Rear Suspension 4A1 – 1

4A1-1

Section 4A1

Rear 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 Information ...............................................................................................................................3

1.1 General Description............................................................................................................................................... 3

1.2 Automatic Level Ride Suspension....................................................................................................................... 5

General Information............................................................................................................................................... 5

Automatic Level Ride Suspension Operation ..................................................................................................... 6

Activation............................................................................................................................................................ 6

Loaded Vehicle................................................................................................................................................... 6

Unloaded Vehicle............................................................................................................................................... 7

Deactivation ....................................................................................................................................................... 7

Reset Procedure ................................................................................................................................................ 7

2 Service Maintenance Operations..........................................................................................................8

2.1 Automatic Level Ride Suspension....................................................................................................................... 8

Air Lines ................................................................................................................................................................. 8

Wiring Harness....................................................................................................................................................... 8

Air Filter.................................................................................................................................................................. 8

3 Service Operations.................................................................................................................................9

3.1 Service Warnings, Cautions and Notes............................................................................................................... 9

3.2 Rear Suspension Control Arm............................................................................................................................ 10

Remove................................................................................................................................................................. 10

Rear Suspension Control Arm Pivot Bushing, Replace................................................................................... 16

Reinstall................................................................................................................................................................ 17

3.3 Outer Rear Wheel Drive Shaft, Flange or Bearing............................................................................................. 19

Replace................................................................................................................................................................. 19

3.4 Rear Suspension Crossmember......................................................................................................................... 26

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

Reinstall................................................................................................................................................................ 32

3.5 Rear Suspension Crossmember Front Mount Bushing ................................................................................... 36

Off-Car Replacement........................................................................................................................................... 36

On-Car Replacement ........................................................................................................................................... 37

3.6 Rear Suspension Crossmember Mass Damper ................................................................................................ 40

Remove................................................................................................................................................................. 40

Reinstall................................................................................................................................................................ 41

3.7 Rear Suspension Crossmember Rear Mount.................................................................................................... 43

Remove................................................................................................................................................................. 43

Reinstall................................................................................................................................................................ 44

3.8 Stabiliser Bar and/or Mountings......................................................................................................................... 46

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

Stabiliser Bar Link Insulators, Replace.............................................................................................................. 47

Reinstall................................................................................................................................................................ 48

3.9 Rear Spring and Insulators................................................................................................................................. 49

Remove................................................................................................................................................................. 49

Reinstall................................................................................................................................................................ 52

Rear Suspension 4A1 – 2

4A1-2

3.10 Rear Shock Absorbers and/or Bushing............................................................................................................. 54

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

Lower Bushing, Replace ..................................................................................................................................... 55

Reinstall................................................................................................................................................................ 56

3.11 Additional Control Arm ....................................................................................................................................... 57

Inspect .................................................................................................................................................................. 57

Remove................................................................................................................................................................. 58

Disassemble......................................................................................................................................................... 58

Reassemble.......................................................................................................................................................... 58

Reinstall................................................................................................................................................................ 59

3.12 Rear Wheel Alignment Checking........................................................................................................................ 60

Camber and Toe Check....................................................................................................................................... 60

Preliminary Checks and Information................................................................................................................. 60

Rear Wheel Toe Adjustment ............................................................................................................................... 61

4 Service Operations – Automatic Level Ride Suspension ................................................................62

4.1 Initial Air Charge.................................................................................................................................................. 62

4.2 Air Leak Test ........................................................................................................................................................ 63

4.3 Relieving System Air Pressure........................................................................................................................... 64

4.4 Compressor Assembly........................................................................................................................................ 65

Remove................................................................................................................................................................. 65

Disassemble......................................................................................................................................................... 66

Reassemble.......................................................................................................................................................... 66

Reinstall................................................................................................................................................................ 67

4.5 Air Lines ............................................................................................................................................................... 68

Remove................................................................................................................................................................. 68

Reinstall................................................................................................................................................................ 69

4.6 Automatic Level Ride Shock Absorber.............................................................................................................. 70

Remove................................................................................................................................................................. 70

Reinstall................................................................................................................................................................ 71

4.7 Ride Height Sensor.............................................................................................................................................. 72

Remove................................................................................................................................................................. 72

Reinstall................................................................................................................................................................ 73

5 Diagnosis......................................................................................................................................................74

5.1 Checking and Testing Shock Absorbers........................................................................................................... 74

Leakage Criteria................................................................................................................................................... 74

5.2 Diagnosis – Automatic Level Ride Suspension................................................................................................ 75

Equipment ............................................................................................................................................................ 75

Ride Height Sensor Reset................................................................................................................................... 75

5.3 Preliminary Diagnostic Procedure ..................................................................................................................... 76

5.4 Compressor Assembly Test – Motor.................................................................................................................. 77

5.5 Compressor Assembly Test – Solenoid ............................................................................................................ 78

5.6 Ride Height Sensor Test – Compressor ............................................................................................................ 79

5.7 Ride Height Sensor Test – Solenoid .................................................................................................................. 80

5.8 Wiring Diagram – Automatic Level Ride Suspension....................................................................................... 81

5.9 Wiring Harness Layout – Automatic Level Ride Suspension .......................................................................... 82

6 Specifications.......................................................................................................................................83

Rear Suspension Service Alignment Data......................................................................................................... 83

Rear Spring Details.............................................................................................................................................. 83

Rear Shock Absorber Details.............................................................................................................................. 84

Rear Stabiliser Bar Details.................................................................................................................................. 84

7 Torque Wrench Specifications............................................................................................................85

8 Special Tools ........................................................................................................................................86

Rear Suspension 4A1 – 3

4A1-3

1 General Information

1.1 General Description

Independent coil spring rear suspension is fitted as standard equipment on all MY 2005 WL Series Models, using

variable rate minibloc coil rear springs and direct acting shock absorbers.

The rear suspension is contained within a rear suspension crossmember assembly that is attached by a large volume

rubber bushing at each front corner to the ve hicle underbody. Rear location is provided by a rear mounting bolted to the

differential carrier assembly that is in turn, attached to the crossmember.

Those vehicles fitted with the GEN III V8 and automatic transmission, have a mass damper located on the rear

suspension cross member, forward of each of the front mounts.

Two rear suspension control arms are attached to the crossmember pivot points through rubber bushings. The rear

suspension control arms provide attachment of the additional control arms, the rear brake components, rear wheel drive

shaft flanges and outer rear wheel drive sh aft (rear wheel) bearings.

A decoupled type stabiliser bar is attached to the top of the crossmember by two brackets and insulating bushings. The

outer ends of the stabiliser bar are attached to each rear suspension control arm by a link and insulating bushings.

Depending on the vehicle specification for different markets, automatic leve l ride (Production Option FX3) may be

available as an option on lev els 4 and 5 for MY 2005 WL Series Models.

Sports suspension (Production Option FE2) is not available on MY 2005 WL Series Level 5 Models.

An additional control arm is al so fitted as standard equipment to all MY 2005 WL Series vehicles. The inner ends of the

additional control arms contain rubber b ush ing and are attached to brackets welded to the rear suspension

crossmember. The outer end of the additional control arm is secured to the rear suspension control arm by a socket

assembly. The purpose of the addition al co ntrol arm is to maintain the rear wheel camber and toe angles during

suspension travel, while also provi din g a means of adjusting the rear wheel toe.

The standard (Production Option FE1) suspension application utilises twin tube hydrau lic shock absorbers that are

double acting and are mounted between the vehicle underbody and each trailing arm. The sports suspension (Production

Option FE2) application, utilises twin tube, gas pressurised shock absorbers. The level ride suspensi on (Production

Option FX3) application utilises the pneumatically adjustable (Superlift) type rear shock absorbers that may also be

available as an accessory or as part of a 2100 kg tow bar package.

NOTE

For further information regarding how to identify

which suspension applicati on (Production Option)

is fitted to a particular vehicle, refer to

Section 0A General Information in this Service

Information.

Rear Suspension 4A1 – 4

4A1-4

Figure 4A1 – 1

Legend

[A] General View

[B] Installed in Vehicle – Looking Forward

1 Rear Shock Absorber

2 Rear Spring

3 Rear Suspension Crossmember Assembly

4 Rear Suspension Control Arm Assembly

5 Additional Control Arm Assembly

6 Stabiliser Bar

7 Driveshaft (2 Places)

8 Rear Final Drive Assembly

9 Rear Suspension Crossmember Rear Mount

10 Rear Suspension Crossmember Front Mounting Brace

11 Rear Suspension Crossmember Front Mount Bushing

12 Propeller Shaft Assembly

Rear Suspension 4A1 – 5

4A1-5

1.2 Automatic Level Ride Suspension

General Information

Automatic level ride is an electr onically controlled system that maintains the vehicle at a constant trim height, regardless

of vehicle load. This feature u s es a specifically designed elec tronic ride height sensor (5), fixed to the rear crossmember

on the right-hand side. This sensor controls an electric motor driving a single cylinder air compressor (2) and an e xhaust

solenoid valve. The compressor (2) supplies the necessary pressure to operate the Superlift shock absorbers (1) via

snap-on air lines (4). The Superlift shock ab sorbers assist the rear springs in supporting the vehicle body under all loads.

The ride height sensor (5) has an integrated electronic controller that is programmed to adjust the ride height only when

necessary, ignoring sudden changes, as experienced on bumpy roads. The design of the s ystem mainta ins trim at all

times when the ignition is on. As a safeguard to prevent the battery discharging, an electronic timer switches off the

compressor if it runs for a prolonged period (i.e. due to an ai r leak in the system).

The compressor assembly includes a maximum pressure release valve and an air drier. All air entering or exhausting the

system flows through the drier, which has an internal minimum retention valve preventing the airbag, surrounding each

shock absorber, from completely exhausting, independent of the sensor controlled exhaust valve.

Electric power to operate the system is supplied by an integrated wiring harness (3).

There are two main benefits resulting from the automatic level ride feature:

• Headlamp aim and rear view mirror adjustment being maintained indep endent of load.

• Rear tyre camber and toe-in are held to their optimum alig nment to minimise tyre wear.

NOTE

If air pressure is lost from the system while the

vehicle is in service (eg. an ai r leak), the Superlift

shock absorber airbag will most likely be

damaged, requiring replacement.

Figure 4A1 – 2

Legend

1 Superlift shock absorbers

2 Air compressor assembly

3 Level ride wiring harness

4 Air lines

5 Ride height sensor ball stud plate

6 Ride height sensor connecting link

7 Ride height sensor

Rear Suspension 4A1 – 6

4A1-6

Automatic Level Ride Suspension Operation

Activation

The sensor's actuating arm (1) is attached to the lower

control arm (2) via a connecting link (3).

Figure 4A1 – 3

Before any activation can occur, the actuating arm must

remain in either the intake (A) or exhaust zone (B) for a

approximately 20 seconds. This time delay prevents the

compressor or exhaust valve from activating when the

vehicle encount ers sudden bumps.

Another stability feature is a 'dead band' zone (C), which

helps to minimise hunting, by deactiv atin g the compressor

and solenoid when the v ehicle trim goes into or onto the

deadband zone or one of its edges.

Figure 4A1 – 4

Loaded Vehicle

When the vehicle is loade d, the vehicle body moves

downward into the intake zone, causing the actuating arm

to move upwards (arrow).

After approximately 20 seconds in this position, the sensor

relieves the compressor head pressure by br iefly activating

the compressor relay. The compressor starts and

pressurises the Superlift shock absorbers until the vehicle

body aligns with the bottom edge of the d ead band, at

which point the compressor stops.

Figure 4A1 – 5

Rear Suspension 4A1 – 7

4A1-7

Unloaded Vehicle

When the vehicle is unloade d, the vehicle body moves

upward into the exhaust zone, causing the actuating arm to

move downwards.

After approximately 20 seconds in this position, the sensor

activates the exhaust relay. The exhaust soleno id activates

and vents pressure from the Superlift shock absorbers until

the vehicle body aligns with the top edge of the dead band,

at which point the solenoid deactivates.

Figure 4A1 – 6

Deactivation

The compressor and exhaust solen oid operations are monitored and controlled by individual but interconnected timers.

The timers deactivate specific trimming operations under the following conditions:

• If the compressor runs for a cumulative time of more than four and a half minutes, the compressor timer

deactivates all system operations.

• If the exhaust solenoid is active for a cumulative time of more than four and a half minutes, the solenoid timer

deactivates the solenoid.

No further operation of these components can take place until the timers are reset.

Reset Procedure

The procedure to reset the timers is:

1 Turn the ignition ON.

2 Turn the ignition OFF for one minute.

3 Turn the ignition ON, once more to complete the operation.

Rear Suspension 4A1 – 8

4A1-8

2 Service Maintenance Operations

2.1 Automatic Level Ride Suspension

If air pressure in the level ride system is lost

during service procedures, do not lower the

vehicle until system pressure has been

restored, as damage will most likely result.

Charge the system as detailed in

4.1 Initial Air Charge in this Section

The level ride system has been designed to be virtually maintenance free. However, at each scheduled service, the

following components must be inspected and rectified if found to be faulty.

Air Lines

Inspect the air lines for rubbing or fouling with the body and other components. Ensure the lines are not kinked and that

they are fitted into the retaining clips. Check the connections for correct fit.

Wiring Harness

Inspect the wiring harness for rubbing or fo uling with the body and other components. Ensure that it is fitted and secured

into the retaining clips and/or cable ties. Check the connections for correct fit.

Air Filter

The compressor air filter (1) should be repla c ed at the

scheduled service intervals set down in the Owner’s

Handbook. Inspect and replace more frequently if required,

where the vehicle is driven in dusty conditions.

To service the compressor air filter, depress the two locking

tabs on the clip retaining the air intake hose (2) and filter to

the hole (3) in the compressor mounting bracket (4) and

withdraw the filter.

Test that the filter is clean and free from restrictions by

removing the filter form the tube and blo wing throu gh it from

the hose connection end. If any restriction is felt, replace

the filter.

Figure 4A1 – 7

Rear Suspension 4A1 – 9

4A1-9

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. W here specified in this Section, fasteners MUST be replaced w ith parts of the

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

Torque values must be used as specified during reassembly to ensure proper retention of all components.

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

identification marks:

 Fasteners must be repl aced 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 or more of these identification marks is present alongside a fastener torque wrench specification, the

recommendation regarding that fastener must be adhered to.

3.1 Service Warnings, Cautions and Notes

Road Wheels

• Whenever a road wheel is removed from or installed to any MY 2005 VZ and WL Series vehicle, it

MUST be done in accordance with the procedure p rovided in Section 10, Wheels and Tyres.

• Whenever a road w heel is removed from the vehicle, the relationshi p of the road wheel to the hub

MUST be marked with a felt tipped pen or similar, to allow those parts to be reinstalled in their

original positions. This is critical to minimise the road wheel runout dimension.

• When reinstalling road wheels, do not use

an impact gun to tighten wheel nuts

unless the impact gun is fitted with a

torque limiter socket (Tool No. AU 534 or

a commercial equivalent). Failure to

correctly tighten w heel nuts to the correct

torque specification and in the correct

order (as shown), may result in a

distorted brake disc, leading to the

development of brake shudder.

Road wheel attaching nut

torque specification..................................110 – 140 N.m

Figure 3A – 8

ABS/TC Components

• 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, refer to

Section 5B, ABS, ABS/TC, Electronic Brake Assist (EBA).

To ensure correct retention of the additional

control arm, the socket assembly stud and

the corresponding tapered hole in the rear

suspension control arm must be cleaned of

dirt and foreign matter prior to installation.

Rear Suspension 4A1 – 10

4A1-10

3.2 Rear Suspension Control Arm

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 this operation:

 Brake caliper anchor plate to rear susp ension control arm bol t.

 Additional control arm socket assembly retaining nut.

 Stabiliser bar link to rear suspen sio n control arm attaching nut and bolt.

 Rear susp ension control arm to rear suspension crossmember attaching nut.

The following fasteners MUST be replaced when performing these operation:

 Rear suspension crossmember mount to under body attaching bolt.

 Rear brake dust shield to rear su spension control arm lower bolts.

 Drive shaft constant velocity joint to rear wheel drive shaft flange attaching bolt.

The following fasteners MUST be at curb height with the vehicle weight on all four wheels before final

tightening is undertaken:

• Shock absorber lower mounting bolt.

• Stabiliser bar link to rear suspension control arm attach ing nut and bolt.

• Rear suspension control arm to rear suspension crossmember attaching nut.

Before disturbing the crossmember rear

mounting bolts, an alignment procedure is

required on installation and a special tool is

required for this purpose. If this tool is not

available, then the crossmember cannot be

correctly aligned and steering and/or handling

abnormali t ies will result.

Remove

1 Raise the vehicle and suppor t in a safe manner. Refer to Section 0A General Information in this Service Information

for the location of recommended lifting and supp ort points.

2 Remove the decorative wheel nut caps, on the side of the ve hicle where the rear suspension control arm is to be

removed.

3 Mark the relationship of the road wheel to hub (eg. end of wheel stud), with a felt tipped pen or similar. Loosen,

then remove the road wheel attaching n uts. Remove the road wheel.

Rear Suspension 4A1 – 11

4A1-11

4 If the vehicle is fitted with the Automatic Level Ride

Suspension (production option FX3), disconnect the

ride height sensor link from the rear suspension

control arm.

Figure 4A1 – 9

5 Loosen both stabiliser bar link (1), attaching bolts (2)

and nuts, to reduce stress on the insulator bushing.

6 Remove the stabiliser bar link to rear suspension

control arm attaching bolt and nut (2) from side of

vehicle where the rear suspension control arm is to be

removed.

Figure 4A1 – 10

7 Loosen the additional control arm socket assembly

retaining nut until level with the top of the socket

assembly stud.

8 Using special tool No. E-9332-A (1), tighten the lever

forcing screw (2) to press the socket assembly stud

free from the taper in the rear suspension control arm,

remove socket assembly retaining nut and discard.

9 Remove the additional control arm socket assembly

from the rear suspension control arm.

Figure 4A1 – 11

Rear Suspension 4A1 – 12

4A1-12

10 Remove the rear brake hose retaining clip (1) from the

rear suspension control arm bracket (2) on the side to

be removed. Pull the brake pi pe (3) and hose (4)

forward from the bracket, and then disconnect from

the rear suspension control arm by lifting the brake

pipe up through the slot in the bracket.

Figure 4A1 – 12

11 Remove the brake hose retai ning clip (1) from the

brake backing plate bracket (2). Disconnect the rear

caliper brake pipe (3) from the brake hose (4) and

disconnect the pipe from the backing plate bracket.

Plug the open ends of the brake pipe and hose to

prevent fluid loss and foreign matter entry.

Figure 4A1 – 13

If the brake pipe to hose is not disconnected,

the brake caliper must be supported with tie

wire secured to the vehicle underbody. THE

CALIPER IS NOT TO HANG BY THE BRAKE

HOSE.

12 Remove the brake caliper anchor plate to rear

suspension control arm attaching bolts (1) and remove

the caliper (2) from the rotor. Set the brake caliper to

one side.

Figure 4A1 – 14

Rear Suspension 4A1 – 13

4A1-13

13 Check that the park brake is in the fully released

position.

14 Release the park brake cable retaining clips (1) on

each of the underbody and free the cables (2).

Figure 4A1 – 15

15 Remove the park brake outer cable retaining bracket

bolt (bolt is not shown) from the vehicle underbody.

16 Pull each park brake inner cable (1) forward and up

(A), out of the cable retainer (2) to release each cable.

17 Pull the outer cable (3) rearward (B) to remove from

the underbody retainer (4).

While the brake rotor to hub location is

marked in production, ensure that the rotor

to hub position is carefully marked (eg. rotor

to end of wheel stud), with a felt tipped pen

or similar. This is necessary to o vercome the

possibility of inducing a brake shudder

condition after reassembly.

Figure 4A1 – 16

18 Remove the brake rotor from the wheel bearing hub.

NOTE

If necessary, adjust the park brake shoe to allow

the brake rotor to be removed, refer to

Section 5A Service and Park Braking Systems for

the necessary procedure.

19 Using Tool No. KM468 over the wheel studs to hold

outer rear wheel drive shaft hub from rotating, loosen

the six drive shaft (1) outer constant velocity joint to

rear wheel drive shaft flange attaching bolts (2), using

an 8 mm Allen key socket (3). Remove and discard

the bolts.

Figure 4A1 – 17

Rear Suspension 4A1 – 14

4A1-14

Bruising to the inside of the drive shaft

constant velocity joint boots will occur if the

rear suspension control arm is lowered. This

will lead to premature failure of the boot and

eventual failure of the joint.

This is why it is important that the constant

velocity joint be disconnected from the rear

wheel drive shaft flange before removing the

shock absorber lower mounting bolt.

20 Disconnect the drive shaft (1) from the flange and lift

upward. While keeping the outer constant velocity joint

in the same plane as the driveshaft, use a length of

wire (2), to tie up the drive shaft to the lower end of the

shock absorber upper mounting.

Figure 4A1 – 18

21 Position the floor jack with a block of wood under the

rear suspension control arm.

22 Raise the jack slightly to take the spring load off the

rear suspension control arm.

23 Remove the rear shock absorber lower mounting bolt

(1) and washer (2) from the rear suspension control

arm (3), then pull the lower end of the shock absorber

(4) from the rear suspension control arm.

Figure 4A1 – 19

24 Lower the floor jack and if necessar y, push down on

the rear suspension control arm and remove the rear

spring (1), upper insulator (2) and lower insulator (3)

from the vehicle underbody and rear sus pe nsion

control arm.

Figure 4A1 – 20

Rear Suspension 4A1 – 15

4A1-15

25 Pull out the differential carrier breather hose (1) from

the vehicle underbody crossmember hole (2).

Figure 4A1 – 21

26 Pull both ABS sensor lead connectors (3) from the

underbody retaining clips (4). Separate the sensor

connectors from the body harness connectors by

levering with a screwdriver.

Figure 4A1 – 22

27 Using a scriber, mark the rear mount (1) to vehicle

under body location (A). This will assist in the rear

suspension crossmember alignment on instal lation.

28 Support the weight of the differential carrier with a floor

jack.

Figure 4A1 – 23

Rear Suspension 4A1 – 16

4A1-16

29 Remove the rear mount (1) to vehicle underbody

attaching bolts (2) and discard.

Figure 4A1 – 24

30 Lower the differential carrier and rear suspe nsion

crossmember assembly enough to allow access to the

outboard rear suspension control arm to front

crossmember attaching bolt and nut.

31 Remove the rear suspension control arm to rear

suspension crossmember attaching bolts and nuts.

32 Remove the rear suspension control arm fro m the

vehicle and discard the nuts.

Figure 4A1 – 25

Rear Suspension Control Arm Pivot Bushing, Replace

1 With the rear suspension control arm (1) removed,

press the bushing (2) from the rear suspensi on control

arm using special tool number s KM619-3 and

KM619-4.

Figure 4A1 – 26

Rear Suspension 4A1 – 17

4A1-17

2 Lightly coat the outside surface of the new bushing

with a soapy water solution.

3 If the bushing is pf the voided type, align the edge of

one of the voids (1), with the welded seam in the

trailing arm (2) as shown.

Figure 4A1 – 27

4 Press the new bushing into rear suspension control

arm (2) using Special tools number KM619-1, KM619-

2 and KM619-4.

Figure 4A1 – 28

Reinstall

The reinstallation of the rear suspension control arm is the reverse of the removal procedure, with the exceptio n of the

following steps:

1 Reinstall the rear suspension control arm to the rear suspension crossmem ber, using bolts and NEW nuts but do

not fully tighten at this stage.

If the rear wheel drive shaft flange or outer

rear wheel drive shaft was replaced, then

runout checks must be carried out on the

installed brake rotor. Refer to

Section 5A Service and Park Braking Sys tems

for important information regarding these

checks.

2 Reinstall the brake rotor, aligning the marks made before removal.

3 Reinstall the brake caliper a nchor plate to the rear suspension control arm, install the attaching bolts and tighten to

the correct torque specification.

 Rear brake caliper anchor

plate to control arm

bolt torque specification.......................................85 N.m

Rear Suspension 4A1 – 18

4A1-18

4 Support rear suspension control arm with a floor jack and wooden block and raise enough to allow the shock

absorber to be reinstalled.

5 Reinstall the shock absorber and stabiliser bar link attaching bolts and nuts but do not fully tighten at this stage.

6 Reinstall the additional control arm socket assembly and a NEW nut and tighten to the correct torque wrench

specification.

 Additional control arm ball joint

nut torque specification........................................65 N.m

7 Reinstall new drive shaft outer constant velocity joint to rear wheel drive shaft flange attac hin g bolts and plates,

then tighten to the correct torque specification.

 Drive shaft constant velocity joint

to rear wheel drive shaft flange

bolt torque specification..............................50 N.m, then

turn through 70°

8 After reconnecting all brake li ne connections, bleed the rear brakes and check for leaks. For the recommended

procedure, refer to Section 5A Service and Park Braking S ystems.

9 Raise the differential carrier and rear suspension crossmember assembly until the rear mount contacts the vehicle

underbody.

10 Align rear suspension crossmember mo unt with the scribed ali gnment mark (refer to step 27 in the Remove section

of this service operation).

11 Install NEW rear suspension crossmember mount to vehicle underbody mounting bolts and tighte n to the correct

torque specification.

 Rear suspension crossmember

rear mount to underbody attachin g

bolt torque specification..............................35 N.m, then

turn through 60°

Failure to correctly align the rear suspension

crossmember to the centreline of the vehicle

will result in steering abnormalities and

uneven tyre wear!

12 The rear suspension crossmember alignment MUST be checked, using the special tool and procedure. Refer to

Section 1A2 Body Dimensions.

13 If the vehicle is fitted with Automatic Level Ride Sus pensio n (prod uction option FX3), reconnect the level ride

sensor link to the rear control arm.

14 Reinstall the road wheel/s, aligni ng the marks made prior to removal and secure with the attaching nuts.

15 Lower the vehicle to the ground an d bounce the rear of the vehicl e several times to settle the suspension

components.

16 With the weight of the vehicle on the four wheels and at curb weight, tighten the follo wing bolts and nuts to the

respective, correct torque specifications.

 Shock absorber lower mounting

bolt torque specification.....................................115 N.m

  Stabiliser bar link to rear

suspension control arm

nut torque specification........................................95 N.m

  Rear suspension control arm to

rear crossmember attaching

bolt torque specification.....................................100 N.m

17 Tighten the road wheel attaching nuts to the correct tor que specification, working in a ‘star’ pattern. Refer to

3.1 Service Warnings, Cautions and Notes in this Section for detailed information regarding the inst allation

procedure for the road wheels.

Road wheel attaching

nut torque specification............................110 – 140 N.m

18 Reinstall the wheel nut dec orative caps.

19 Road test the vehicle to check for correct vehicle operation.

Rear Suspension 4A1 – 19

4A1-19

3.3 Outer Rear Wheel Drive Shaft, Flange or

Bearing

LT Section No. – 05-290

ATTENTION

The following fasteners MUST be replaced when performing these operations:

 Lower rear disc brake shield to rear suspension control arm bolts.

 Outer rear wheel drive shaft collar nut.

Replace

The rear wheel bearing should only be

removed if it is faulty, or the outer rear wheel

drive shaft is to be removed.

Trunnion Assembly – Sectioned View

Legend:

1 Collar Nut Lock Plate

2 Collar Nut

3 Rear Wheel Drive Shaft Flange

4 Rear Suspension Control Arm

5 Brake Backing Plate

6 Brake Rotor

7 Brake Caliper

8 Rear Wheel Bearing

9 Outer Rear Wheel Drive Shaft

10 Rear Wheel Bearing Retaining Ring

Figure 4A1 – 29

1 Remove the rear suspension control arm. R efer 3.2 Rear Suspensio n Control Arm in this Section.

2 Secure the flange holding tool, KM620-1-A and rear

wheel drive shaft flange ring tool KM620-2 to the rear

wheel drive shaft flange (1) with three of the remove d

drive shaft constant velocity joint to rear wheel drive

shaft flange attaching bolts (2).

NOTE

Align holes marked ‘B’ on the flange holding tool

KM620-1-A and KM620-2 with holes in the rear

wheel drive shaft flange before installing and

tightening bolts.

Figure 4A1 – 30

Rear Suspension 4A1 – 20

4A1-20

3 Distort the rear wheel drive shaft flange collar nut lock

plate, using a suitable size pin punch and hammer,

then remove and discard the lock plate.

4 Mount the assembly in a vice (1), gripping the handle

or the flats of the flange holding tool KM620-1-A.

Loosen, then remove and discard the rear wheel drive

shaft flange to outer rear wheel drive shaft collar nut

and lock plate.

NOTE

The collar nut and the lock plate must be

replaced on reassembly.

5 Leave the holding tool KM620-1-A and the rear wheel

drive shaft flange ring tool KM620-2 assemb led to the

rear wheel drive shaft flange.

Figure 4A1 – 31

6 Lubricate the threads of the forcing screw KM620-3,

then install the screw to adaptor KM620-4-A. Appl y

grease to the ball end of the plung er, Tool No. KM620-

5-B, then install that, into the end of the forcing screw

KM620-3.

7 Install the whole sub-assembly through the central

opening of the flange holding tool KM620-1-A. Secure

the adaptor KM620-4-A to the flang e holding tool

KM620-1-A, using three suitable bolts (1).

NOTE

Adjust the position of the forcing scre w KM620-3

in the adaptor KM620-4-A, to allow the adaptor

to be in full contact with the flange holding tool

KM620-1-A. Figure 4A1 – 32

8 With the flange holding tool KM620-1-A held in a vice

(1), turn the forcing screw (KM620-3) using suitable

socket equipment (2), until the flange is free from the

outer rear wheel drive shaft.

NOTE

Use an assistant to hold and support the weight

of the rear suspension control arm assembly

during this operation.

9 Remove and separate the sp ecial tool components

from the rear wheel drive shaft flange.

Figure 4A1 – 33

Rear Suspension 4A1 – 21

4A1-21

10 Using Torx bit socket, Tool No. AU416, remove the

two upper bolts attaching the brake backing plate to

the rear suspension control arm.

11 Using suitable socket equipment, remove the two

longer, hexagonal headed, lo wer bo lts. Discard the

removed lower bolts.

Figure 4A1 – 34

12 Prior to removing the outer rear wheel drive shaft and

rear wheel bearing from the rear suspension control

arm, use a commercially available M10 x 1.25

bottoming tap and a suitable lubricant, clean the four

backing plate to rear suspension control arm bolt

threads working from the outer rear wheel drive shaft

side.

NOTE

This step is necessary to clear any dried mud,

dirt etc, from the exposed portion of the threads

on the inboard side of the rear suspension

control arm. Also, the deepest thread (position

‘C’) may not be completely formed throu gh to the

inboard side.

13 Install two supports KM620-7-A in positions ‘A’ and

two KM620-7-AUS to ‘B’ and ‘C’ in th e rear

suspension control arm, as indicated.

NOTE

As a guide, the two longest supports (KM620-7-

A) are to be installed at the brake caliper

mounting side (position ‘A’). The longer of

KM620-7-AUS supports is installed at position

‘B’ and the shorter is installed at positio n ‘C’.

14 After installing all four supports in the correct positions,

tighten with a set spanner.

Figure 4A1 – 35

Rear Suspension 4A1 – 22

4A1-22

15 Install the flange holding tool KM620-1-A over the four

supports, KM620-7-A (2 places) and KM620-7-AUS (2

places), install four suitable nuts (1) and tig hten to

secure.

16 Pre-assemble the lubricated forcin g screw KM620-3 to

the adaptor KM620-4-A. App ly grease to the ball end

of the plunger KM620-5-B, then install that, into the

end of the forcing screw KM620-3.

17 Install this sub-assembly through the central opening

of holding tool KM620-1-A. Secure the adaptor

KM620-4-A to the flange holdi ng tool KM620-1-A,

using three suitable bolts (2).

NOTE

Adjust the position of the forcing scre w KM620-3

into the adaptor KM620-4-A, to allow full contact

of the adaptor to the flange holding tool KM620-

1-A.

18 Tighten the three bolts securing adaptor KM620-4-A to

the flange holding Tool KM620-1-A.

19 Mount the assembly in a vice (3) by the handle of the

flange holding tool KM620-1-A as shown, then turn the

forcing screw KM620-3 and press the out er rear wheel

drive shaft (4) from the rear wheel bearing.

Figure 4A1 – 36

20 When the outer rear wheel drive shaft has been removed, unscrew the forcing screw, as this same arrangement is

used to press the rear wheel bearing from the rear suspension control arm.

NOTE

The inner rear wheel bearing cone will separate

from the bearing assembly and be retained on

the outer rear wheel drive shaft.

21 Remove the brake backing plate and park brake assem bly from the rear suspension control arm an d set to one

side.

22 If the outer rear wheel drive shaft (1) is to be re-used,

then the outer half of the inner rear wheel bearing

cone (2) will need to be removed from the outer rear

wheel drive shaft.

23 Install the press plates J22912-01 over the bearing

cone and tighten the press plate bolts to grip the

bearing cone.

24 Press the outer rear wheel drive shaft from the bearing

cone and discard bearing cone.

NOTE

• If the outer rear wheel drive shaft is to be

replaced, then step 20, is not required.

• A new outer rear wheel drive shaft is

supplied with wheel studs already installed.

Figure 4A1 – 37

Rear Suspension 4A1 – 23

4A1-23

25 Remove the wheel bearin g retaining ring (1) from the

rear suspension control arm (2), using suitable circlip

pliers (3).

Figure 4A1 – 38

26 With the tool components set up as sho wn, insert the

rear axle bearing removing disc KM620-6 into the rear

of the axle bearing.

27 Reposition the forcing screw KM620- 3 and the adaptor

KM620-5-B to retain the removing plate KM620-6 in

place.

28 With KM620-1-A mounted in the vice jaws (1), turn the

forcing screw KM620-3 clockwise to press the wheel

bearing from the rear suspension control arm (2).

29 If installing a replacement rear suspension control arm

without bushing, install new bushing. Refer to

3.2 Rear Suspension Control Arm in this Section.

30 Ensure that the bearing bore of the rear suspension

control arm is clean and free of any foreign matter.

31 Coat the outside diameter of a new wheel bearing and

the bore of the rear suspension control arm wit h an

NLGI No. 2 lithium soap based EP grease with

molybdenum disulphide, such as Shell Retinax HDX2

grease or BP Energrease LMS-EP 23 (or eq uivalent). Figure 4A1 – 39

32 Remove the bolts securing adaptor KM620-4 - A to the

holding tool KM620-1-A, then remove the adaptor and

forcing screw KM620-3.

33 Lubricate the thrust ball bearing race (1) (part of

KM620-A) with lubricant such as with an NLGI No. 2

lithium soap based EP grease with molybdenum

disulphide, such as Shell Retinax HDX2 grease or BP

Energrease LMS-EP 23 (or equivalent).

34 Assemble the bearing onto the flang ed end of adaptor

KM620-4-A.

35 Install the forcing screw and adaptor/bearing assembly

to the flange holding tool KM620-1-A. Do not install the

adaptor (KM620-4-A) to holding tool (KM620 -1-A)

attaching bolts.

36 Install the bearing installer KM620-8-A into a new

bearing (2) and install both into the rear suspension

control arm (3).

37 Join the forcing screw (KM620-3), and the bearing

installer (KM620-8-A) by engaging the screw thread of

the forcing screw (KM620-3) with the installer (KM620-

8-B) and tightening the forcing screw to engage at

least 8 full threads.

Figure 4A1 – 40

38 While holding the forcing screw (KM620-3) from turning by using suitable socket equipment (4), rotate the adaptor

KM620-4-A in the direction shown, with a suitable 40 mm wrench to draw the new bearin g (2) fully into position.

Rear Suspension 4A1 – 24

4A1-24

39 Remove the installer KM620-8-A once the bearing is fully install ed, then install the retaining ring into the rear

suspension control arm using suitable circlip pliers, ensuring that the ring is seated correctly.

40 Separate all special tool comp onents from the rear wheel drive shaft flange, after the bearing has been fully

installed.

41 Reinstall the upper two Torx headed bolts (3) and

washers (4) to secure the rear brake dust shield to the

rear suspension control arm.

NOTE

The two washers (4) are to be installed with the

cut-out edge facing around the rear suspension

control arm hub outer surface.

42 Install NEW rear brake shield (1) to rear suspens ion

control arm (2) bolts (5).

43 Tighten all four fasteners to the correct torque

specification.

Rear brake shield to rear

suspension control arm

upper bolt torque specification.............................75 N.m

Rear brake shield to rear

suspension control arm

lower bolt torque specification..............................88 N.m

Figure 4A1 – 41

44 Position the outer rear wheel drive shaft (2) with the

centre hub section resting on a suitable support (1)

and press plates.

NOTE

Check that the outer rear wheel drive shaft

wheel studs do not contact press plates.

45 Position the rear suspension control arm (3) with the

wheel bearing onto the outer rear wheel drive shaft.

46 With an assistant supporting the rear suspension

control arm assembly in this position, use installer

KM620-9-A and steel pipe (4) of suitable length and

diameter, press wheel bearin g onto the outer rear

wheel drive shaft.

Figure 4A1 – 42

Rear Suspension 4A1 – 25

4A1-25

47 Remove the installer KM620-9-A and steel pipe.

Assemble the flange holding t ool KM620-1-A and rear

wheel drive shaft flange ring KM620-2 to the rear

wheel drive shaft flange using three drive shaft

attaching bolts (1).

48 Lubricate the rear wheel drive shaft flange splines and

the outer rear wheel drive shaft threads with an NLGI

No. 2 lithium soap based EP grease with molybdenum

disulphide, such as Shell Retinax HDX2 grease or BP

Energrease LMS-EP 23 (or equivalent).

49 Reinstall the rear wheel drive shaft flange, flange ring

and holder assembly onto the outer rear wheel drive

shaft, aligning the splines on each.

50 With the outer rear wheel drive shaft supp orted on

press plates, as in step 36, press the rear wheel drive

shaft flange onto the outer rear wheel drive shaft using

installer KM620-9-A and a suitable steel pipe (2).

51 Remove the rear suspension control arm assembly

from the press and support the assembly in a vice b y

the flats on flange holding tool KM620- 1-A. Figure 4A1 – 43

52 Install a new collar nut to the outer rear wheel drive shaft and tighte n to the correct torqu e specification.

 Collar nut to outer rear wheel

drive shaft nut torque specification.....................300 N.m

53 Remove the rear suspension control arm assembly

from the vice and remove all the spec ial tools from the

rear wheel drive shaft flange.

54 Using a suitable diameter socket (1), 150 mm socket

shaft (2) and hammer (3), install a new lock plate over

the collar nut.

Figure 4A1 – 44

55 Use a suitable sized pin punc h and hammer to distort

the rear wheel drive shaft flange (1) into the cut-outs

on each side of the driveshaft flange.

56 Reinstall the rear suspension control to the vehicle.

Refer to 3.2 Rear Suspension Control Arm, Reinsta ll,

in this Section.

Figure 4A1 – 45

Rear Suspension 4A1 – 26

4A1-26

3.4 Rear Suspension Crossmember

LT Section No. – 07-150

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 this operation:

 Additional control arm socket assembly retaining nut.

 Stabiliser bar link to rear suspen sio n control arm attaching nut and bolt.

 Rear susp ension control arm to rear suspension crossmember attaching nut.

The following fasteners MUST be replaced when performing these operation:

 Rear suspension crossmember rear mounting to underbody attaching bolts.

 Final drive assembly to rear suspension crossmember bolts.

 Rear suspensi o n crossmember front mounting bolt.

The following fasteners MUST be at curb height with the vehicle weight on all four wheels before final

tightening is undertaken:

• Shock absorber lower mounting bolt.

• Stabiliser bar link to rear suspension control arm attach ing nut and bolt.

• Rear suspension control arm to rear suspension crossmember attaching nut.

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; refer ABS Function

Check, in Section 5B ABS & ABS/TC &

Electronic Brake Assist (EBA).

Before disturbing the rear suspension

crossmember mounting bolts, an alignment

procedure is required on reinstallation and a

special tool is required for this purpose. If this

tool is not available, then the crossmember

cannot be correctly aligned and steering

and/or handling abnormalities will result.

Rear Suspension 4A1 – 27

4A1-27

Remove

1 Raise the vehicle and suppor t in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 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 3.1 Service Warnings, Cautions and Notes, in this Section.

NOTE

Step 2 is necessary to maint ain part relationships

and to avoid brake rotor distortion and the

creation of brake shudder, after the vehicle is

placed back in service.

3 Disconnect and remove the exhaust system from the rear of the catalytic converter/s, rearward.

Refer to Section 8B Exhaust System.

4 Remove the intermediate muffler heat shield from the vehicle underbody. Refer to Section 8B Exhaust S ystem.

5 If the vehicle is fitted with the Automatic Level Ride

Suspension (production option FX3), disconnect the

ride height sensor link from the rear suspension

control arm.

Figure 4A1 – 46

6 To enable the propell er shaft to be installed in the

original position relative to the pinion flange, use a felt

tipped pen or similar to identify the relationship (‘A’)

between the two components.

7 Select the ‘Park’ position with the shift select lever and

firmly apply the park brake.

Do not loosen and remove any of the Torx

headed bolts (1) before relieving any torque

loading on the rubber coupling.

8 Using a commerciall y available E20 Torx socket and

suitable socket equipment loosen the three Torx

headed bolts (1).

9 Release the park brake to relieve any torque loading

on the rubber coupling, then remove the three Torx

headed bolts. Figure 4A1 – 47

Rear Suspension 4A1 – 28

4A1-28

10 Remove the centre bearing he at shield, if fitted.

11 While supporting the centre bearing carrier (1),

remove the two bolts (2) securing the centre bearing

carrier to the underbody reinforcement.

12 While supporting the centre beari ng section, slide the

propeller shaft assembly forward to disengage from

the rear suspension differential assembly pinion

support pin.

Figure 4A1 – 48

Do not allow the rear of the propeller shaft to

hang without support. This would place

undue stress on the front constant velocity

joint, causing premature failure.

13 Temporarily reinstall the centre bear i ng support bolts (do not tighten) and use a suitable length of wire to tie the

rear of the propeller shaft to a suitable point on the vehicle underbody.

14 Check that the park brake is in the fully released

position.

15 Release the park brake cable retaining clips (1) on

each of the underbody and free the cables (2).

Figure 4A1 – 49

16 Remove the park brake outer cable retaining bracket

bolt (underbody bracket and bolt are not shown) from

the vehicle underbody.

17 Pull each park brake inner cable (1) forward and up in

the direction of the arro w (A) and out of the cable

retainer (2) to release each cable.

18 Pull the outer cable (3) rearward (B) to remove from

the underbody retainer (4).

Figure 4A1 – 50

Rear Suspension 4A1 – 29

4A1-29

19 Disconnect the brake pipe (1) from the brake hose (2)

at the rear suspension control arm bracket (3) and

remove the brake hose retaining clip (4).

20 Plug the open ends of both pipes and hos es to prevent

unnecessary fluid loss and/or foreign matter entry.

21 Repeat for the other side.

Figure 4A1 – 51

22 Pull the differential carrier breather hose (1) out of the

hole (2) in the vehicle underbody rear suspension

crossmember.

Figure 4A1 – 52

23 Pull both ABS sensor lead connectors (3) from the

underbody retaining clips (4). Separate the sensor

connectors from the body harness connectors by

levering with a screwdriver.

Figure 4A1 – 53

Rear Suspension 4A1 – 30

4A1-30

24 Using a scriber, mark the location (A) of the rear

mount (1) to vehicle under body location. This will

assist in rear suspension crossmember alig nment on

installation.

25 Support the weight of the differential carrier with a floor

jack.

Figure 4A1 – 54

26 Remove the rear mount (1) to vehicle underbody

attaching bolts (2) and discard.

27 Lower the differential carrier and rear suspe nsion

crossmember assembly by at least 60 mm.

Figure 4A1 – 55

• If automatic level ride suspension is fitted

to the vehicle, there are specific

procedures relating to the system

pressure and the removal of the shock

absorber. Refer to 4 Service Operations –

Automatic Level Ride Suspension, in this

Section.

• During driveshaft removal and

reinstallation, the driveshaft 'free' end

MUST be supported to keep constant

velocity joint angles to a minimum.

Excessive angles and/or dropping the

'free' end will cause damage to the boot

cap and the joint itself.

Rear Suspension 4A1 – 31

4A1-31

Position the floor jack with a block of wood under the rear

suspension control arm.

28 Raise the jack slightly to take the spring load off the

rear suspension control arm.

29 Remove the rear shock absorber lower mounting bolt

and washer (1) from the rear suspension control arm

(2), then pull the lower end of the shock absorber (3)

from the rear suspension control arm (2).

Figure 4A1 – 56

30 Remove the rear springs (1), the upper insulators (2)

and the lower insulators (3) from the vehicle

underbody and rear suspensi on control arms.

31 Raise the differential carrier and rear suspension

crossmember on a floor jack until the rear mount

contacts the vehicle underbody.

Figure 4A1 – 57

32 Use a floor jack and a block of wood to support the

differential carrier and crossmember assembly.

33 Remove brace to underbody bolts (1) (3 places) and

crossmember to vehicle underbod y attaching bolt (2)

from each side.

34 Remove the braces (3) from the vehicle.

35 With an assistant supporting front end of rear

crossmember, lower assembly on jack and remove

from beneath vehicle.

Figure 4A1 – 58

Rear Suspension 4A1 – 32

4A1-32

36 Remove the stabiliser bar mounting bracket attaching

bolts (1). Use a screwdriver to lever up the brackets

(2) from the mounting points and remove the brackets.

37 Remove and discard the differential carrier to

crossmember attaching bolts (3).

38 Remove the rear suspension control arm to

crossmember attaching bolts and nuts (4). Discard the

nuts, as new ones must be used on reassembly.

Disengage the rear suspensi on control arms from the

crossmember.

39 After loosening the stabiliser li nk attaching nuts (5) at

each end and on each side to avoid stress on the

bushing, swing the stabiliser bar (6) back from the

crossmember.

40 Remove the additional control arm inner shaft to rear

suspension crossmember retaining nut and bolt and

manoeuvre the additional control arm free from the

crossmember.

41 Lift up and remove the crossmember from the vehicle.

Figure 4A1 – 59

Reinstall

Installation of the rear suspension crossmember is the reverse of the removal procedur es, except for the following steps:

1 If replacing a crossmember that does not have front mount bushing, install new bushing.

Refer to 3.5 Rear Suspension Crossmember Front Mount Bushing in this Section.

2 Reinstall the crossmember ov er the differential carrier and rear suspension control arms.

3 Assemble the rear suspension control arms into the crossmember brackets and install the attaching bolts and new

self-locking nuts. Do not fully tighten nuts at this stage.

4 Align the crossmember and final drive assembly mounting holes, install new attaching bolts and tighten to the

correct torque specification.

 Final drive assembly to rear

crossmember attaching bolt

torque specification.....................................90 N.m, then

turn through 40°

5 Position the stabiliser bar onto the crossmember, with the insulators located over the crossmember mounting

points.

6 Engage the brackets into the mounting points and install over the insulators, install attaching bolts and tighten to

the correct torque specification.

Stabiliser bar mounting bracket

bolt torque specification.......................................22 N.m

7 Reinstall the additional control arm into the rear suspension crossmember, install attaching bolt and a NEW nut and

tighten to the correct torque specification.

 Additional control arm, inner

shaft nut torque specification ...............................65 N.m

Rear Suspension 4A1 – 33

4A1-33

8 With the aid of two assistants, place the differentia l carrier and rear suspension crossmember assembly onto a floor

jack.

When raising the crossmember into place,

ensure that the rear suspension control arms

are also supported on safety stands, to keep

the drive shafts as near to horizontal as

possible.

If not, then bruising to the insides of the

constant velocity joint boots will result,

leading to boots splitting and eventually joint

failure, if left unchecked.

9 Position the assembly under the vehicle, raise with the jack and, with the aid of the assistants and guide the

crossmember front mounting points into pos ition.

10 Install both crossmember front mounting braces (3),

the six mounting brace attaching bolts (1) and the two

rear suspension crossmember front mounting bolts (2)

but do not fully tighten any of these bolts at this stage.

Figure 4A1 – 60

11 Lower the final drive assembly and rear suspension

crossmember assembly on the floor jack and safety

stands.

12 Reinstall rear springs (1) and t he upper (2) and lower

(3) spring insulators between the rear susp ension

control arm and the vehicle underbody.

Figure 4A1 – 61

Rear Suspension 4A1 – 34

4A1-34

If automatic level ride suspension is fitted to

the vehicle, there are specific procedures

relating to the system pressure and the

installation of the shock absorbers. These

operations MUST be carried out before

lowering the vehicle to the ground. Refer to

4 Service Operations – Automatic Level Ride

Suspension, in this Section.

13 With both springs and insulators installed, use a

second floor jack to raise each rear suspension control

arm (2), enough to allow the shock absorber (3) lower

mounting to be installed to the rear suspension control

arm.

14 Install washers and bolts (1) into the shock absorber

lower mounts but do not fully tighten at this stage.

Repeat for the other side.

Figure 4A1 – 62

15 Raise the assembly until the rear mount contacts the

vehicle underbod y.

16 Align the rear mount (1) with the marks (A) on the

underbody, made on disassembly, then loosely install

new attaching bolts but do not fully tighten at this

stage.

Failure to correctly alig n the rear suspension

crossmember to the centreline of the vehicle

will result in steering abnormalities and

uneven tyre wear!

17 The rear suspension crossmember MUST now be

aligned to the vehicle centreline, using the special tool

and procedure as detai led in

Section 1A2 Body Dimensions. Figure 4A1 – 63

18 Tighten all crossmember mou nting faste ners to the correct torque specification.

 Rear suspension crossmember

rear mount to vehicle underbody

attaching bolt torque specification................35 N.m then

turn through 60°

 Rear suspension crossmember

front mounting bolt torque specification 125 N.m, then

turn through 40°

 Rear suspension crossmember

front mounting brace bolt

torque specification..............................................75 N.m

19 Install the differential carrier breather hose i nto t he hole in the vehicle under body rear suspension crossmember,

ensuring that the end of the hose is pushe d into the hole approximately 25 mm.

20 Reconnect the ABS wheel speed sens or wiring harness connectors and install the connectors into the retaining

clips.

21 Check the park brake adjustment and bleed the brake hydraulic s ystem, refer to

Section 5A Service and Park Braking Systems.

22 Reinstall the exhaust system, using new gasket/seal at the flanges on the catalytic converters.

Refer to Section 8B Exhaust System.

Rear Suspension 4A1 – 35

4A1-35

23 Tighten the intermediate e xhaust pip e to catalytic converter bolts to the correct torque specification.

Intermediate exhaust pipe to

catalytic converter bolt

torque specification (All engines).........................45 N.m

24 Check the exhaust clearances. Refer to Section 8B Exhaust System.

25 If the vehicle is fitted with Automatic Level Ride Sus pensio n (prod uction option FX3), reconnect the level ride

sensor link to the rear control arm.

26 Reinstall the road wheel/s, aligni ng the marks made prior to removal and secure with the attaching nuts but do not

fully tighten at this stage.

If automatic level ride suspension is fitted to

the vehicle, there are specific procedures

relating to the system pressure and the

installation of the shock absorbers. These

operations MUST be carried out before

lowering the vehicle to the ground. Refer to

4 Service Operations – Automatic Level Ride

Suspension, in this Section.

27 Lower the vehicle to the ground.

28 Bounce the rear of the vehicle several times to settle the suspension.

29 With the vehicle at curb weight and the vehicl e weight on all four wheels, tighten rear suspensi on control arm to

crossmember attaching nuts, stabiliser bar link nuts an d the shock absorber lower mounting bolts to the correct

torque specifications.

  Rear suspension control arm

to rear crossmember nut

torque specification............................................100 N.m

 Stabiliser bar link, upper and lower

nut torque specification........................................95 N.m

 Shock absorber lower mounting

nut torque specification......................................115 N.m

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

3.1 Service Warnings, Cautions and Notes, in this Section.

Road wheel attaching

nut torque specification............................110 – 140 N.m

31 Reinstall the decorative wheel nut caps.

32 Start the vehicle and check the exhaust system for leaks. Repair as necessary.

33 Road test the vehicle to check for correct operation.

Rear Suspension 4A1 – 36

4A1-36

3.5 Rear Suspension Crossmember Front

Mount Bushing

LT Section No. – 07-150A

ATTENTION

The following fasteners MUST be replaced when performing these operations:

 Rear suspensi o n crossmember front mounting bolt.

 Rear suspension crossmember front mounting brace to underbody bolts.

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; refer ABS Function

Check, in Section 5B ABS & ABS/TC &

Electronic Brake Assist (EBA).

Before disturbing the rear suspension

crossmember mounting bolts, an alignment

procedure is required on reinstallation and a

special tool is required for this purpose. If this

tool is not available, then the crossmember

cannot be correctly aligned and steering

and/or handling abnormalities will result.

Off-Car Replacement

1 With the rear suspension crossmember (1) removed,

install the crossmember to underbody attaching bolt

(2) into the bushing (3) from above.

NOTE

Refer to 3.4 Rear Suspension Crossmember in

this Section for removal details.

2 Screw the underbody attaching bolt into puller, Tool

No. AMKM-557 and adaptor, Tool No. KM-557-5 (part

of Tool No. AMKM-557).

3 Tighten the forcing nut while holdin g the threaded

shaft of Tool No. AMKM-557 until the bushing is

removed from the crossmember.

4 Remove the crossmember to underbody attachin g bolt

from the puller and adaptor assembly and discard the

bush. Figure 4A1 – 64

5 Draw the new bushing (1) into the crossmember (2)

using Tool No. AU 592.

Figure 4A1 – 65

Rear Suspension 4A1 – 37

4A1-37

On-Car Replacement

1 Using a floor jack (2) with a suitable wood block (1)

mounted on top of the floor jack to support and protect

the underside of the centre differential carr ier, raise

the rear of the vehicle.

Figure 4A1 – 66

2 Position safety stands (2) to support the vehicle weight

at both the LH side and RH side under b od y rear

jacking points (1).

Refer to Section 0A General Information for the

location of recommended lifting and supp ort points.

Figure 4A1 – 67

3 Position a floor jack (1) with a suitable bl ock of wood

(2) mounted on top of the jack lifting pad to support

and protect the rear suspension crossmember

assembly.

4 Take up the weight of the crossmember by raising the

floor jack to make contact, nearest to the side where

the bushing is to be replaced.

5 Remove the brace attaching bolts (4 & 5) and the

crossmember brace (6) from the same side of the

vehicle. Discard the removed bolt (4).

6 Lower the floor jack slightly to allo w clearance

between the crossmember and the vehicle underbod y.

Figure 4A1 – 68

Rear Suspension 4A1 – 38

4A1-38

7 Support a suitable block of wood (1) (approximately

100 mm square by 40 mm thick), positioned over the

bush mounting bolt hole.

8 Raise the floor jack (4), until the clearance between

the crossmember bush, distance piece (2) and the

block of wood (1) is reduced to zero and a d ownward

force is applied to the bush.

9 Increase the pressure applied by the floor jack ,

gradually pressing the bush ing downward, freeing it

from the crossmember.

NOTE

The vehicle weight and the upward m ovement of

the jack will apply enough force to remove the

bush.

10 Discard the removed bushing.

Figure 4A1 – 69

11 Lower the floor jack to allow cleara nce for installation

of the new bush.

12 Apply a soap solution to the o uter diameter of the new

bush, to assist in the installation of the bushing into the

crossmember.

13 Apply hand pressure to initially start the leading edge

of the bushing (1) into crossmember bushing aperture.

14 Apply the installation Tool No. AU 592 to the bushing

and crossmember.

15 Draw the remaining exposed section of the new

bushing into the crossmember.

Figure 4A1 – 70

16 With the floor jack still in position to support and protect the rear suspension crossmem ber assembly, raise the

crossmember using the floor jack.

17 Reinstall the brace (6), a new crossmember front

mounting to underbody bolt (4), and the three smaller

original brace attaching bolts (5), but do not tighten the

bolts at this stage.

Figure 4A1 – 71

Rear Suspension 4A1 – 39

4A1-39

18 If necessary, repeat steps 3 to 17 for the opposite side.

Failure to correctly align the rear suspension

crossmember to the centreline of the vehicle

will result in steering abnormalities and

uneven tyre wear!

19 The rear suspension crossmember MUST now be checked for correct alignment to the vehicle centrelin e. Using the

special tool and procedure. Refer to Section 1A2 Body Dimensions.

20 Tighten bolts (4 and 5) to the correct torque specification.

 Rear suspension crossmember

to underbody front mounting

bolt torque specification..............................35 N.m, then

turn through 35°

 Rear suspension crossmember

brace mounting bolt

torque specification..............................................75 N.m

21 Using a floor jack (2) with a suitable block of wood (1)

mounted on top of the jack lifting pad to support and

protect under the centre of the differential carrier, raise

the rear of the vehicle from the safety stands.

22 Remove the safety stands and lo wer the vehicle to the

floor.

23 Remove the floor jack.

24 Road test the vehicle to check for correct operation.

Figure 4A1 – 72

Rear Suspension 4A1 – 40

4A1-40

3.6 Rear Suspension Crossmember Mass

Damper

LT Section No. – 07-150A

ATTENTION

The following fasteners MUST be replaced when performing these operations:

 Rear suspension crossmember front mounting brace to under body attaching bolts.

 Rear suspensi o n crossmember front mounting bolt.

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; refer ABS Function

Check, in Section 5B ABS & ABS/TC &

Electronic Brake Assist (EBA).

Before disturbing the rear suspension

crossmember mounting bolts, an alignment

procedure is required on reinstallation and a

special tool is required for this purpose. If this

tool is not available, then the crossmember

cannot be correctly aligned and steering

and/or handling abnormalities will result.

Remove

1 Raise the vehicle and suppor t in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Position a floor jack (1) with a suitable bl ock of wood

(2) mounted on top of the jack lifting pad to support

and protect the rear suspension crossmember

assembly (3).

3 Take up the weight of the crossmember by raising the

floor jack to make contact with the crossmember on

side where the rear suspension crossmemb er mass

damper is to be replaced.

4 Remove the rear suspension crossmemb er front

mounting attaching bolt (4). Discard the removed bolt.

5 Remove the bolt (5), three places, and remove the

rear suspension crossmember front mounting brace

(6). Discard the removed bolts.

6 Lower the floor jack slightly to allo w clearance

between the crossmember and the vehicle underbod y.

Figure 4A1 – 73

Rear Suspension 4A1 – 41

4A1-41

7 Using a back-up spanner on the rear sus pe nsion

crossmember mass damper bolt (1), remove the nut

(2).

8 Remove the bolt, washer (3) and rear suspension

crossmember mass damper (4) from the

crossmember.

Figure 4A1 – 74

Reinstall

Failure to achieve the correct clearance may

result in driveline vibration.

1 Reinstall the bolt (1), washer (2), rear suspension

crossmember mass damper (3) and nut to the

crossmember. Check that there is a 4 mm clearance

(A) from the rear suspension crossmember mass

damper to the bracket edge. Do not tighten the

retaining nut and bolt at this stage.

NOTE

The squared edge (4) of the rear suspension

crossmember mass damper, faces towards the

centre of the vehicle.

Figure 4A1 – 75

2 Using a back-up spanner on the rear suspe nsion crossmember mass damper bolt, tighten the nut to the correct

torque specification.

Rear suspension crossmem ber mass

damper bolt torque specification..........................45 N.m

NOTE

Make sure the mass damper does not rotate

when tightening the retaining nut

Rear Suspension 4A1 – 42

4A1-42

3 With the floor jack (1) still in position to support and

protect the rear suspension crossmember assembly,

raise the crossmember into position, using the floor

jack.

4 Install the brace (6), a new rear suspension

crossmember front mounting bolt (4), and the rear

suspension crossmember front mounting bra c e

attaching bolt (5), three places. Do not tighte n the

bolts at this stage.

Figure 4A1 – 76

Failure to correctly align the rear suspension

crossmember to the centreline of the vehicle

will result in steering abnormalities and

uneven tyre wear!

5 Check the rear suspension crossmember alignment. Refer to Section 1A2 Body Dimensi ons.

6 Tighten the rear suspension crossmember front mounting bolt to the correct torque specification.

 Rear suspension crossmember

front mount to underbody

bolt torque specification............................125 N.m, then

turn through 40°

7 Tighten the rear suspension crossmember front mounting brace attachi ng bolts to the correct torque specification.

 Rear suspension crossmember

brace mounting bolt

torque specification..............................................75 N.m

8 Remove the safety stands and lo wer the vehicle.

9 Road test the vehicle to check for correct operation.

Rear Suspension 4A1 – 43

4A1-43

3.7 Rear Suspension Crossmember Rear

Mount

LT Section No. – 07-150A

ATTENTION

The following fasteners MUST be replaced when performing these operations:

 Rear suspension crossmember rear mount to underbody attaching bolt.

 Rear suspension crossmember rear mount to rear final drive cover, attaching bolts.

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; refer ABS Function

Check, in Section 5B ABS & ABS/TC &

Electronic Brake Assist (EBA).

Before disturbing the rear suspension

crossmember rear mounting bolts, an

alignment procedure is required on

reinstallation and a special tool is required for

this purpose. If this tool is not available, then

the crossmember cannot be correctly aligned

and steering and/or handling abnormalities

will result.

Remove

1 Raise the vehicle and suppor t in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Using a scriber, mark the rear mount (1) to the vehicle

under body location (A). This will aid with the rear

suspension crossmember alignment on instal lation.

3 Support the weight of the differential carrier with a floor

jack.

Figure 4A1 – 77

Rear Suspension 4A1 – 44

4A1-44

4 Remove the rear mount (1) to vehicle underbody

attaching bolts (2) and discard.

5 Lower the differential carrier and rear suspe nsion

crossmember assembly by at least 60 mm.

Figure 4A1 – 78

6 Remove and discard the rear mount to differential

carrier attaching bolts (1) and remove the rear mount

(2).

Figure 4A1 – 79

Reinstall

1 Install the rear mount to differential carrier rear cover,

using NEW attaching bolts .

2 While tightening the attaching bolts to the correct

torque specification, check that the mount does not

twist. The mount to vehicle underbody mating surface

should be parallel to within 1 mm (‘X’) of the rear

suspension crossmember.

 Rear mount to final drive

carrier rear cover bolt

torque specification..............................................95 N.m

NOTE

Use a spirit level on t he r ear mount to u nder bod y

surface and the top surface of the crossmember

to ensure that both surfaces are parallel.

Dimension ‘A’ is to be 56.7 mm.

Figure 4A1 – 80

Rear Suspension 4A1 – 45

4A1-45

3 Raise the final drive carrier and rear susp ension crossmember assembly until the rear mou nt contacts veh icle

underbody.

4 Align the mount with the marks made on the und erbody during disassembly and install new attaching bolts but do

not tighten at this stage.

Failure to correctly align the rear suspension

crossmember to the centreline of the vehicle

will result in steering abnormalities and

uneven tyre wear!

5 The rear suspension crossmember MUST now be aligned to the vehicle centreline, using the special tool and

procedure as detailed in Section 1A2 Body Dimensions.

6 Tighten the rear suspension crossmember rear mount to underbody bolts to the correct torque specification.

 Rear suspension crossmember

rear mount to vehicle underbody

bolt torque specification..............................35 N.m, then

turn through 60°

7 Lower the vehicle to the ground.

Rear Suspension 4A1 – 46

4A1-46

3.8 Stabiliser Bar and/or Mountings

LT Section No. – 07-150A

ATTENTION

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

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

 Stabiliser bar link attaching nuts and bolts.

The following fasteners MUST be replaced when performing these operations:

 Rear suspension crossmember rear mount to underbody attaching bolt.

The following fasteners MUST be at curb weight with the vehicle weight on all four wheels:

• Brake caliper to steerin g knuckle retaining bolts.

Before disturbing the rear suspension

crossmember rear mounting bolts, an

alignment procedure is required on

reinstallation and a special tool is required for

this purpose. If this tool is not available, then

the crossmember cannot be correctly aligned

and steering and/or handling abnormalities

will result.

Remove

1 Raise the vehicle and suppor t in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Using a scriber, mark the rear mount (1) to vehicle

under body location (A). This will assist in the rear

suspension crossmember alignment on instal lation.

3 Support the weight of the differential carrier with a floor

jack.

4 Remove and discard the rear mount to vehicle

underbody attaching bolts (2).

5 Lower the differential carrier and rear suspe nsion

crossmember assembly enough to allow access to the

brackets securing the stabiliser bar to the rear

suspension crossmember.

NOTE

Do not allow the propeller shaft or left-hand side

drive shaft to rest on the exhaust system.

Figure 4A1 – 81

Rear Suspension 4A1 – 47

4A1-47

6 Remove both stabiliser bar link to rear suspension

control arm attaching nuts (1) and bolts (2).

7 Rotate links (3) until clear of the rear suspension

control arms (4).

8 Remove the stabiliser bar to the crossmember bracket

attaching bolts (5).

9 Using a screwdriver, lever the brackets (6) up an d out

of the crossmember (7).

10 Remove the stabiliser bar (8) from the vehicle.

11 Remove the insulators (9) from the stabiliser bar.

12 Remove the stabiliser bar to link mounting bolts and

nuts.

13 Separate the links from the stabiliser bar.

Figure 4A1 – 82

Stabiliser Bar Link Insulators, Replace

NOTE

The same procedure is used to replace both the

upper and lower insulator.

1 While supporting link (1) on open vice jaws, use a

suitable drift (2) and hammer to remove the steel

sleeve from the centre of the insulator (3).

2 Distort the flanged edge of the insulator and remove

from the link.

3 Repeat the procedure for the remainin g insulator if

required.

Figure 4A1 – 83

4 To reduce the installation force requ ired, apply

petroleum jelly (such as Vase line™ or equivalent), to

insulator (1), then install into the eye of the link (2).

5 Apply a smear of petroleum jelly to the steel inner

sleeve (3), then insert into the insulator until the sleeve

is centralised.

Figure 4A1 – 84

Rear Suspension 4A1 – 48

4A1-48

Reinstall

1 Loosely install the stabiliser bar link to stabiliser bar

bolts and nuts but do not fully tighten at this stage.

2 Install the insulators (1) and brackets (2) to the

stabiliser bar (3).

3 Position the stabiliser bar onto the crossmember (4),

engaging the tangs on the brackets with the slots in

the mounting points on the rear suspension

crossmember.

4 Install and tighten the bracket attaching bolts (5) to the

correct torque specification.

Stabiliser bar mounting bracket

to rear suspension crossmember

bolt torque specification.......................................22 N.m

5 Reinstall the links (6) into position between the rear

suspension control arm brackets and loosely install

NEW attaching bolts (7) and nuts (8), but do not fully

tighten at this stage. Figure 4A1 – 85

6 Raise the final drive assembly and suspension crossmember assembly until the rear mount contacts the vehicle

underbody.

7 Align the mount with the marks made on the und erbody during disassembly, and install NEW attaching bolts but do

not tighten at this stage.

Failure to correctly align the rear suspension

crossmember to the centreline of the vehicle

will result in steering abnormalities and

uneven tyre wear!

8 The rear suspension crossmember MUST now be aligned to the vehicle centreline, using the special tool and

procedure as detailed in Section 1A2 Body Dimensions.

9 Tighten the rear suspension crossmember, rear mount to underbody bolts to the correct torque specification.

 Rear suspension crossmember

rear mount to vehicle underbody

bolt torque specification..............................35 N.m, then

turn through 60°

10 Lower the vehicle, then bounce the rear of th e vehicle several times to settle the suspension.

11 Tighten the stabiliser bar link mounting bolts and nuts to the correct torque specification.

  Stabiliser bar link bolts

and nuts torque specification ...............................95 N.m

12 Road test the vehicle to check for correct operation.

Rear Suspension 4A1 – 49

4A1-49

3.9 Rear Spring and Insulators

LT Section No. – 07-150

ATTENTION

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

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

 Additional control arm socket assembly retaining nu t.

 Stabiliser bar link to rear suspen sio n control arm attaching nut and bolt.

The following fasteners MUST be replaced when performing these operations:

 Drive shaft constant velocity joint to rear wheel drive shaft flange attaching bolt.

Final tightening of the following fasteners MUST be with the vehicle weight on all four wheels and at curb

weight:

• Stabiliser bar link to rear suspension control arm attach ing nut and bolt.

• Shock absorber lower mounting bolt.

Remove

1 Raise the vehicle and suppor t in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Remove the decorative wheel nut covers from the rear wheel on the side of the vehicle where the sprin g is to be

removed.

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 3.1 Service Warnings, Cautions and Notes, in this Section.

4 If the vehicle is fitted with the Automatic Level Ride

Suspension (production option FX3), disconnect the

ride height sensor link from the rear suspension

control arm.

Figure 4A1 – 86

Rear Suspension 4A1 – 50

4A1-50

5 Either firmly apply the park brake with the vehicle in

Park, or use two wheel nuts to secure holding tool No.

KM 468 to the wheel studs.

6 Remove the six drive shaft (1) outer constant velocity

joint to rear wheel drive shaft flange attaching bolts (2)

with an 8 mm Allen key socket (3). Discard the

removed bolts.

Figure 4A1 – 87

7 Disconnect the drive shaft (1) from the flange and lift

upward.

• Bruising to the inside of the drive shaft

constant velocity joint boots will occur if

the rear suspension control arm is

lowered any further. This will lead to

premature failure of the boot and eventual

failure of the joint if left unchecked.

• For this reason, it is important that the

constant velocity joint is disconnected

from the rear wheel drive shaft flange

before removing the shock absorber

lower mounting bolt.

8 Keep the drive shaft horizontal, using a length of wire

(2), support the driveshaft to the lower end of the

shock absorber upper mounting. Figure 4A1 – 88

9 Loosen the additional control arm socket assembly

retaining nut until level with the top of the socket

assembly stud.

10 Using special tool No. E-9332-A (1), tighten the lever

forcing screw (2) until the socket assembly stud

breaks free from the taper in the rear suspension

control arm, then remove and discard the socket

assembly retaining nut.

11 Remove the additional control arm socket assembly

from the rear suspension control arm.

Figure 4A1 – 89

Rear Suspension 4A1 – 51

4A1-51

12 Remove the stabiliser bar link (1) to rear suspension

control arm attaching bolt (2) and nut from the side of

the vehicle where the spring is bein g removed.

Figure 4A1 – 90

If automatic level ride suspension is fitted to

the vehicle, there are specific procedures

relating to the system pressure and the

installation of the shock absorbers. These

operations MUST be carried out before

lowering the vehicle to the ground. Refer to

4 Service Operations – Automatic Level Ride

Suspension, in this Section.

13 Position a floor jack under the rear suspension control

arm.

14 Raise the jack slightly to take the spring load off the

rear suspension control arm.

15 Disconnect rear shock absorber lower mounting bolt

(1) and washer (2) from the rear suspension control

arm (3).

16 then remove the lower end of the shock absorber (4)

from the rear suspension control arm.

Figure 4A1 – 91

17 Lower the jack and remove the rear spring (1), upper

insulator (2) and lower insulator (3) from between the

vehicle underbod y and the rear suspension control

arm.

NOTE

• It may be necessary to push the rear

suspension control arm downward by hand

slightly to provide sufficient space for the

spring to be removed.

• Ensure that the rear brake hose is not pulled

tight while pushing down on the rear

suspension control arm.

Figure 4A1 – 92

Rear Suspension 4A1 – 52

4A1-52

Reinstall

1 Reinstall the lower insulator (3) onto the rear

suspension control arm. Assemble the upper insulator

(2) into the spring (1) then push down on the rear

suspension control arm and install the spr in g and

upper insulator.

Figure 4A1 – 93

If automatic level ride suspension is fitted to

the vehicle, there are specific procedures

relating to the system pressure and the

installation of the shock absorbers. These

operations MUST be carried out before

lowering the vehicle to the ground. Refer to

4 Service Operations – Automatic Level Ride

Suspension, in this Section.

2 Position the jack under the rear suspension control

arm (2) and raise it sufficiently to allo w the shock

absorber (3) lower mounting washer and bolt (1) to be

reinstalled.

3 Reinstall the washer and bolt on to the shock absorber

lower mount and into the rear suspension control arm,

but do not tighten at this stage.

Figure 4A1 – 94

4 Remove the wire from the drive shaft and shock absorber upper mount. Lower the drive shaft and align the drive

shaft constant velocity joint to rear wheel drive shaft flange, then fit NEW attaching bolts into the corresponding

holes in the rear wheel drive shaft flange

5 Tighten the drive shaft constant velocity joint to rear wheel drive shaft flange attaching bolts to the correct torque

specification.

 Drive shaft constant velocity joint

to rear wheel drive shaft flange

bolt torque specification..............................50 N.m, then

turn through 70°

6 Rotate the stabiliser bar link into position over the rear suspension control arm bracket.

7 Reinstall the attachin g bolt and a NEW nut but do not tighten at this stage.

Rear Suspension 4A1 – 53

4A1-53

8 If the vehicle is fitted with Automatic Level Ride Sus pensio n (prod uction option FX3), reconnect the level ride

sensor link to the rear control arm.

9 Reinstall the additional control arm socket assembly with a NEW nut and tighten to the correct torque wrench

specification.

 Additional control arm ball joint

retaining nut torque specification .........................65 N.m

10 Reinstall the road wheel, aligning the previously made marks and secure with the attaching nuts but do not tighten

at this stage.

11 Lower the vehicle to the ground.

12 Bounce the rear suspension several times to settle components.

13 Tighten road wheel attaching nuts to the correct torque specification, working in a ‘star’ pa ttern, refer to

3.1 Service Warnings, Cautions and Notes, in this Section.

Road wheel attaching

nut torque specification............................110 – 140 N.m

14 Tighten the stabiliser bar link to rear suspension control arm nut to the correct torque specification.

  Stabiliser bar link bolts

and nuts torque specification .............................100 N.m

15 Tighten the shock absorber l ower mount to rear suspension control arm attaching bolt to the correct specification.

 Shock absorber lower mounting

bolt torque specification.....................................115 N.m

16 Reinstall the wheel cover/ decorative wheel nut covers.

17 Road test the vehicle to check for correct operation.

Rear Suspension 4A1 – 54

4A1-54

3.10 Rear Shock Absorbers and/or Bushing

LT Section No. – 07-150

ATTENTION

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

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

 Upper shock absorber mounting plate retaining nut (Wagon and Utility only).

Final tightening of the following fasteners MUST be with the vehicle weight on all four wheels and at curb

weight:

• Stabiliser bar link to rear suspension control arm attach ing nut and bolt.

• Shock absorber lower mounting bolt.

Remove

If the vehicle is fitted with Automatic Level

Ride Suspension, there are unique

procedures required when removing the rear

shock absorbers f rom thes e vehicles. Refer to

4.6 Automatic Level Ride Shock Absorber, in

this Section, for details.

1 Raise the vehicle at the rear, using a floor jack under the centre of the differential carrier.

2 Place safety stands under the rear suspension control arms to support weight of the vehicle.

3 Loosen and remove the shock absorber lower

mounting bolt and washer (1) and remove th e shock

absorber (3) from the rear suspension c ontrol arm (2).

Figure 4A1 – 95

Rear Suspension 4A1 – 55

4A1-55

4 Open the rear compartment lid and prise off the shock

absorber upper mounting cap cover (1).

5 Remove the shock absorber upper mo unting nut (2),

upper plate (3) and upper bushing (4).

6 Remove the upper mounting lower bushing (5) and

lower plate (6) from the shock absorber (7).

Figure 4A1 – 96

Lower Bushing, Replace

1 To replace the shock absorber lower bushing:

a. With the shock absorber (1) lower mount

supported on suitable press plates, use a

suitable press tool (2) such as Tool No. KM619

to press the bushing (3) from the mount.

b. Lubricate the ne w bushin g with soapy water and

place in sleeve, Tool No. KM508-2

c With the shock absorber lower mount supp orted

on press plates, position KM508-2 onto the lower

mount. Press the new bushing into the lower

mount using a suitable press t ool such as Tool

No. KM619.

Figure 4A1 – 97

Rear Suspension 4A1 – 56

4A1-56

Reinstall

1 Before installation, check shock the absorb er action and inspect the rubber bushi ng. Replace components as

required. Refer to 5 Diagnosis in this Section for testing details.

2 Assemble the upper mounting lower plate (6) and

bushing (5) to the shock absorber (7).

3 Position the shock absorber into the upper mounting

hole. Install the upper mounting upper bushing (4),

upper plate (3) and mounting nut (2), then hand

tighten the nut to the correct torque specification.

Upper shock absorber retaining

nut torque specification........................................14 N.m

NOTE

Do not use power operated tools for this

operation, as thread damage will result.

4 Reinstall the upper mounting cap cover (1).

Figure 4A1 – 98

5 Install the shock absorber (3) lower mount into the rear suspension control arm (2) and install the washer and bolt

(1) but do not fully tighten at this stage.

6 Lower the vehicle to the ground an d bounce the rear of the vehicle several times to settle the suspension.

7 Tighten the shock absorber l ower mounting bolt (1) to

the correct torque specification.

 Shock absorber lower mounting

nut torque specification......................................115 N.m

8 Road test the vehicle to check for correct operation.

Figure 4A1 – 99

Rear Suspension 4A1 – 57

4A1-57

3.11 Additional Control Arm

LT Section No. – 07-150A

ATTENTION

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

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

 Additional control arm inner shaft attaching nut.

 Additional control arm socket assembly retaining nut.

The following fasteners MUST be replaced when performing these operations:

 Additional control arm adjusting shaft lock nut.

Inspect

Inspection of the additional control arm may be required in

the following circumstances:

• Poor handling.

• Uneven tyre wear.

A visual inspection of the additiona l control arm should be

performed with the arm installed in the vehicle. The

following conditions would require replacement of the

additional control arm or some of its components:

• Bent or damaged shafts.

• Bent or damaged adjusting shaft.

• Excessive play in the socket assembly.

• Excessive play in the inner bushing.

• Damaged socket assembly boot. Figure 4A1 – 100

Legend

1 Socket Assembly Retaining Nut

2 Additional Control Arm Outer Shaft and Ball Joint

3 Outer Adjuster Lock Nut

4 Adjusting Shaft

5 Inner Adjuster Lock Nut

6 Additional Control Arm Inner Shaft

7 Additional Control Arm Inner Bushing

8 Additional Control Arm to Rear Crossmember Retaining Bolt

Rear Suspension 4A1 – 58

4A1-58

Remove

1 Raise the vehicle and suppor t in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 If the additional control arm is being disassembled, measure and record the len gth of the adjusting shaft between

the lock nuts.

3 Loosen the additional control arm socket assembly

retaining nut until level with the top of the socket

assembly stud.

4 Using special tool No. E-9332-A (1), tighten the lever

forcing screw (2) to press the socket assembly stud

free from the taper in the rear suspension control arm

then remove the socket assembly retaining nut.

5 Remove the additional control arm to rear suspension

crossmember retaining nut and bolt.

6 Carefully manoeuvre the add itional control arm from

the vehicle.

Figure 4A1 – 101

Disassemble

1 Using a suitable vice fitted with soft jaws, hold the

centre adjusting shaft (1) and loosen the two lock nuts

(2).

2 Rotate the inner shaft (3) clockwise (noting the

number of turns) until the inner shaft is disengaged

from the threaded area of the adjusting shaft.

NOTE

The inner additional control arm shaft, the inner

lock nut and the corresponding end of the

adjuster shaft have left-hand threads.

3 Rotate the outer shaft counter clockwise (noting the

number of turns) until the outer shaft is disengage d

from the threaded area of the adjusting shaft.

4 Remove the lock nuts from the adjusting shaft.

Figure 4A1 – 102

Reassemble

The reassembly procedure for the additional control arm is t he reverse of the disassembly proced ure. The inner and

outer shafts are to be installed onto the adjusting shaft with the same number of turns and the arm when assembled, is

adjusted to the correct length.

NOTE

• The inner additional control arm shaft, the

inner lock nut and the corresponding end of

the adjuster contain left-hand threads.

• The additional control arm lock nuts should

only be tightened when the arm is installed

into the vehicle and the suspension is under

load.

Rear Suspension 4A1 – 59

4A1-59

Reinstall

NOTES

• The additional control arm lock nuts should

only be tightened when the arm is installed

into the vehicle and the suspension is under

load.

• The socket assembly may be rotated and

misaligned, if allowed to move during the

tightening of the lock nut, resultin g in possible

damage to socket assembly internals. When

tightening the additional co ntrol arm lock nuts,

use a suitable spanner on the hexagonal

crimped section near the socket assembly to

prevent the socket assembly from being

deflected.

• To ensure proper retention of the additional

control arm, the socket assembl y stud and t he

corresponding tapered hole in the rear

suspension control arm must be cleaned of

dirt and foreign matter prior to installation.

NOTES

• The inner addit ional control arm shaft, MUST

be installed into the vehicle with the

protruding side of the bushing towards the

front of the vehicle (as indicated).

• Check the rear wheel toe setting, refer to

3.12 Rear Wheel Alignment Checking in this

Section.

1 Tighten all fasteners to the correct torque

specification.

 Additional control arm ball joint

nut torque specification........................................65 N.m

 Additional control arm inner shaft

nut and bolt torque specification ..........................65 N.m

 Additional control arm adjusting

shaft lock nut torque specification........................50 N.m

Figure 4A1 – 103

Rear Suspension 4A1 – 60

4A1-60

3.12 Rear Wheel Alignment Checking

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 , rep lacement is recommended when performing these operations:

 Rear susp ension control arm to rear suspension crossmember attaching nut.

The following fasteners MUST be replaced when performing these operations:

 Rear suspensi o n crossmember front mounting bolt.

 Rear suspension crossmember mount to under body attaching bolt.

 Rear suspension crossmember mounting brace to underbody attaching bolts.

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

• Rear suspension control arm to rear suspension crossmember attaching nut.

Camber and Toe Check

Preliminary Checks and Information

The following conditions must be checked to ensure accurate measurement of rear wheel alignment.

1 Tread on rear tyres must be uniform and in a roadworthy condition.

2 Tyre pressures must be equal on both sides and to the correct pressure. Refer to the tyre placard on the vehicle for

correct tyre pressures.

3 Wheel rim flange lateral run-out should be checked and be to specification, refer to Section 10 Wheels and Tyres.

4 The vehicle must be at curb height: i.e. vehicle ready to drive with all fluids at recommended lev els, fuel tank full,

without driver, passengers or luggage.

5 Stabilise vehicle springs by bounci ng the rear of vehicle several times.

NOTE

This step is very important, particularly if the

vehicle was raised before checking. In that

instance, the camber angle measured will be

incorrect, because the rear suspension control

arms will not have resumed their normal position.

Camber

Camber is not adjustable. If there is any deviation from specification, the condition and alignment of the crossmember,

rear suspension control arms and b ush ing should be checked.

Wheel Toe

1 When checking wheel toe, if one side h as e xcessive toe-in and the opposite side h as excessive toe-out, this may

be due to:

a The rear suspension control a rm attaching nuts being tightened when the vehicle was not at curb height.

b The rear suspension crossmember not correctly aligned to the vehicle centreline.

2 To correct such a condition, check the rear suspension cros smember a lignment.

Refer to Section 1A2 Body Dimensions . NOTE

Alignment of the rear suspension crossmember

requires the use of a special tool. Attempting to

align the rear suspension crossmember without it

will not prove to be successful.

3 Re-check the rear wheel alignment toe setting and adjust as required. Refer to Rear Wheel Toe Adjustment, in this

Section.

Rear Suspension 4A1 – 61

4A1-61

Rear Wheel Toe Adjustment

The rear suspension toe setting is adjustab le in vehicles equipped with the additional control arm by varying the length of

the additional control arm. To adjust toe setting:

1 Loosen the two lock nuts (1).

NOTE

The inner additional control arm shaft, the inner

lock nut and the corresponding end of the

adjuster have left-hand threads.

2 Rotate the centre adjusting shaft, using a suitable

spanner (2).

3 Tighten the two lock nuts (1) by holding onto the

hexagonal crimped secti on near the socket assembly

(3). NOTE

• Increasing the additional control arm length

will increase rear wheel toe in and vice versa.

• The socket assembly may be over extended

if allowed to move during the tightening of the

lock nuts, causing damage to socket

assembly internals. During the toe

adjustment procedure, use a suitable

spanner (3) to prevent the socket assembly

from being deflected.

Figure 4A1 – 104

4 Tighten all fasteners to the correct torque specifications.

 Rear suspension crossmember

front mounting bolt

torque specification...................................125 N.m, then

turn through 35°

 Rear suspension crossmember

rear mount to vehicle body

torque specification.....................................35 N.m, then

turn through 60°

 Rear suspension control arm

to rear suspension crossmember

bolt and nut torque specification ........................100 N.m

Rear Suspension 4A1 – 62

4A1-62

4 Service Operations – Automatic

Level Ride Suspension

4.1 Initial Air Charge

LT Section No. - 06-212

1 Turn ignition ON.

2 Disconnect the lower end of the sensor connectin g

link.

3 Push the sensor arm upward, above the horizontal

plane for approximately 2 0 se conds, until the

compressor is activated.

4 Leave the compressor runni ng for approximately 30

seconds to inflate the Superlift shock absorbers.

5 Turn ignition OFF .

6 Check the system for leaks.

Refer to 4.2 Air Leak Test, in this Section.

7 Reconnect the sensor connecting li nk.

Figure 4A1 – 105

Rear Suspension 4A1 – 63

4A1-63

4.2 Air Leak Test

LT Section No. - 06-212

If air pressure in the level ride system is lo st

during service procedures, do not lower the

vehicle until system pressure has been

restored, as damage will most likely result.

Charge the system as detailed in

4.1 Initial Air Charge in this Section.

1 Ensure the system is pressurised. Refer to

4.1 Initial Air Charge in this Section if required.

2 Starting at the shock absorber connections, apply a

foaming leak check solution (commercially available,

or a soap solution mixed with water) to all fittings and

connections.

3 Carefully inspect the fittings and con nections for the

presence of air bubbles in the solution. Figure 4A1 – 106

4 Repair any detected leaks as required.

5 Retest the system for air leaks.

6 If air still leaks from the system, isolate sections of the system until the source of the leak is found.

7 Clean off the residual solution.

Rear Suspension 4A1 – 64

4A1-64

4.3 Relieving System Air Pressure

LT Section No. - 06-212

If air pressure in the level ride system is lost

during service procedures, do not lower the

vehicle until system pressure has been

restored, as damage will most likely result.

Charge the system; refer to

4.2 Initial Air Charge in this Section.

Prior to carrying out service operations on

the level ride suspension system where the

air pressure in the system needs to be

released, the following procedure must be

followed

1 With the rear of the vehicle raised an d supported on

safety stands under the trailing arms, turn ignition ON.

2 Disconnect the lower end of the sensor connectin g

link.

3 Pull the sensor arm downward, below the horizontal

plane and hold until the exhaust solenoid is activated.

4 Maintain the sensor lever position, allow the exhaust

solenoid to remain active for approximately 30

seconds to relieve the system air pressure or until no

sound of exhausting air remains. Figure 4A1 – 107

Do not leave the sensor lever in the lowered

position for more than four and a half minutes

(with the ignition on), otherwise the solenoid

timer will deactivate the solenoid and the

timer must then be reset.

5 Turn ignition OFF .

6 Proceed with service operations as required.

NOTE

After service work has been completed, the

system pressure must be reinstated before

lowering the vehicle. Refer to 4.1 Initial Air

Charge in this Section for the procedure.

Rear Suspension 4A1 – 65

4A1-65

4.4 Compressor Assembly

LT Section No. - 06-212

Figure 4A1 – 108

Legend

1 Level Ride Compressor Wiring Harness Connector

2 Level Ride Compressor Bracket to Underbody Mounting

Bolts (3 Places).

3 Airline to Compressor T-piece

4 Level Ride Compressor Mounting Bracket

Remove

• If air pressure in the level ride system is

lost during service procedures, do not

lower the vehicle until system pressure

has been restored, as damage will most

likely result. Charge the system a s detaile d

in 4.1 Initial Air Charge in this Section.

• Disconnection of the battery affects

certain vehicle electronic systems. Refer

to Section 00 Cautions and Notes,

5. Battery Disconnection Procedures

before disconnecting the battery.

Rear Suspension 4A1 – 66

4A1-66

1 Disconnect the battery, negative lead first.

2 Raise the vehicle.

3 Relieve system air pressure. Refer to 4.3 Relieving System Air Pressure, in this Section.

4 Unclip the level ride wiring har ness (1) from the compressor assembly mounting bracket (4) and disconnect the

wiring connector, refer to Figure 4A1 – 108.

5 Remove the three bolts (2) attaching the compressor assembly mounting bracket (4) to the vehic le body.

Support the compressor assembly. Do not

allow it to drop.

6 Disconnect the airline T-connector (3) from the compressor by rotating the T-piece 90°, then carefully pull it away

from the compressor.

7 Lower the compressor assembly.

Disassemble

1 Remove the filter (1) from the mounting bracket (2).

2 Remove the three bolts (3) attaching the compressor

(4) to the mounting bracket.

3 Test that the filter is clean and free from restrictions

by removing the filter form the tube and blowing

through it from the hose connection end. If an y

restriction is felt, replace the filter.

Reassemble

1 Reinstall the components in the reverse order to

disassembly.

2 Tighten the bolts to the specified torque.

Compressor mounting bolt

torque specification.............................................5.0 N.m

Figure 4A1 – 109

Rear Suspension 4A1 – 67

4A1-67

Reinstall

1 If the left-hand rear longitudin al an d/or crossmember

has been replaced, compressor assemb ly mounting

holes (1) will have to be drilled as requ ired.

Figure 4A1 – 110

2 Bring the compressor assembly up to the air li ne and connect the T-piece.

NOTE

Ensure that the airline is correctly routed, placed

in all of its mounting clips and does not foul with,

or rub against any components or body fittings.

3 Reinstall the three mounting bolts and tighten to the specified torque.

Compressor assembly mounting

bolts torque specification ....................................5.0 N.m

4 Connect the wiring harness connector and clip the harness into position.

NOTE

Ensure that the harness is correctly routed,

placed in all of its mounting clips/ties and does

not foul with, or rub against any components or

body fittings.

5 Connect the battery.

NOTE

Do not completely lower the vehicle until the

system air pressure has been reinstated.

6 Charge the system with air and check the system for leaks; refer to 4.1 Initial Air Charge and 4.2 Air Leak Test in

this Section.

Rear Suspension 4A1 – 68

4A1-68

4.5 Air Lines

LT Section No. - 06-212

If air pressure in the level ride system is lost

during service procedures, do not lower the

vehicle until system pressure has been

restored, as damage will most likely result.

Charge the system as detailed in

4.1 Initial Air Charge in this Section.

The air lines are routed between the compressor and each shock absorber. Retaining clips are placed along each line to

secure the air line to the vehicle. Either scre w-on t ype or clip-on type connectors are used to attach the air line to the

shock absorbers, and a clip-on T-piece attaches the air line to the compress or.

Figure 4A1 – 111

Remove

1 De-pressurise the system. Refer to 4.3 Relieving System Air Pressure in this Section.

2 Rotate the applicable connector 90°, then carefully pull the conn ector and air line away from the component.

Rear Suspension 4A1 – 69

4A1-69

Reinstall

1 Route the airline in the retaine r s ensuring that there

are no kinks and it does not foul on the body or any

components.

2 Push the connection cap (1) onto the shock absor ber

port (2) until the spring clip engages the gro ove in the

shock absorber fitting.

3 Charge the system with air and test for air leaks as

detailed in 4.1 Initial Air Char ge and

4.2 Air Leak Test, in this Section.

Figure 4A1 – 112

4 Fit each air line connection onto the T-piece (1).

5 Push the T-piece onto the compressor fitting,

ensuring it is secure.

Figure 4A1 – 113

Rear Suspension 4A1 – 70

4A1-70

4.6 Automatic Level Ride Shock Absorber

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 , rep lacement is recommended when performing these operations

 Upper shock absorber mounting plate retaining nut (AWD Wagon only).

Final tightening of the following fasteners MUST be with the vehicle weight on all four wheels and at curb

weight:

• Stabiliser bar link to rear suspension control arm attach ing nut and bolt.

• Shock absorber lower mounting bolt.

Remove

If air pressure in the level ride system is lost

during service procedures, do not lower the

vehicle until system pressure has been

restored, as damage will most likely result.

Charge the system as detailed in

4.1 Initial Air Charge in this Section.

1 Raise the rear of the vehicle by placing a jack under the centre of the differential carrier, raise the ve hicle and place

safety stands under the trailing arms to support the weight of the vehicle.

2 De-pressurise the system. Refer to 4.3 Relieving System Air Pressure in this Section.

3 Disconnect the air line connec tion from the shock absorber. Refer to 4.5 Air Lines in this Section.

4 Open the rear compartment lid and prise off the shock

absorber upper mounting cap cover (1).

5 Remove the shock absorber upper mo unting nut (2),

upper plate (3) and bush (4).

Figure 4A1 – 114

Rear Suspension 4A1 – 71

4A1-71

6 Loosen then remove the lo wer shock absorber

mounting bolt (1) and washer from the lower mounting

(2).

Figure 4A1 – 115

7 Lower the shock absorber (3) to clear the upper mounting stud from the bo dy, then remove the shock absorber

assembly from the vehicle.

8 Remove the upper mounting, lo wer bush (5) and washer (6) from the shock absorber, as required.

Reinstall

The installation procedure is the reverse of the removal procedures e xcept for the following:

1 Reassemble the upper mounting lower plate (6) and

bushing (5) to the shock absorber (7).

2 Position the shock absorber into the upper mounting

hole.

3 Reinstall the upper mounting upper bushing (4), upper

plate (3).

4 Reinstall the mounting nut (2), then hand tighten the

nut to the correct torque specification.

Upper shock absorber retaining

nut torque specification........................................14 N.m

NOTE

Do not use power operated tools for this

operation, as thread damage will result.

5 Reinstall the upper mounting cap cover (1).

Figure 4A1 – 116

6 Reinstall the shock absorber (3) lower mount into the

rear suspension control arm (2) and i nstall th e washer

and bolt (1) but do not fully tighten at this stage.

Figure 4A1 – 117

7 Reinstall the air line to the shock absorber. Refer to 4.5 Air Lines in this Section.

8 Before lowering the vehicle to the groun d, charge the system with air and test for air leaks as detailed in

4.1 Initial Air Charge and 4.2 Air Leak Test in this Section.

9 Lower the vehicle to the ground, then bounce the vehicle s evera l times to settle the suspension.

10 Tighten the shock absorber l ower mounting bolt to the correct torque specification.

• Shock absorber lower mounting

bolt torque specification......................................115 Nm

11 Road test the vehicle to check for correct operation.

Rear Suspension 4A1 – 72

4A1-72

4.7 Ride Height Sensor

LT Section No. - 06-212

Remove

• If air pressure in the level ride system is

lost during service procedures, do not

lower the vehicle until system pressure

has been restored, as damage will most

likely result. Charge the system a s detaile d

in 4.1 Initial Air Charge in this Section.

• The position of the ride height sensor is

critical to the level ride system's operation.

A bent or damaged mounting bracket,

connecting link or ball stud plate, or

incorrect installation of the sensor and

components can cause incorrect

operation.

• Disconnection of the battery affects

certain vehicle electronic systems. Refer

to Section 00 Cautions and Notes,

5. Battery Disconnection Procedures

before disconnecting the battery.

1 Disconnect the battery, ground lead.

2 Unclip or cut the cable ties securing the sensor wiring

harness to the sensor bracket.

3 Disconnect the wiring harness connector (1) from the

sensor (2).

4 Disconnect the sensor link (3) from either the sensor

arm or ball stud plate (4).

5 While holding the sensor assembly, remove the

bolt (5) attaching the sensor mounting bracket (6) to

the crossmember.

6 Remove the sensor assembly.

7 If required, remove the nuts (7) attaching the sensor

to the mounting bracket.

8 If required, remove the bolt (8) attaching the ball stud

plate to the trailing arm.

Figure 4A1 – 118

Rear Suspension 4A1 – 73

4A1-73

Reinstall

Installation of the ride height sensor is the reverse to removal procedures, ensuring to tighten all fasteners to the correct

torque specification.

Ride height sensor bracket

to crossmember

bolt (5) torque specification..................................25 N.m

Sensor to bracket nut (7)

torque specification.............................................5.0 N.m

• Stabiliser bar link bolt (8)

and nut torque specification...............................100 N.m

NOTE

If the rear suspension crossmember has been

replaced, insert the nut cage (1) into the

crossmember as shown.

Figure 4A1 – 119

Rear Suspension 4A1 – 74

4A1-74

5 Diagnosis

5.1 Checking and Testing Shock Absorbers

For a positive check of shock absorber operation it is advisable to remove them from the vehicle. However, before

proceeding with the removal, it is good pr actice to ensure that the noise causing concern, is not coming from another

source.

Check the shock absorber mountings for tightness; check the rubber mou nt bushing and replace if worn.

This test proc edure is not fo r gas pressurised

shock absorbers.

Test shock absorber action as follows:

1 Clamp the shock absorber (1) by its lower mount in a

vice (2).

2 Slowly pump the shock absorber up an d down the full

stroke at least six times before checking its resistance.

3 Pump the shock absorber by hand at various rates of

speed and observe the resist ance.

When extending the shock ab sorber, the resistance should

be marginally greater than when collapsing the unit. The

resistance should be consistent throughout both strokes and

there should be no ‘slack' spots.

‘Slack' spots indicate either loss of oil – which is usually

visible on the outside – or the internal valves not seating.

4 It is normal to detect a hissing noise (orifice swish).

5 The following conditions are considered abnormal and

replacement is recommended:

a. A skip or lag at reversal near mid-stroke.

b. A seize (except at either extreme end of travel).

c. A noise such as a grunt or squeal after

completing one full stroke in both directions.

d. A clicking noise at fast reversal.

e. Fluid leakage. Refer to Leak age Criteria for

guidelines.

Figure 4A1 – 120

Leakage Criteria

A shock absorber 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 shock absorb er body.

• Road grease, oil, sand and dust discol ouration on the body, does not constitute a leaking shock absorber. If this

condition is evident, the shock absorber should be wiped cle an and checked at a later service.

NOTE

Should one shock absorber prove to be leaking

and require replac ement, providing the remaining

shock absorber is serviceable, it does not also

need to be replaced.

Rear Suspension 4A1 – 75

4A1-75

5.2 Diagnosis – Automatic Level Ride

Suspension

The following procedures are designed to assist in the diagnosis of a fau lt in the level ride system. To achieve an

accurate diagnosis, the Technician must be famili ar with the principles of operation of the system before proceeding.

The diagnosis tables contained in this Section are to be used in conjunction with the wiring schematic and wiring harness

diagrams, also provided.

Equipment

A digital multimeter with a minimum 10 Mega ohm impedance must be used when undertaking any electrical checks with

this system.

When performing tests on the wiring harness, use the appropriate probe adaptor to ensure the wiring and/or connectors

are not damaged during testing.

Ride Height Sensor Reset

If the compressor or exhaust solenoid operat e for more than four and a half minutes, the sensor timers must be reset by

turning the ignition on, then off for 1 minute, then on again.

Rear Suspension 4A1 – 76

4A1-76

5.3 Preliminary Diagnostic Procedure

Step Action Value(s) Yes No

1 Does the vehicle trim? – Go to Step 2. Go to Step 3.

Does the vehicle trim to the correct height?

Refer to 6

Specifications

in this Service

Information.

System OK.

Check all

suspension

components for

wear and damage,

particularly the ride

height sensor

mounting and

bracket.

3 Does the vehicle rise after the specifie d time whe n the

vehicle is loaded?

Place load in the vehicle.

20 seconds.

Go to Step 4.

Refer to

5.2 Compressor

Assembly Test -

Motor.

4 Does the vehicle lower after the specified time when

the vehicle is unloaded.

Remove load from the vehicle.

20 seconds.

System OK.

Refer to

5.3 Compressor

Assembly Test -

Solenoid.

Rear Suspension 4A1 – 77

4A1-77

5.4 Compressor Assembly Test – Motor

Step Action Value(s) Yes No

1 Has a system reset been performed? – Go to Step 2.

Perform ride height

sensor reset, in this

Section.

2 Is fuse F105 OK?

(Located in the engine compar tment fuse and relay

panel assembly).

–

Go to Step 3.

Replace blown fuse.

Check wiring for the

cause of the blown

fuse. Re-check

system.

3 Are fuses F38 and F15 OK?

(Located in the passenger compartment fuse and

relay panel assembly).

–

Go to Step 4.

Replace blown

fuse(s). Check

wiring for the cause

of the blown fuse(s).

Re-check system.

1 Disconnect the wiring harness at the ride height

sensor.

2 Turn the ignition on.

3 Bridge pins 3 and 4 in the ride height sensor

connector X1.

Listen for the compressor motor running, or check for

voltage between pins B and D at the compressor

harness connector X1.

Is the compressor motor running or the voltage as

specified?

Motor running.

12 volts at the

compressor

harness

connector A8,

pins X1-B and

X1-D.

Compressor motor

OK. Refer to

5.4 Ride Height

Sensor Test -

Compressor. Go to Step 5.

5 Check the level ride wiring har ness for continuity.

Is the wiring harness continuity OK?

Continuity.

Replace the

compressor

assembly. Refer to

3.5 Compressor

Assembly in this

Section. Repair or replace

harness.

Rear Suspension 4A1 – 78

4A1-78

5.5 Compressor Assembly Test – Solenoid

Step Action Value(s) Yes No

1 Has a system reset been performed? – Go to Step 2.

Perform ride height

sensor reset, in this

Section.

2 Is fuse F102 OK?

(Located in the engine compar tment fuse and relay

panel assembly).

–

Go to Step 3.

Replace blown fuse.

Check wiring for the

cause of the blown

fuse. Re-check

system.

3 Are fuses F6 and F15 OK?

(Located in the passenger compartment fuse and

relay panel assembly).

–

Go to Step 4.

Replace blown

fuse(s). Check

wiring for the cause

of the blown fuse(s).

Re-check system.

1 Disconnect the wiring harness at the ride height

sensor connector X1.

2 Turn the ignition on.

3 Bridge pin 2 and pin 4 in the ri de height sensor

connector X1.

Listen for a clicking of the solenoid valve and air

escaping from the system, or check for voltage

between pins A and C at the compressor harness

connector.

Are all conditions present or voltage as specified?

Clicking sound

from the

solenoid and

air escaping.

12 volts at the

compressor

harness

connector A8,

pins X1-A and

X1-C.

Compressor motor

OK. Refer to

5.5 Ride Height

Sensor Test –

Solenoid. Go to Step 5.

5 Check the level ride wiring har ness for continuity.

Is the wiring harness continuity OK?

Continuity.

Replace the

compressor

assembly. Refer to

3.5 Compressor

Assembly - Level

Ride Suspension in

this Section. Repair or replace

harness.

Rear Suspension 4A1 – 79

4A1-79

5.6 Ride Height Sensor Test – Compressor

Step Action Value(s) Yes No

1 Has a system reset been performed? – Go to Step 2.

Perform ride height

sensor reset, in this

Section.

1 Disconnect the ride height sensor connecting

link. Refer to 3.8 Ride Height Sensor - Lev el

Ride Suspension in this Section.

2 Turn the ignition on.

3 Raise the ride height sensor arm 45 degrees

and wait 20 seconds.

4 Listen for the compressor motor running, or

check for voltage between pins B and D at the

compressor harness connector.

Does the compressor run or is the voltage as

specified?

Compressor

motor running

12 volts at

compressor

harness

connector A8,

pins X1-B and

X1-D.

Go to Step 3. Go to Step 6.

The compressor motor may be operating but the

compressor may have failed.

Run the motor for 2 minutes and check the shock

absorber air bags are bein g pressurised.

Is air pressure present in the shock absorber air

bags?

– System OK.

Recheck system for

correct operation if

necessary. Go to Step 4.

Check the air compressor filter for blockage.

Is the filter blocked? Filter OK.

Go to Step 5.

Replace filter and

recheck the system,

refer to 4 Service

Maintenance

Operations in this

Section.

Check the air lines for correct fitment, kinks and

damage.

Are all air lines OK? –

Replace the

compressor

assembly and

recheck the system.

Refer to 3.5

Compressor

Assembly in this

Section.

Replace air line and

recheck the system,

refer to 4 Service

Maintenance

Operations in this

Section.

Check ride height sensor wiring harness for continuity.

Is the wiring harness continuity OK? Continuity.

Replace the ride

height sensor

assembly. Refer to

3.8 Ride Height

Sensor in this

Section.

Repair or replace

harness, refer to

12P, Wiring

Diagrams.

Rear Suspension 4A1 – 80

4A1-80

5.7 Ride Height Sensor Test – Solenoid

Step Action Value(s) Yes No

1 Has a system reset been performed? – Go to Step 2.

Perform ride height

sensor reset, in this

Section.

1 Disconnect the ride height sensor connecting

link. Refer to 3.8 Ride Height Sensor in this

Section.

2 Turn the ignition on.

3 Lower the ride height sensor arm 45 de grees

and wait 20 seconds.

4 Listen for clicking of the solenoid valve and air

escaping from the system, or check for voltage

between pins A and C at the compressor

harness connector X1.

Are all conditions present and voltage as specified?

Clicking sound

from the

solenoid and

air escaping.

12 volts at

compressor

harness

connector A8,

pins X1-A and

X1-C.

System OK.

Recheck system for

correct operation if

necessary. Go to Step 3.

3 Check the ride height sensor wiring har ness for

continuity.

Is the wiring harness continuity OK?

Continuity.

Replace the ride

height sensor

assembly. Refer to

3.8 Ride Height

Sensor in this

Section.

Repair or replace

harness, refer to

12P Wiring

Diagrams.

Rear Suspension 4A1 – 81

4A1-81

5.8 Wiring Diagram – Automatic Level Ride

Suspension

Figure 4A1 –121

Rear Suspension 4A1 – 82

4A1-82

5.9 Wiring Harness Layout – Automatic

Level Ride Suspension

Figure 4A1 – 122

Legend

1 Level Ride Compressor Wiring Harness

2 Body Wiring Harness

3 Level Ride Wiring Harness

4 Level Ride Harness to Body Harness Connector

5 Level Ride Harness to Level Ride Sensor Connector

6 Level Ride Harness-to-Compressor Harness

Connector

Rear Suspension 4A1 – 83

4A1-83

6 Specifications

Rear Suspension Service Alignment Data

Suspension

Configuration Rear Track

(mm) Rear Wheel Camber

(Variation Side to Side) Toe – Deg rees per Wheel

(Variation Side to side)

Level 1 with LPG &

FE1 1587 -1°23’ to -0°07’ (0°35’ Maximum)

Level 1 & FE2 1587 -1°41’ to -0°25’ (0°35’ Maximum)

Level 1 & FX3 1587 -1°23’ to -0°07’ (0°35’ Maximum)

Levels 2 to 5 & FE1 1577 -1°23’ to -0°07’ (0°35’ Maximum)

Levels 2 to 5 & FE2 1577 -1°41’ to -0°25’ (0°35’ Maximum)

Levels 2 to 5 & FX3 1577 -1°23’ to -0°07’ (0°35’ Maximum)

+0° 40' to 0° 00' (0° 10' Maximum)

Dimensions shown are for a vehicle at curb height, i.e. vehicle ready to drive with all fluids at the recommended levels, the

fuel tank full and without the driver, passenger/s or luggage.

Refer to 3.12 Rear Wheel Alignment Checkin g in this Section for specific details.

Rear Spring Details

Type Variable rate 'Minibloc'

Identification of the rear spring fitted to a particular ve hicle

can be achieved by cross-referenci ng the two digit code,

which is provided on the production identification tag (1)

with the table below.

Figure 4A1 – 123

Suspension No. of Coils Free Length

(mm) Outside

Diameter (mm) Spring Type and Rate Production

I.D. Code

All with FE1 7.8 284 158 Variable

40 N/mm – 71 N/mm

(5200 ± 180 N @ 156 mm) EV

All with FE2 7.5 250 158 Variable

40 N/mm – 71 N/mm

(5200 ± 180 N @ 156 mm) EM

All with FX3 7.8 284 158 Variable

40 N/mm – 71 N/mm

(5200 ± 180 N @ 156 mm) EY

Rear Suspension 4A1 – 84

4A1-84

Rear Shock Absorber Details

Type

Production Option FE1 (Standard) Twin tube hydraulic

Production Option FE2 (Sports) Twin tube hydraulic, gas pressurise d

Production Option FR1 (Country Pack) Twin tube hydraulic, gas pressurised

Identification of the rear shock absorber fitted to a particular

vehicle can be achieved by cross-referencing the two digit

code which is provided on the production identification tag

(1) with the table below.

The table also provides nominal extended lengths (A).

All with FE1 670 MO

All with FE2 670 HJ

All with FX3 664 ME

Figure 3A – 124

Rear Stabiliser Bar Details

Identification of the rear stabilis er shaft fitted to a particular

vehicle can be achieved by cross-referencing the two digit

code which is provided on the production identification tag

(1) with the table below.

The table also provides stabi liser shaft diameters (2).

All with FE1 13 FL

All with FE2 15 F J

All with FX3 13 FL

Figure 3A – 125

Rear Suspension 4A1 – 85

4A1-85

7 Torque Wrench Specifications

ATTENTION

 Fasteners must be repl aced after loosening.

 Vehicle must be at curb height before final tightening.

 Fasteners either ha ve micro encapsu lated seal ant ap plied o r incorpo rate a mechan ical thread lo ck 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 .

 Additional Control Arm Adjusting Shaft Lock Nut...............................................50 N.m

 Additional Control Arm Ball Joint to Trailing Arm Nut.........................................65 N.m

 Additional Control Arm Inner Shaft to Rear Suspension Crossmember Nut ......65 N.m

 Collar Nut to Outer Rear Wheel Drive Shaft.....................................................300 N.m

Compressor Assembly Mounting Bolts .............................................................5.0 N.m

  Control Arm to Rear Suspension Crossmember Nut .......................................100 N.m

 Crossmember Front Mounting Bolt.........................................................125 N.m, then

turn through 40°

 Crossmember Front Mounting Brace Bolt to Underbody....................................75 N.m

 Crossmember Rear Mount to Final Drive Rear Cover Attaching Bolt ................95 N.m

 Crossmember Rear Mount to Underbody Attaching Bolt ..........................35 N.m, then

turn through 60°

 Drive Shaft Constant Velocity Joint to Rear Wheel Flange Bolt................50 N.m, then

turn through 70°

 Final Drive Assembly to Crossmember Bolt..............................................90 N.m, then

turn through 40°

Intermediate Exhaust Pipe to Catalytic Converter Attaching Bolt .......................45 N.m

Rear Brake Caliper Anchor Plate to Control Arm Bolt........................................85 N.m

Rear Brake Shield to Rear Suspension Control Arm Attachin g Bolt

Upper..............................................75 N.m

 Lower..............................................88 N.m

Rear Crossmember Mass Damper Attaching Bolt .............................................45 N.m

Ride Height Sensor Bracket to Crossmember Bolt ............................................25 N.m

Ride Height Sensor to Bracket Nut ...................................................................5.0 N.m

Road Wheel Attaching Nut.....................................................................110 – 140 N.m

 Shock Absorber Lower Mounting Bolt..............................................................115 N.m

Shock Absorber Upper Mounting Nut.................................................................14 N.m

  Stabiliser Bar Link to Rear Suspension Control Arm Nut.................................100 N.m

Stabiliser Bar Mounting Bracket to Rear Suspension Crossmember Bolt .........22 N.m

Rear Suspension 4A1 – 86

4A1-86

8 Special Tools

Tool Number Illustration Description Classification

AMKM-557

Puller

Used for removing bushing from

crossmember front mounting.

Previously released.

Desirable

AU 385-4

Remover/Installer

Used to remove and install bushin g

into stabiliser bar.

Previously released.

Desirable

AU 416

Torx Bit

Used to remove and install brake

backing plate to rear suspension

control arm attaching bolts.

Previously released.

Unique

AU 534

Torque Limiting Socket

Used in conjunction with an impact

gun to tighten wheel nuts.

Previously released.

Mandatory

AU 592

Bush Remover/Installer

Used to remove and install the rear

crossmember, front bush.

Previously released.

Desirable

C4150-C

Stud Remover

Used to remove the wheel studs from

the rear trunnion.

Previously released.

Unique

E7110

Press Plate

Used for supporting stabiliser bar li nk

while pressing out or installin g

bushing.

Previously released.

Available

Rear Suspension 4A1 – 87

4A1-87

Tool Number Illustration Description Classification

E7115

Angle Wrench

Used to tighten various components

where a turn angle is specifie d in

addition to an initial torque s etting.

Previously released.

Mandatory

E9332-A

Socket Assembly Release Tool

Used to release the additional control

arm socket assembly from the rear

suspension control arm.

Previously released.

Desirable

J22912-01

Press Plates

Used for various press support

operations.

Previously released.

Desirable

KM 307-B

Press Plates

Used to support rear trunnion during

trunnion removal.

Previously released.

Desirable

KM468

Holding Bar

Used to hold outer rear wheel drive

shaft hub from rotating.

Previously released.

Unique

KM508-2

Installing Sleeve

Used to install new bushing in shock

absorber lower mount.

Previously released.

Unique

Rear Suspension 4A1 – 88

4A1-88

Tool Number Illustration Description Classification

KM557-5

Adaptor

Used with puller AMKM-557 for

removing bushing from crossmember

front mounting.

Previously released.

Desirable

KM619

Remover/Installer

Used to press bushing from and into

rear suspension control arms.

Previously released.

Desirable

KM620-7-AUS

Supports

The two revised length supports are

required when undertaking:

Rear wheel drive shaft flange

Rear wheel bearing

Rear outer rear wheel drive shaft

Previously released.

Desirable

KM620-A

Remover/Installer

Used to remove and install rear wheel

drive shaft flange, rear wheel bearing

and outer rear wheel drive shaft.

Previously released.

Unique