, refer to 3.5 Front Strut Assembly in this Section.

Front Suspension Page 3–29

Page 3-29

3.7 Front Spring

LT Section No. – 06-210

Remove

1 Remove the front strut, refer to 3.5 Front Strut Assembly in this Section.

2 Remove the front strut upper mount and bearing assembly, refer to 3.6 Upper Strut Support Bearing and Mount in

this Section.

NOTE

The spring compressor is not shown in this

exploded view, as it is assumed that Steps 1 and

2 have already been carried out.

3 Remove the retaining clamp (1) securing the front strut

dust shield assembly (2) and filter (3) to the upper

spring seat collar (4).

4 Remove the upper spring seat collar (4), spring

insulator (5) and comp ression bumper (6) from the top

of the spring (7).

5 Remove the spring (7) from the strut (8) and release

the spring co mpressor.

Figure 3 – 34

Reinstall

NOTE

If installing a replacement spring, ensure that the

spring is the correct type for this vehicle. Refer to

5. Specifications in this Section for details.

1 Position spring on strut with straight projecting end of spring correctly located in the lower spring seat.

2 Install spring compressor Tool No. 180 or a commercially available equivalent to the spring (refer to Figure 3-32)

and compress it.

3 Reinstall the upper spring insulator, spring seat collar and compression bumper so that the double notch in the

upper flange of the spring seat collar is assembled, facing inward. The spring insulator has a step which locates on

to the straight projecting end of the spring.

4 Install the front strut upper bearing and support (9), refer to 3.6 Upper Strut Support Bearing and Mount in this

Section.

NOTE

Check that the lower washer (10) is not binding

with the lower edge of the mount.

5 Fit the upper end of the front strut dust shield assembly over the lower flange of the spring seat collar and secure

with a retaining clamp. Tighten the clamp until the boot rubber is firmly secured to the spring seat collar flange.

6 Reinstall front strut, refer to 3.5 Front Strut Assembly in this Section.

Front Suspension Page 3–30

Page 3-30

3.8 Front Strut Unit

LT Section No. – 06-212

Replace

NOTE

• W hen r e pl ac i ng th e f r ont s t r ut, e n s u r e th at t he

replacement unit is the correct type for this

vehicle. Refer to 5. Specifications in this

Section for details.

• As the strut assembly is a sealed component,

no overhaul procedures are possible. If any

strut component is found to be unserviceable,

the complete strut must be replaced.

1 Remove the front strut assembly, refer to 3.5 Front Strut Assembly in this Section.

2 Remove the upper support components, refer to 3.6 Upper Strut Support Bearing and Mount in this Section.

3 Remove the spring, refer to 3.7 Front Spring in this Sectio n.

4 Remove the lower boot, worm drive retaining clamp.

Slide the front strut dust shield assembly (1) and filter

(2) from the strut assembly (3).

5 Pull the strut rod fully up and, while supporting the rod

to stop it from slipping back into the strut, reinstall the

front strut dust shield assembly over the strut tube,

ensuring that the filter (2) remains seated inside the

boot assembly (1).

Figure 3 – 35

6 Ensure that the bottom of the front strut dust shield

assembly is positioned so that distance ‘A’ is between

30 – 35 mm.

7 Install a new worm drive retaining clam p and tighten

until the rubber on the front strut dust shield assembly

is firmly secured.

8 Reinstall the front spring refer to 3.7 Front Spring in

this Section.

9 Reinstall the upper strut support assembly refer to

3.6 Upper Strut Support Bearing and Mo unt in this

Section.

10 Reinstall the front strut assembly refer to 3.5 Front

Strut Assembly in this Section.

Figure 3 – 36

Front Suspension Page 3–31

Page 3-31

3.9 Steering Knuckle

LT Section No. – 06-212

ATTENTION

The following fasteners have either micro encapsulation or incorporate a mechanical thread lock and should

only be used once. If in doubt, replacement is recommended when performing these operations:

# Front control arm ball joint stud nut.

The following fasteners MUST be replaced when performing these operations:

! Front driveshaft outer retaining nut.

! Steering knuckle to strut attaching nuts and bolts.

! Brake caliper anchor plate to steering knuckle retaining bolts.

Remove

1 Observing the jacking precautions as outlined in 2.3 Jacki ng Precau tion s in this Section, raise the front of the

vehicle and support on safety stands.

2 Remove the decorative wheel nut caps and mark the relationship of the wheel to the hub stud, using a felt tipped

pen or similar.

3 Loosen, then remove the road wheel attaching nuts, working in a 'star' pattern. Refer to Section 10 Wheels and

Tyres in the MY 2003 VY and V2 Series Service Information, for detailed information. Remove the road wheel.

NOTE

Steps 2 and 3 are necessary to maintain part

relationships and to avoid brake rotor distortion

and the creation of brake shudder, after the

vehicle is placed back in service.

4 Attach holding tool KM-468 to the wheel hub with two

inverted wheel nuts. Support the tool outer end on a

safety stand (1).

5 Using a 36 mm socket and suitable socket equipm ent,

loosen then remove the driv es haft retain ing nut and

flat washer. Discard the removed nut.

Figure 3 – 37

Front Suspension Page 3–32

Page 3-32

Under no circumstances is the end of the

driveshaft to be struck with a hammer to

dislodge the splines. To do so, will not only

damage the front hub bearing but the

driveshaft to outer CV joint snap ring can be

also be dislodged.

6 Install Tool No. 7208 to the front hub studs and secure

with three of the wheel nuts (1).

NOTE

If not previously modified, it will be necessary to

use a round file to lengthen the slots in Tool No.

7208, to fit over the wheel studs.

7 Tighten the forcing screw to separate the front hub

and outer driveshaft splines. Remove Tool No. 7208.

Figure 3 –38

8 Remove the split pin and loosen the castellated nut (1)

until the nut is flush with the end of the tie rod end

stud.

9 Install Tool No. 7311 as shown and, using a ring

spanner (2), press the stud out from the steering

knuckle.

Figure 3 – 39

10 After marking the relationship of the brake rotor to the front hub with a felt tipped pen or similar, remove the front

brake caliper and rotor. Discard the caliper attaching bolts as they must be replaced on reassembly.

11 Remove the three screws securing the brake shield to the steering knuckle, then remove the shield and set to one

side.

Front Suspension Page 3–33

Page 3-33

12 Loosen the front control arm ball joint retaining nut (1)

until the nut is flush with the end of the front lower

control arm soc ket stu d thread .

13 Install Tool No. 7311 as shown, then apply forc e to the

end the lower control arm ball joint stud by tightening

the forcing bolt on the tool, separating the lower

control arm from the ball joint stud.

Figure 3 – 40

14 Loosen, remove and discard the two lower strut

attaching bolts and nut s (1).

15 If the steering knuckle is to be replaced, remove the

cambe r adjusting bolt (2) f rom the arm.

Figure 3 – 41

16 After placing a piece of wood on the lifting pad of a floor jack, place under the front control arm and raise to

temporarily jam the front control arm ball joint stud taper into the knuckle. Fully remove and discard the ball joint

nut, as it has micro-encapsulation sealant applied and should be replaced on reassembly.

17 Before removing the steering knuckle, support the driveshaft with wire tied to the brake pipe bracket. Do not apply

the wire around the outer CV joint boot. Driveshaft support is needed to avoid damage to the inner tripot joint boot

and to prevent joint separati on , w hen the steering knu ck le is remov ed from the veh ic le.

18 Separate the front hub, steering knuckle and ball joint stud from the lower control arm and remove the assembly

from the vehicle. Leave the floor jack supporting the front control arm.

Front Suspension Page 3–34

Page 3-34

Reinstall

Reinstallation is the reverse of the removal procedures except for the following:

1 If removed, reinstall the brake shield to the steering knuckle, refer to 3.3 Front Wheel Hub Assembly, Brake Rotor

and/or Brake Shield, Reinstall, in this Section.

2 Reinstall the front hub to the steering knuckle, reinstall the three retaining bolts and tighten to the correct torque

specification.

Front wheel hub assembly to

steering knuckle attaching bolt

torque specific atio n ............................................108 Nm

3 Lightly lubricate the outer driveshaft splines (1) with

the recommended final drive lubricant.

4 Reinstall the steering knuckle and ball joint assembly

over the lower control and engage the splines of the

driveshaft with those in the hub.

5 Pull on the wheel speed sensor pulse ring (2) fitted to

the outer CV joint to install the splines into the front

hub. Take care not to damage the wheel speed sensor

ring in the process.

NOTE

As the splined shaft is designed to be an

interference fit to the hub, use the old retaining

nut and washer to fully install the shaft through

the front wheel hub.

Figure 3 – 42

6 Install NEW lower strut to steering knuckle, bolts and nuts but do not tighten fully at this stage.

7 With the floor jack and block of wood (1) still

supporting the front control arm, jam the front control

arm ball joint stud taper into the front control arm.

Reinstall the self-locking nut on to the ball joint stud,

then use an ac curate torque wrench (2) to tighten the

nut to the correct torque specification.

( # ) Front control arm ball joint

stud nut torque specification ................................. 55 Nm

Figure 3 – 43

8 Reinstall the steering linkage outer tie rod socket stud into the steering knuckle and tighten the castellated

attaching nut to the correct torque specification. Install new split pin.

Outer tie rod end stud, castellated nut

torque specific atio n ..............................................65 Nm

9 Reinstall the front brake rotor and caliper as sem bly , refer to 3.3 Front Wheel Hub Assembly, Brake Rotor and/or

Brake Shield in this Section.

Front Suspension Page 3–35

Page 3-35

The brake rotor must be installed, aligning the

marks made prior to removal.

10 Install holding tool KM-468 to two of the wheel studs

and secure with two wheel nuts. Support the outer end

of the holding tool on a safety stand (1).

11 Remove the old driveshaft nut and washer used during

the reassembly process. Reinstall the washer with a

new nut and tighten to the correct torque specification.

( ! ) Front driveshaft outer

retaining nut torque

specification.................Stage 1..........................130 Nm

Stage 2....Loosen nu t until loose

Stage 3..........................200 Nm

12 If it was the left driveshaft that was removed, check

the final drive lubricant level, topping up as required.

Refer to 2.1 Checking Final Drive Lubricant Level, in

Section 4B2 Front Final Drive, Bearing Housing &

Driveshafts, in the MY 2004 AWD W agon Service

Information.

13 Reinstall the road wheel, aligning the marks made

prior to removal.

Figure 3 – 44

14 Temporarily install the road wheel/s and lower the vehicle to the ground.

15 Bounce the vehicle up and down several times to settle the suspension.

16 Check the wheel alignment, refer to 2.2 Wheel Alignment Checking and Adjustment in this Secti on.

Following the wheel alignment, it will be

necessary to raise the vehicle and tighten the

NEW steering knuckle to strut bolts and nuts

to the correct torque specification.

( ! ) Steering knuc kle to strut

attaching nut torque specification.........Stage 1 – 85 Nm

Stage 2 – 100 Nm

Stage 3 – Turn through 90°

17 Lower the vehicle to the ground and tighten the road wheel attaching nuts to the correct torque specification,

working in a ‘star’ pattern, refer to 2.3 Wheel and Tyre Removal and Installation, in Section 10 Wheels and Tyres,

in the MY 2003 VY and V2 Series Service Information.

Road wheel attaching nut

torque specific atio n ............................................125 Nm

18 Install the decorative wheel nut caps .

Front Suspension Page 3–36

Page 3-36

3.10 Front Control Arm Ball Joint Assembly

LT Section No. – 06-200

Inspect

The followi ng procedure should be used when checking the lower control arm ball joint assembly for wear.

1 Raise the vehicle with the jack lift pad located under the centre of the front suspension crossmember cradle.

2 Holding the road wheel at the top and bottom, check for play in the lower control arm ball joint assembly by rocking

the wheel.

3 If any up or down movement of stud in lower control arm ball joint assembly housing is detected, the steering

knuckle and lower control arm ball joint assembly must be replaced.

Replace

As the ball joint is not serviced separately from the steering knuckle, should inspection show that the ball joint is faulty,

then the steering knuckle and ball joint assembly must be replaced as an assembly. Refer to 3.9 Steering Knuckle, in this

Section.

Front Suspension Page 3–37

Page 3-37

3.11 Front Control Arm

LT Section No. – 06-200

ATTENTION

The following fasteners have either micro encapsulation or incorporate a mechanical thread lock and should

only be used once. If in doubt, replacement is recommended when performing these operations:

# Front control arm ball joint stud nut.

The following fasteners MUST be replaced when performing these operations:

! Front control arm front isolator and rear bushing retaining bolts.

Before the following fasteners are fully tightened, the vehicle MUST be at curb height:

•

••

• Front control arm front isolator and rear bushing retaining bolts.

Remove

1 Observing the jacking precautions, refer to 2.3 Jacking Precautions in this Section, raise the front of the vehicle and

support on safety stands.

2 Remove the decorative wheel nut caps and mark the relationship of the wheel to the hub stud, using a felt tipped

pen or similar.

3 Loosen, then remove the road wheel attaching nuts, working in a 'star' pattern. Refer to Section 10, Wheels and

Tyres in the MY 2003 VY and V2 Series Service Information, for detailed information. Remove the road wheel.

NOTE

Steps 2 and 3 are necessary to maintain part

relationships and to avoid brake rotor distortion

and the creation of brake shudder, after the

vehicle is placed back in service.

4 Turn the steering out on full lock.

5 Loosen the front control arm ball joint retaining nut (1)

until the top of the nut is flush with the end of the front

control arm ball joint stud thread.

6 Install the release Tool No. 7311, then tighten the

forcing bolt on the tool to separate the front control

arm ball joint stud from the front control arm.

7 Temporarily jam the front control arm ball joint stud

taper into the knuckle to hold the stud, before fully

removing the retaining nut. As the ball joint stud nut

has micro-encapsulation seala nt applie d to the

threads, it should be replaced on reassembly.

Do not allow the front driveshaft to extend to

the stage where the inner tripot end becomes

separated. After release of the ball joint,

ensure that the outer end is released from the

wheel hub and supported by tie wire.

8 Separate the front control arm ball joint stud from the

control arm. Figure 3 – 45

Front Suspension Page 3–38

Page 3-38

9 Remove the screws and scrivets securing the front

plastic under tray from the front bumper, then remove

the under tray from the vehicle.

10 Using a 24 mm socket and suitable equipment, loosen

then remove the front control arm front isolator bolt (3),

until several threads remain.

NOTE

Thread sealant on this front bolt may make the

removal effort high. However, under no

circumstances is heat to be applied to the control

arm, in an attempt to soften the sealant.

Figure 3 – 46

12 Remove the split pin and loosen the castellated nut (1)

until the nut is flush with the end of the tie rod end

stud.

13 Install Tool No. 7311 as shown and, using a ring

spanner (2), press the stud out from the steering

knuckle.

14 To gain acce ss to the rear bushing retaining bolt (4),

turn the steering out on full lock and hold in this

position. Allow the tie rod to drop under its own weight.

This will provide enough space to gain access to the

front control arm rear bushing bolt.

Figure 3 – 47

15 Use a 19 mm socket and suitable equipment, loosen the front control arm rear bushing bolt (4) from the rear but

leave installed to support the rear bushing.

16 While supporting the front control arm, completely remove the front control arm front isolator bolt (3) and the rear

bushing bolt (4), then remove the front control arm (1) from the crossmember cradle.

Front Suspension Page 3–39

Page 3-39

Reinstall

1 Reinstall the front control arm (1) to the crossmember

cradle (2), then install new front isolator (3) and rear

bushing (4) bolts but do not fully tighten at this stage.

NOTE

As the front control arm is a heavy component,

aligning the bolts may prove difficult unless a

suitable floor jack, fitted with a block of wood (or

an assistant), is used to support and raise the

control arm into position.

Figure 3 – 48

2 Using a suitable floor jack fitted with a block of wood positioned under the front control arm, raise the jack sufficient

to support the weight of the strut assembly and jam the front control arm ball joint stud into the steering knuckle.

3 It is recomm ended that a new self-locking nut is fitted to the lower control arm ball joint stud. Tighten the nut to the

correct torque specification.

# ) Front control arm ball joint

stud nut torque specification ................................. 55 Nm

4 Reinstall the road wheel, aligning marks made prior to removal. Reinstall the wheel nuts but do not fully tighten at

this time.

5 Lower vehicle to the ground.

6 Roll the vehicle back and forth, then bounce the vehicle up and down several times to settle the suspension.

The weight of the vehicle must be on all four

wheels before tightening the front control arm

isolator bolts to specification. Tensioning

these bolts when the insulating bushing is

incorrectly pre-loaded will result in reduced

insulator bushing life and will adversely affect

the ride and handling characteristics of the

vehicle.

7 With the weight of the vehicle on the suspension components, tighten both the front control arm isolator and the

rear bushing bolts to the correct torque specification.

( ! ) Front control arm front isolator

bolt torque specification......................................340 Nm

( ! ) Front control arm rear bushing

bolt torque specification......................................140 Nm

8 Straighten the wheels and, with the vehicle on the ground, tighten the road wheel attaching nuts to the correct

torque specification, working in a ‘star’ pattern, refer to 2.3 Wheel Removal and Installation, in Section 10 Wheels

and Tyres, in the MY 2003 VY and V2 Series Service Information.

Road wheel attaching nut

torque specific atio n ............................................125 Nm

Front Suspension Page 3–40

Page 3-40

9 Reinstall the front plastic under tray to the front bumper and front suspension cradle, securing with the screws, self

tapping screws and scrivets.

10 Reinstall the decorative wheel nut caps.

11 Check the wheel alignment, refer to 2.2 Wheel Alignment Checking and Adjustment in this Section.

Front Suspension Page 3–41

Page 3-41

3.12 Front Control Arm Rear Bushing

LT Section No. – 06-200

Replace

1 Remove the fron t control arm (1), refer to 3.11 Front C ontro l Arm in this Section.

2 Secure the front control arm in a vice fitted with soft jaws.

3 Install the removal tool with the thrust bearing CH-

47569-2 under the bolt head CH-47569-1, then insert

the receiver cup CH-47569-6. With this sub-assembly

inserted through the bush to be removed, install the

smaller cupped piece, CH-47569-5 over the bolt and

secure with a nut and flat washer.

4 While holding the nut, turn the bolt head to force the

bushing (2) into the receiving cup, Tool No. CH-47569-

5 After bush removal, check the bore of the control arm

(1) for damage or rust. Clean up as required.

Figure 3 – 49

6 Apply a soap solution or petroleum jelly (e.g.

Vaseline ™) to the bore of the control arm and to the

smaller flange ( 1) of the new bushing.

NOTE

Apart from the smaller diameter of the inboard

end of the bushing, this is also the end with the

larger groove (2) that allows greater bush flange

distortio n during the ins tal lati o n proces s.

Figure 3 – 50

Front Suspension Page 3–42

Page 3-42

7 Assemble the installation tools with the thrust bearing

CH-47569-2 under the bolt head CH-47569-1,

followed by the larger of the two cups, CH-47569-4,

then the lubricated bush (1). Install the receiver cup

CH-47569-3 over the inserted bolt, then secure with

the flat washer and nut.

8 To install the new bush, proceed as follows:

a While holding the nut, slowly turn the bolt head

to compress the bush.

b With the bush compressed, wait until the bush

land distorts and starts to enter the control arm,

before proceeding.

c Continue to turn the bolt head until the bush is

fully installed.

d Remove the installation tools and check that the

bush is centrally located on each side of the

control arm.

NOTE

If the bush has been installed too far, assemble

the tools in the removal position and centralise

the bush. Refer to Figure 3-49 for the tool setup.

9 Reinstall the front control arm, refer to 3.11 Front

Control Arm, in this Section.

Figure 3 – 51

Front Suspension Page 3–43

Page 3-43

3.13 Front Control Arm Front Isolating

Bushing

LT Section No. – 06-200

ATTENTION

The following fasteners MUST be replaced when performing these operations:

! Front control arm, front isolator and rear bushing retaining bolts.

The following fasteners MUST be at curb height before final tightening:

•

••

• Front control arm, front isolator and rear bushing retaining bolts.

Inspect

The front control arm, front isolating bushing is a hydraulically dampened component. Visible splits in the bushing do not

necessarily mean that the bush has failed. The bush may also appear to be 'off-centre' when the vehicle is standing

stationary but this is a normal condition.

The main criteria that indicates that the bushing has failed, is the indication or presence of hydraulic fluid leaking from the

bushing. Therefore, only if fluid is observed to be leaking from the bushing, is it to be replaced, by following the

procedure detailed in this service operation.

Replace

1 Remove the front control arm. Refer to 3.11 Front Control Arm, in this Section.

2 Install Tool No. CH-47568 to the front is olating bush to

be replaced, as show n in Figur e 3-52.

NOTE

The receiving cup (CH-47568-1), forcing screw

(2) and thrust race (CH-47568-5) are installed

from front to rear.

3 While holding the nut (1), use suitable socket

equipment to tighten the forcing screw (2) of Tool No.

CH-47568, to remove the isolating bush from the front

su spension crossmember cradle (3), into the r eceiver,

CH-47568-1. Discard the removed bush.

Figure 3 – 52

Front Suspension Page 3–44

Page 3-44

4 Lightly lubricate the outer steel sleeve (1) of a new

isolating bush, with a light coating of molybdenum

disulphide grease.

NOTE

Ensure that the voids in the bush are aligned

correctly, as shown in Figure 3-55.

5 Assemble the forcing screw (3), thrust bearing CH-

47568-5 and installing cup CH-47568-3, into the new

isolating bush, then install into the front suspension

crossmember cradle, working from front to rear.

NOTE

Arrange the slot in cup, Tool No. CH-47568-2, so

a measurement can be taken from the rear of

the isolating bush, inner flange. Refer to Step 7.

6 While holding the nut of the fo rcing screw of Tool CH-

47568, turn the bolt head to push the front isolating

bush into the crossmember cradle.

Figure 3 – 53

7 The correct positioning of the bush is assessed by measuring the distance from the inner flange of the front

isolating bush (1), to the rear land (2) for the rear bush in the front crossmember cradle (3), which is to be from

337.1 to 337.6 mm.

NOTE

If the bush is installed too far, it will not be

possible to reinstall the control arm. Therefore, it

will be necessary to extract the isolating bush,

until the required dimension is achieved. Refer to

Figure 3-52 for the tool arrangement.

Figure 3 – 54

Front Suspension Page 3–45

Page 3-45

It is vital that the bush voids are aligned

vertically, as shown. If not, then the ride and

handling of the vehicle will be severely

affected.

8 Reinstall the front control arm. Refer to 3.11 Front

Control Arm, Reinstall, in this Section.

Figure 3 – 55

Front Suspension Page 3–46

Page 3-46

3.14 Front Suspension Crossmember Cradle

LT Section No. – 06-200

ATTENTION

The following fasteners MUST be replaced when performing these operations:

! Steering rack housing to crossmember cradle bolts and nuts.

! Front control arm ball joint stud nut

! Front suspension crossmember cradle to side member attaching bolt.

! Front control arm to crossmember cradle front isolating and rear bushing bolts.

! Engine mount to crossmember cradle attaching nuts.

The following fasteners MUST be at curb height before final tightening:

" Front control arm to crossmember cradle front isolating and rear bushing bolts.

Remove

1 Observing the jacking precautions, refer to 2.3 Jacking Prec autio ns in this Section, raise the front of vehicle and

place safety stands under the side frame members.

2 Remove the decorative wheel nut caps.

3 Mark the relationship of each road wheel to its hub and rotor. Loosen, then remove the road wheel attaching nuts.

Remove the road wheels. Do not mix from side to side.

4 Remove the screws and scrivets securing the front plastic under tray from the front bumper and front suspension

cradle, then remove the under tray from the vehicle.

5 With a backing set spanner holding the stabiliser bar

link inner stud hexagon (1), use a second spanner to

loosen then remove the retaining nut (2).

6 Separate the stabiliser bar link (3) from the stabiliser

bar (4).

7 Repeat steps 4 and 5 for the other side.

Figure 3 – 56

Front Suspension Page 3–47

Page 3-47

8 Remove the split pin from the steering linkage outer tie

rod end castellated nut (1), then loosen the nut until

the top of the nut is level with the top of the steering

linkage outer tie rod socket stud.

9 Install Tool No. 7311 and use a ring spanner (2) to

separate the steering linkage outer tie rod socket stud

from the steering knu ck le.

10 Repeat steps 6 and 7 for the other side.

Figure 3 – 57

11 Remove the air chute to crossmember securing screws. Refer to Section 6B3 Engine Cooling – GEN III V8 in the

MY 2004 AWD Wagon Service Information, for locations.

12 Remove the steering gear housing (1) to front

crossmember cradle (2) mounting bolts (3) and nuts

(4).

13 Remove the steering gear housing from th e

crossmembe r mountings (5), then support the rack

with tie wire to convenient points on the vehicle

underbody.

NOTE

Dependent on personal choice but disconnecti ng

the steering shaft coupling cam bolt and nut will

provide more flexibility with steering rack

movement. The nut however, must be replaced

on reassembly.

Figure 3 – 58

14 Remove the screws and brackets securing the power

steering pipes and engine coolant transfer tube to the

front crossmemb er cradl e:

a At the right (1) and left (2) side rails.

b In two places across the front rail (3).

Figure 3 – 59

Front Suspension Page 3–48

Page 3-48

15 Turn each wheel out in turn.

16 Loosen the front control arm ball joint retaining nut (1)

until the top of the nut is flush with the end of the stud

thread.

17 Install release Tool No. 7311 as shown, then apply

force to the ball joint stud by tightening the forcing bolt

on the tool, separating the front control arm from the

ball joint stud.

18 Temporarily jam the front control arm socket assembly

stud taper into the knuckle to hold the stud, before fully

removing the retaining nut. Disc ard the removed nut

as it has micro-encapsulation sealant applied and

should be replaced on reassembly.

Figure 3 – 60

19 Separate the ball joint stud from the front control arm.

20 Remove each of the front driveshafts from the vehicle. Refer to Section 4B2 Front Final Drive, Bearing Housing &

Driveshafts in the MY 2004 AWD Wagon Service Information, for the procedure.

21 Use a suitable length wooden prop, support the steering knuckle, disc, front hub and strut against the side rail.

Repeat for the other side of the vehicle.

22 Disconnect the windscreen washer tubing, mark the engine hood hinge positions then remove the engine hood.

23 Support the engine with a suitable lifting device, then remove the front engine mount to crossmember cradle nuts

from under the vehicle, using an 18 mm deep socket and suitable socket equipment.

24 Support the crossmember cradle (3) on a jack and

suitable pieces of wood, then remove the four bolts (1

and 2) securing the crossmember cradle to the side

frame member s.

NOTE

If working from a hoist, use a commercially

available, hydraulic scissor lift, mobile bench to

support the crossmember.

25 Lower, then remove the crossmember cradle

assembly (3) from vehicle.

26 As required, remove the front control arms, front

control arm rear bushings, front isolating bushes and

stabiliser bar from the crossmember. Refer to;

3.11 Front Control Arm.

3.12 Front Control Arm Rear Bushing.

3.13 Front Control Arm Front Isolating Bushing.

3.17 Stabiliser Bar.

Figure 3 – 61

Front Suspension Page 3–49

Page 3-49

Reinstall

While the majority of the reinstallation process is the reverse of the removal procedures, note the following points:

1 If removed, reinstall the stabiliser bar insulating rubbers and brackets onto the crossmember cradle, refer to

3.17 Stabiliser Bar. Tighten the retaining nuts to the correct torque specification.

Stabiliser bar bushing bracket

nut torque specification ........................................28 Nm

2 Reinstall the two front control arms to the crossmember cradle, installing new, front isolating and rear bushing bolts

but do not fully tighten at this stage.

3 After raising the crossmember cradle, install two NEW front, stepped bolts (‘1’ in Figure 3-61). This will correctly

align the crossmember to the side frames.

4 Install two NEW rear, plain shanked bolts (‘2’ in Figure 3-61) to the two rear positions and tighten all four bolts to

the correct torque specification.

( ! ) Crossmember cradle to side

frame bolt torque specif icat ion ............................122 Nm

5 Reinstall the ball joint stud into each front control arm, fit NEW nuts and tighten to the correct torque specification.

( ! ) Front control arm ball joint

stud nut torque specification ................................. 55 Nm

6 Lower the engine to engage the engine mount pins with the holes provided in the crossmember cradle supports.

7 Install new engine mount ing n uts, then us e an 18 mm deep soc ket and torqu e wr ench to tighten the nut s to the

correct torque specification.

( ! ) Front engine mount attaching

nut torque specification ........................................80 Nm

8 Reinstall the road wheels, aligning marks made prior to removal.

9 Reinstall the engine hood .

10 Lower the vehicle to the ground, roll the vehicle back and forth about 1 metre in each direction, then bounce the

vehicle several times to settle the suspension.

The weight of the vehicle must be on all four

wheels before tightening the front control arm

isolator and bushing bolts to specification. If

not, the bushings will be stressed with the

vehicle at rest and the bushings will fail

prematurely w hen the vehicle is put back into

service.

11 With the weight of the vehicle on the suspension components, tighten all front control arm isolator and rear bushing

bolts to the correct torque specification.

( ! ) Front control arm, front isolator

bush bolt torque specification.............................340 Nm

( ! ) Front control arm, rear bushing

bolt torque specification......................................140 Nm

12 Tighten the road wheel attaching nuts to the correct torque specification, working in a ‘star’ pattern. Refer to

Section 10, Wheels and Tyres in the MY 2003 VY and V2 Series Service Information. Reinstall the decorative

wheel nut caps.

Road wheel attaching

nut torque specification ......................................125 Nm

Front Suspension Page 3–50

Page 3-50

13 Install the steering gear housing to the crossmember cradle and tighten NEW mounting nuts and bolts. Hold the

nuts and tighten the bolts to the correct torque specificat ion.

( ! ) Steering rack housing to

crossmember mounting bolt

torque specific atio n .....................................60 Nm, then

turn through 50°

14 If the power steering flare pipes were disconnected during the removal process, remove plugs from the power

steering hydraulic pipes and valve housing apertures, then reinstall the pipes. Tighten each flare nut to the correct

torque specif ication.

Hydraulic pipe to steering rack

valve housing flare nut

torque specific atio n ..............................................35 Nm

15 Bleed the power steering hydraulic system. Refer to Section 9 Steering, in the MY 2003 VY and V2 Series Service

Information.

16 Reinstall the front plastic under tray to the front bumper and front suspension cradle, securing with the screws, self

tapping screws and scrivets.

17 Reinstall the decorative wheel nut caps.

18 Check the wheel alignment, refer to 2.2 Wheel Alignment Checking and Adjustment in this Section.

Front Suspension Page 3–51

Page 3-51

3.15 Stabiliser Bar Link

LT Section No. – 06-205

Replace

1 Raise the front of the vehicle and place safety stands under side frame members. Refer to 2.3 Jacking Precautions

in this Section.

2 Remove the decorative wheel nut caps on the side where this procedure is to be carried out.

3 Mark the relationship of the wheel to the hub and brake rotor, then loosen and remove the road wheel attaching

nuts and remove the road wheel. Refer to Section 10, Wheels and Tyres in the MY 2003 VY and V2 Series Servic e

Information.

NOTE

Step 3 is necessary to maintain component

relationships and to avoid brake rotor distortion

with the resultant creation of brake shudder, after

the vehicle is placed back in service.

4 Using a suitable size spanner, hold the stabiliser bar

spacer stud (1) at ‘A’, then use another spanner to

loosen and remove the stabiliser bar spacer stud nut

(2).

5 Remove the upper washer (3), upper insulator (4) and

centre washer (5).

Figure 3 – 62

6 With a backing set spanner holding the stabiliser bar

link inner stud hexagon (1), use a second spanner to

loosen then remove the retaining nut (2).

7 Separate the stabiliser bar link (3) from the stabiliser

bar (4) and remove from the strut mounting bracket.

Figure 3 – 63

Front Suspension Page 3–52

Page 3-52

The installation procedure is the reverse to removal, except

for the following points:

8 As required, replace the lower link washer (1) and

insulator (2).

9 Before reinstallation of the stabiliser bar link (3) to the

stabiliser bar (4), insert the upper threaded end of the

link into the strut mounting bracket.

10 Reinstall the link ball socket stud to the stabiliser bar

(4), tighten the retaining nut (5) to the correct torque

specification, while holding the inner stud hexagon

with a spanner ('1' in Figure 3-62).

Stabiliser bar link ball socket retaining

nut torque specification ........................................50 Nm

11 Reinstall the upper seat (6), upper insulator (7) and

washer (8).

12 Reinstall the upper link retaining nut (9).

Figure 3 – 64

13 While holding the spacer stud (3) with a suitable open end spanner at ‘A’, use another spanner to tighten the upper

retaining nut (9) until the end of the thread on the stud is contacted. Do not over-tighten.

14 Reinstall the road wheels, aligning the marks made prior to removal, and secure with the wheel attaching nuts, but

do not fully tighten at this stage.

15 Remove the safety stands and lower the vehicle.

16 Tighten the road wheel attaching nuts to the correct torque specification, working in a ‘star’ pattern. Refer to

Section 10 Wheels and Tyres, in the MY 2003 VY and V2 Seri es Service Information.

Road wheel attaching nut

torque specific atio n ............................................125 Nm

17 Reinstall the decorative wheel nut caps.

Front Suspension Page 3–53

Page 3-53

3.16 Stabiliser Bar Isolator Bushes

Replace

1 Raise the vehicle and support in a safe manner. Refer to 2.3 Jac kin g Precaut ion s in this Section.

NOTE

Access to the stabiliser bar isolator bushing/s is

made easier by turning the wheels out on the

side being worked on.

2 Using suitable socket equipment, remove the two nuts

(1), securing the insulato r bracket (2) to the

crossmembe r cradle (4). Repeat for the second side.

NOTE

Both sides need to be released to allow removal

of the bushing/s (3) from the crossmember

cradle.

3 Lift the stabiliser bar free from the crossmember

cradle, then remove the bushing/s (3).

4 Reinstall new bushing/s, taking note of the orientation,

reinstall the bracket/s, washers and nuts.

NOTE

The slot in each insulator should face forward,

and the rounded sections on the insulators

should seat in the mating recesses in the

crossmember cradle.

Ensure the stabiliser bar is centralised in the

bushings and brackets. If not corrected,

contact between the stabiliser bar and the

driveshaft outer grease boot may occur on

full suspension hang and/or on full steering

lock.

5 Tighten the nuts to the correct torque specification.

Stabiliser bar bushing bracket

nut torque specification ........................................28 Nm

6 Remove safety supports and lower vehicle to the

ground.

Figure 3 – 65

Front Suspension Page 3–54

Page 3-54

3.17 Stabiliser Bar

LT Section No. – 06-205

NOTE

To remove the stabiliser bar completely from the

vehicle, it will first be necessary to lower the

crossmember cradle to provide the required

space. Refer to 3.14 Front Suspension

Crossmember Cradle in this Section.

Remove

1 Raise the front of the vehicle and support in a safe manner. Refer to 2.3 Jacking Precautions in this Sectio n.

2 Remove the decorative wheel nut caps on both sides.

3 Mark the relationship of each wheel to its hub and brake rotor, then loosen and remove each of the road wheel

attaching nuts, then remove the road wheels. Refer to Section 10, Wheels and Tyres in the MY 2003 VY and V2

Series Service Information.

NOTE

Step 3 is necessary to maintain component

relationships and to avoid brake rotor distortion

with the resultant creation of brake shudder, after

the vehicle is placed back in service.

4 With a set spanner holding the stabiliser bar link inner

stud hexagon (1), use a second spanner to loos en

then remove the retaining nut (2).

5 Separate the stabiliser bar link (3) from the stabiliser

bar (4).

6 Support the engine/tran smi ssion assembly , then lower

the crossmember cradle, enough to provide space for

the stabiliser bar removal. Refer to 3.14 Front

Suspension Crossmem ber Cradle, in this Section.

Figure 3 – 66

Front Suspension Page 3–55

Page 3-55

7 Remove the nuts (1) securing the insulator bracket (2)

to each side of the crossmember cradle (4), then

remove the support brackets, stabiliser bar, and

insulators (3) from the crossmember cradle.

8 Remove the stabiliser bar from the vehicle.

Figure 3 – 67

Reinstall

The reinstallation procedure of the stabiliser bar is the reverse of the removal procedure, except for the followi ng:

1 Reassemble the two insulators onto the stabiliser bar, then reinstall to the crossmember cradle tower.

NOTE

The slot in each insulator should face forward,

and the rounded sections on the insulators

should seat in the mating recesses in the

crossmember cradle.

2 Reinstall both insulator brackets and nuts, then tighten the stabiliser bar insulator bracket nuts to the correct torque

specification.

Stabiliser bar bushing bracket

nut torque specification ........................................28 Nm

3 Reinstall the front suspension crossmember cradle. Refer to 3.14 Front Suspension Crossmember Cradle, in this

Section.

4 Reinstall the stabiliser bar link socket stud nut and, while holding the stud hexagon with a set spanner, tighten to

the correct torque specification.

Stabiliser bar link ball stud nut

torque specific atio n ..............................................50 Nm

5 Reinstall the road wheels, aligning the marks made prior to removal, and secure with the wheel attaching nuts, but

do not fully tighten at this stage.

6 Remove the safety stands and lower the vehicle.

7 Bounce the vehicle up and down several times to settle the suspension.

8 Check and correct the wheel alignment, as required. Refer to 2.2 W heel Alignment Checking and Adjustment, in

this Section.

9 Tighten the road wheel attaching nuts to the correct torque specification, working in a ‘star’ pattern. Refer to

Section 10 Wheels and Tyres, in the MY 2003 VY and V2 Seri es Service Information.

Road wheel attaching nut

torque specific atio n ............................................125 Nm

10 Reinstall the decorative wheel nut caps.

Front Suspension Page 3–56

Page 3-56

4 Diagnosis

4.1 General

When diagnosing suspected front suspension problems, it should be remembered that steering, wheels and tyres all

have an effect on front end performance. Refer to Section 9, Steerin g and Section 10, Wheels and Tyres in the MY 2003

VY and V2 Series Service Information, for details.

Strut Diagnosis

1. Test by quickly pushing up and down on the bumper bar at the front corner of the vehicle. Compare the resistance

to movement with a similar vehicle having acceptable ri de quality.

2. Inspect the struts for excessive fluid leakage.

Acceptance Cri t eria

A strut DOES NOT require replacement, if any or a combination of the following are present:

•

••

•

An oily build-up at the end of the piston rod, up to 1 cm wide.

•

••

•

Oily ‘sludge’ accumulated from normal operating conditions to 4 cm from the top of the strut body.

•

••

•

Road grease, oil, sand and dust discolouration on the body, does not constitute a leaking strut. If this condition is

evident, the strut should be wiped clean and checked at a later service.

NOTE

Should one strut prove to be leaking and require

replacement, provided the remaining strut is

serviceable, it does not also need to be replaced

Front Suspension Page 3–57

Page 3-57

4.2 Diagnosis Guide

Hard or Heavy St eering

Symptom and Probable Cause Remedy

1 Low or uneven tyre pressures. 1 Inflate tyres to specified pressure for specific load

conditions. Refer to tyre placard attached to the

vehicle.

2 Steering gear or connections too tight or misaligned. 2 Adjust steering gear or replace components as

necessary. Refer to Section 9 Steering in the MY

2003 VY and V2 Series Service Inform ation.

3 Insufficient fluid in steering gear. 3 Check steering gear fluid level. Top up, using only

DEXRON III® fluid. Check system for leaks. Refer to

Section 9 Steering in the MY 2003 VY and V2 Series

Service Information.

4 Excessive caster. 4 Caster is not adjustable. Check for bent or damaged

components. Repair as required.

5 Excessive toe-in. 5 Check and adjust wheel toe. Refer to 2.2 Wheel

Alignment Ch eck i ng and Adju stment in this Section.

Excessive Play or Looseness in Steering

Symptom and Probable Cause Remedy

1 Steering gear or connections loose or worn. 1 Adjust steering gear or install new components as

required. Refe r to Section 9 Steering in the MY 2003

VY and V2 Series Service Information.

2 Front control arm ball joint loose or worn. 2 Replace control arm ball joint assembly. Refer to

3.10 Front Control Arm Ball Joint Assembly, in this

Section.

3 Front wheel bearings worn. 3 Replace front wheel hub assembly. Refer to

3.3 Front Wheel Hub Assembly, Brake Rotor and/or

Brake Shield, in this Section.

4 Loose attachment of crossmem ber cradle to frame. 4 Replace and tighten crossmember cradle attaching

bolts. Refer to 3.14 Front Suspension Crossmember

Cradle in this Section for tightening procedures.

Front Suspension Page 3–58

Page 3-58

Erratic Steering on Ap pl ication of Brakes

Symptom and Probable Cause Remedy

1 Low or uneven tyre pressures. 1 Inflate tyres to specified pressure for specific load

conditions. Refer to the tyre placard attached to the

vehicle.

2 Excessive front brake rotor runout. 2 Machine front rotors. Refer to Section 5A Service

and Park Braking System in the MY 2003 VY and

V2 Series Service Information.

3 Front brake pads contaminated with lubricant. 3 Replace brake pads. Correct cause of lubricant

leakage. Refer to Section 5A Service and Park

Braking System in the MY 2003 VY and V2 Series

Service Information.

4 Insufficient or uneven caster. 4 Caster is not adjustable. Check for bent or

damaged components. Repair as required.

5 Steering knuckle bent. 5 Replace steering knuckle. Refer to Section 9

Steering in the MY 2003 VY and V2 Series Service

Information.

6 Excessive play in steering gear. 6 Adjust steering gear or replace worn components.

Refer to Section 9 Steering in the MY 2003 VY and

V2 Series Service Information.

Vehicle Pulls to One Side

Symptom and Probable Cause Remedy

1 Low or uneven tyre pressures. 1 Inflate tyres to specified pressure for specific load

conditions. Refer to tyre placard attached to the

vehicle.

2 Rear wheels not tracking wi th front wheels. 2 Check alignment of rear wheels with front wheels

and correct as necessary. Refer to Section 4A Rear

Suspension, in the MY 2004 AWD W agon Service

Information, for details of rear wheel alignment.

3 Front brake pads contaminated with lubricant. 3 Replace brake pads. Correct cause of lubricant

leakage. Refer to Section 5A Service and Park

Braking System in the MY 2003 VY and V2 Series

Service Information.

4 Toe-in incorrect. 4 Adjust toe-in to specification. Refer to 2.2 Wheel

Alignment Ch eck i ng and Adju stment, in this Section.

5 Incorrect or uneven caster or camber. 5 Check and adjust wheel alignment. Refer to

2.2 Wheel Alignmen t Checking and Adjustment, in

this Section.

6 Rear final drive/rear suspension crossmember

shifted. 6 Check attaching bolts for looseness and rear trailing

arm bushings for wear. Refer to Section 4A Rear

Suspension, in the MY 2004 AWD W agon Service

Information

7 Steering knuckle bent. 7 Replace steering knuckle. Refer to 3.9 Steering

Knuckle, in this Section.

Front Suspension Page 3–59

Page 3-59

Front or Rear Wheel Tramp

Symptom and Probable Cause Remedy

1 Wheels and tyres out of balanc e. 1 Balance wheels and tyres. Also check for eccentric or

bulged tyres. Replace as necessary. Refer to

Section 10. Wheels and Tyr es in the MY 2003 VY

and V2 Series Service Information.

2 Front struts or rear sho ck abs o rbers opera ting

incorrectly, leaking fluid or inoperative. 2 Check operation and replace components as

necessary. Refer to 3.8 Front Strut Unit in this

Section or Section 4A Rear Suspension in the

MY 2004 AWD Wagon Service Information.

Road Shocks

Symptom and Probable Cause Remedy

1 Incorrect tyre pressur es. 1 Inflate tyres to specified pres s ure for specif ic loa d

conditions. Refer to tyre placard attached to the

vehicle.

2 Steering gear incorrectly adjusted. 2 Adjust steering gear. Refer to Section 9 Steering in

the MY 2003 VY and V2 Series Service Information.

3 Front struts or rear sho ck abs o rbers opera ting

incorrectly or unevenly, leaking fluid or inoperative. 3 Check operation and replace components as

necessary. Refer to 3.8 Front Strut Unit in this

Section or Section 4A Rear Suspension in the

MY 2004 AWD Wagon Service Information.

4 Compression or rebound rubbers damaged or

missing. 4 Replace missing or damaged parts. Refer to

3.8 Front Strut Unit in this Section.

5 Unbalanced wheels. 5 Balance wheels. Refer to Section 10 Wheels and

Tyres in the MY 2003 VY and V2 Series Service

Information.

6 Incorrect wheel alignment. 6 Check and adjust. Refer to 2.2 Wheel Alignment

Checking and Adju stment, in this Section .

Scuffed Tyres

Symptom and Probable Cause Remedy

1 Toe-in incorrect. 1 Adjust toe-in. Refer to 2.2 Wheel Alignment Checking

and Adjustment, in this Section.

2 Tyres improperly inflated. 2 Inflate tyres to specified pressure for specific load

conditions, as detailed on the tyre placard attached to

the vehicle.

3 Wheels or tyres out-of-true. 3 Check for wh eel and tyre wobble. Check that the

wheels and tyres are corre ctly moun ted. Bala nce

wheels and tyres. Refer to Section 10 Wheels and

Tyres, in the MY 2003 VY and V2 Series Service

Information.

4 Front lower control arm socket/s worn. 4 Replace worn components. Refer to 3.11 Front

Control Arm in this Section.

5 Uneven caster and camber. 5 Check wheel alignment. Adjust as necessary. Refer

to 2.2 Wheel A lignment Checking and Adjustment in

this Section.

6 Steering knuckle bent. 6 Replace steering knuckle. Refer to 3.9 Steering

Knuckle in this Section.

Front Suspension Page 3–60

Page 3-60

Cupped Tyres

Symptom and Probable Cause Remedy

1 Tyres improperly inflated. 1 Inflate tyres to specified pressure for specific load

conditions, as detailed on the tyre placard attached to

the vehicle.

2 Wheels and tyres out-of-balance. 2 Balance wheels and tyres. Also check for eccentric or

bulged tyres. Replace as necessary. Refer to Section

10. Wheels and Tyres, in the MY 2003 VY and V2

Series Service Information.

3 Dragging brak es. 3 Check for seizing of the brake calipers and/or park

brake mechanism. Refer to Section 5A Service and

Park Braking System in the MY 2003 VY and V2

Series Service Information.

4 Front control arm ball joints and/or wheel bearings

worn. 4 Replace worn components. Refer to 3.10 Front

Control Arm Ball Joint Assembly or 3.3 Front Wheel

Hub Assembly, Brake Rotor and/or Brake Shield, in

this Section.

5 Uneven caster. 5 Check wheel alignment. Adjust as necessary. Refer

to 2.2 Wheel A lignment Checking and Adjustment in

this Section.

6 Steering knuckle bent. 6 Replace steering knuckle. Refer to 3.9 Steering

Knuckle in this Section.

Front Wheel Shimmy

Symptom and Probable Cause Remedy

1 Low or uneven tyre pressures. 1 Inflate tyres to specified pressure for specific load

conditions, as detailed on the tyre placard attached to

the vehicle.

2 Steering connections incorrectly adjusted or worn. 2 Adjust steering gear or install new components as

required. Refe r to Section 9 Steering, in the MY 2003

VY and V2 Series Service Information.

3 Front control arm ball joints and/or wheel bearings

worn. 3 Replace worn components. Refer to 3.10 Front

Control Arm Ball Joint Assembly or 3.3 Front Wheel

Hub Assembly, Brake Rotor and/or Brake Shield, in

this Section.

4 Wheels and tyres out-of-balance. 4 Balance wheels and tyres. Also check for eccentric or

bulged tyres. Replace as necessary. Refer to Section

10 Wheels and Tyres, in the MY 2003 VY and V2

Series Service Information.

5 Wheels or tyres out-of-true. 5 Check for wh eel and tyre wobble. Check that the

wheels and tyres are corre ctly moun ted. Bala nce

wheels and tyres. Refer to Section 10. Wheels and

Tyres, in the MY 2003 VY and V2 Series Service

Information.

6 Incorrect or uneven caster or incorrect toe-in setting. 6 Caster is not adjustable. Check for bent or damaged

components. Repair as required. Check and adjust

toe-in setting. Refer to 2.2 Wheel Alignment Checking

and Adjustment in this Section.

7 Steering knuckle bent. 7 Replace steering knuckle. Refer to 3.9 Steering

Knuckle in this Section.

Front Suspension Page 3–61

Page 3-61

Vehicle Wanders

Symptom and Probable Cause Remedy

1 Low or uneven tyre pressures. 1 Inflate tyres to specified pressure for specific load

conditions, as detailed on the tyre placard attached to

the vehicle.

2 Steering connections loose or worn. 2 Adjust steering gear or install new components as

needed. Refer to Section 9 Steering, in the MY 2003

VY and V2 Series Service Information.

3 Steering gear connections adjusted too tightly. 3 Test steering system for binding with front wheels off

the ground. Refer to Section 9 Steering, in the MY

2003 VY and V2 Series Service Inform ation.

4 Front control arm ball joint worn. 4 Replace wo rn ball joint. Refer to 3.10 Front Control

Arm Ball Joint Assembly in this Section.

5 Wheel toe settings outside specifications. 5 Adjust toe-i n. Refer to 2.2 Wheel Alignment Checking

and Adjustment in this Section.

6 Incorrect or uneven caster. 6 Caster is not adjustable. Check for bent or damaged

components. Repair as required.

7 Steering knuckle bent. 7 Replace steering knuckle. Refer to 3.9 Steering

Knuckle in this Section.

8 Rear final drive/rear suspension crossmember

shifted. 8 Check all attachment fasteners for security, tightening

to specification, as required. Refer to Section 4A

Rear Suspension, in the MY 2004 AWD Wagon

Service Information.

9 Loose attachment of front suspension crossmember

to side members. 9 Check, align and tighten all fastener s to specification.

Refer to 3.14 Front Suspension Crossmember

Cradle, in this Section.

Front Suspension Page 3–62

Page 3-62

5 Specifications

Suspension Travel

Suspension Configuration Compression – 2/3 Compression of

Bumper (mm) Rebound (mm)

MY 2004 AWD Wagon – FE1 90 88

Front Spring Details

Identification of the front spring fitted to a partic ular vehicle

can be achieved by cross-referencing the two digit code

provided on the production identification tag (1) with the

table below.

Figure 3-68

Suspension

Configuration Number of

Coils Free Length

(mm) Inside Diameter Spring Type &

Rate Production ID

Code

MY 2004 AWD

Wagon – FE1 6.97 436 – 440

136 ± 1.5 VARIABLE

24 – 31 N/mm

(5026 ± 110N

@ 234 mm)

Front Stabiliser Bar Details

The stabiliser bar identification is contained in a label (1)

attached to the stabiliser bar.

Front Stabiliser Bar Diameter (2) = 27 mm

Figure 3 – 69

Front Suspension Page 3–63

Page 3-63

Front Strut Details

Type Wet strut – non-serviceable

Piston Diameter 30 mm

Identification of the front strut assemblies fitted to a

vehicle, can be achieved by cross-referencing the two

digit code provided on the production identification tag

(1) with the table below.

SUSPENSION

CONFIGURATION RIGHT SIDE

STRUT

ID CODE

LEFT SIDE

STRUT

ID CODE

WAGON FE1 PM NZ

Figure 3-70

Front Control Arm Detail s

Type Forged with a rubber bushing at the rear for attachment to front suspension crossmember cradle. The

hydraulically dampened front bushing is pressed into the front suspension crossmember cradle.

Front Control Arm Ball Joint

The front control arm ball joint assembly is a press fit into the steering knuckle. The ball joint is not serviced separately.

Front Wheel Bearings

Type Double row ball bearing

Lubricant Sealed for life, non-adjustable

Wheel Bearing Angul ar 'Float'

New Bearing 0.106 mm Maximum

Used Bearing 0.213 mm Maximum

For 'float' measuring procedure, refer to 2.4 Front Wheel Hub Assembly – End Float Checking Procedure, in this Section.

Front Suspension Page 3–64

Page 3-64

Suspension Trim Height Specifications

Figure 3-71

A Front Trim Height Check Location

B Rear Trim Height Check Location 1 Wheelbase – 2,938 mm

2 Reference Point – 584.5 mm 3 Trim Height Spacing – 1,765 mm

4 Ground Line

The measuring point for the trim height is from the stud to

the ground.

The vehicle must be at curb weight and on level ground.

Legend

A Trim Height

1 Door

2 Trim

3 Ground Line

Figure 3-72– Rear Trim Height Checking Location

(Front Similar)

NOTE

• The following suspension/trim height

dimensions are for reference only and

intended as a guide. Refer to 3.2 Suspension

and Trim Height, Check for ride height

variations and additional procedures.

• With the plastic wheel aperture fairings fitted

to this vehicle, accurate suspension height

measurements are not possible.

MY 2004 AWD Wagon Models Trim Height

(mm)

VEHICLE DESCRIPTION TRANSMISSION SUSPENSION Front

(‘A’ in Fig. 3-71) Rear

(‘B' in Fig. 3-71)

Level 1 and 2 Wagon Automatic FE1 275 294

Front Suspension Page 3–65

Page 3-65

Front Wheel Alignment Specifications

FRONT WHEEL ALIGNMENT AT CURB WEIGHT

Wheel Alignment Angle Specifications - All Models

Camber -0° 12' ± 0° 18'

Caster 8° 30' ± 1° 15'

Toe-in Degrees Total 0° 10’ ± 0° 10'

Degrees per Wheel

0° 5’ ± 0° 5’

Toe-out on Turns 1° 42’ @ 20 ° turn angle ± 1° 30'

Steering Axis Inclination Angle 13° 18’ ± 1° 30'

Included Angle 13° 06’ ± 1° 30'

SERVICE INFORMATION

• The adjusting values for camber, caster and toe-in must remain within

the tolerances specified. The difference between left and right must not

exceed the following:

CASTER 0° 36'

CAMBER 0° 48'

TOE-IN 0° 10'

• The specifications listed are the nominal value, with acceptable

variance from this central point. Where possible, an attempt should

always be made to achieve the nominal settings when adjusting.

• Front wheel camber alters as a function of front suspension height.

• Camber adjusting bolt: After loosen ing both lower strut to steering

knuckle bolts and nuts, adjust camber by turning the adjusting bolt

clockwise to decrease negative camber and anti-clockwise to increase

negative camber. After adjustment, both lower strut to steering knuckle

bolts and nuts MUST be replaced with new parts and tightened to the

recommended torque setting.

• The rear wheel alignment should be checked and corrected if

necessary (refer to Section 4A, Rear Suspension, in the MY 2004

AWD Wagon Service Information, in Section ) before checking front

wheel alignment.

Fuel Mass with Full Tank - All Models 56 kg

Figure 3-73

Techline

Front Suspension Page 3–66

Page 3-66

6 Torque Specifications

ATTENTION

! Fasteners must be replaced after loosening.

" Vehicle must be at curb height before final tightening.

# Fasteners either have micro encapsulated sealant applied or incorporate a mechanical thread lock and

should only be re-used once. If in doubt, replacement is recommended.

! # Brake Caliper Anchor Plate Retaining Bolt.....Stage 1............................85 Nm

Stage 2 ............Turn through 45°

Brake Shield Retaining Screw ......................................................................10 Nm

! Crossmember Cradle To Side Frame Bolt...............................................122 Nm

! # Front Control Arm Ball Joint Assembly Stud Nut.....................................55 Nm

! " Front Control Arm Front Isolator Bolt.....................................................340 Nm

! " Front Control Arm Rear Bushing Bolt....................................................140 Nm

! Front Driveshaft Outer Retaining Nut.......Stage 1:..................................130 Nm

Stage 2: Loosen Until Nut is Loose

Stage 3:..................................200 Nm

Front Engine Mount Attaching Nut................................................................80 Nm

Front Wheel Hub Assembly To Steering Knuckle Attaching Bolt................ 108 Nm

Front Wheel Speed Sensor Retaining Screw................................................10 Nm

Hydraulic Pipe to Steering Rack Valve Housing Flare Nut............................35 Nm

Outer Tie Rod End Stud, Castellated Nut.....................................................65 Nm

Road Wheel Attaching Nut..........................................................................125 Nm

Stabiliser Bar Link Ball Stud Nut...................................................................50 Nm

Stabiliser Bar Bushing Bracket Nut...............................................................28 Nm

Stabiliser Bar Link Upper Nut.............................................Tighten to end of thread

! Steering Knuckle To Strut Attaching Nut..........Stage 1:............................85 Nm

Stage 2:..........................100 Nm

Stage 3:............Turn through 90°

Steering Linkage Tie Rod To Outer Tie Rod End Lock Nut ..........................65 Nm

! Steering Rack Housing To Crossmember Cradle Mounting Bolt

Stage 1:.........................60 Nm

Stage 2:.........Turn through 50°

Upper Strut Bearing Retaining Nut ...............................................................78 Nm

! Upper Strut Locating Plate Retaining Nut..................................................55 Nm

Front Suspension Page 3–67

Page 3-67

7 Special Tools

Tool Number Illustration Description Tool Classification

180

Spring Compressor

Used to compress the front

suspension spring, prior to removal.

Previously released

Desirable

7208

Hub Puller

Used to press the front driveshaft from

the front hub. Also used to check LSD

breakaway torque on final drives so

equipped.

Previousl

released

Mandatory

7311

Steering Linkage Outer Tie Rod

End Remover

Can also be used on earlier ‘V’ cars

for the same purpose.

Previously released

Desirable

AU-534

Torque Limiting Socket

Used in conjunction with an impact

gun to tighten wheel nuts

Previously released.

Mandatory

CH-47568 Remover/Installer Control Arm,

Front Isolator Bush

Used to remove and install the front

control arm, front hydraulic bushing

from/to the front suspension

crossmember cradle.

Available

CH-47569 Remover/Installer Control Arm,

Rear Bush

Used to remove and install the rear

bushing, from/to the front control arm.

Available

DT-47570 Remover/Installer, Front

Driveshafts

Used in conjunction with slide hammer

J 6125-1B (and adaptor), or J 23907

slide hamm er to remove and reinstall

the front driveshafts.

Mandatory

E7115

Angle Wrench

Used to tighten fasteners that require

and angle torque to be applied.

Previously released.

Mandatory

Front Suspension Page 3–68

Page 3-68

Tool Number Illustration Description Tool Classification

J 6125-1B

Slide Hammer & Adaptor

Used in conjunction with driveshaft

remover/installer DT-47570.

Previously released.

Available

KM-468

Holding Bar

Used to hold wheel hub assembly

from rotating.

Previously released.

CH-47569