Section 3C-2 - Front Suspension (4x2 High Ride

Suspension, 4x4)

Service Precaution

Shock Absorber

Shock Absorber and Associated Parts

Removal

Inspection and Repair

Installation

Stabilizer Bar

Stabilizer Bar and Associated Parts

Removal

Inspection and Repair

Installation

Torsion Bar

Torsion Bar and Associated Parts

Removal

Inspection and Repair

Installation

Knuckle

Knuckle and Associated Parts

Removal

Inspection and Repair

Installation

Upper Control Arm

Upper Control Arm and Associated

Parts

Removal

Inspection and Repair

Installation

Lower Control Arm

Lower Control Arm and Associated

Parts

Removal

Inspection and Repair

Installation

Upper Ball Joint

Upper Ball Joint and Associated Parts

Removal

Inspection and Repair

Installation

Lower Ball Joint

Lower Ball Joint and Associated Parts

Removal

Inspection and Repair

Installation

Bump Rubber

Bump Rubber and Associated Parts

Removal

Inspection and Repair

Installation

Special Tools

Service Precaution

WARNING: THIS VEHICLE HAS A SUPPLEMENTAL

RESTRAINT SYSTEM (SRS). REFER TO THE SRS

COMPONENT AND WIRING LOCATION VIEW IN

ORDER TO DETERMINE WHETHER YOU ARE

PERFORMING SERVICE ON OR NEAR THE SRS

COMPONENTS OR THE SRS WIRING. WHEN YOU

ARE PERFORMING SERVICE ON OR NEAR THE

SRS COMPONENTS OR THE SRS WIRING, REFER

TO THE SRS SERVICE INFORMATION. FAILURE TO

FOLLOW WARNINGS COULD RESULT IN

POSSIBLE AIR BAG DEPLOYMENT, PERSONAL

INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM

REPAIRS.

CAUTION: Always use the correct fastener in the

proper location. When you replace a fastener, use

ONLY the exact part number for that application.

HOLDEN will call out those fasteners that require a

replacement after removal. HOLDEN will also call

out the fasteners that require thread lockers or

thread sealant. UNLESS OTHERWISE SPECIFIED,

do not use supplemental coatings (Paints, greases,

or other corrosion inhibitors) on threaded fasteners

or fastener joint interfaces. Generally, such

coatings adversely affect the fastener torque and

the joint clamping force, and may damage the

fastener. When you install fasteners, use the

correct tightening sequence and specifications.

Following these instructions can help you avoid

damage to parts and systems.

Shock Absorber

Shock Absorber and Associated Parts

RTW340MF000901

Legend

(1) Nut

(2) Rubber Bushing and Washer

(3) Bolt and Nut

(4) Shock Absorber

(5) Rubber Bushing and Washer

Removal

1. Raise the vehicle and support it with suitable

safety stands.

2. Remove wheel and tire assembly. Refer to Wheel

Replacement in this section.

3. Remove bolt and nut.

4. Remove nut.

5. Remove rubber bushing and washer.

6. Remove shock absorber.

7. Remove rubber bushing and washer.

Inspection and Repair

Make necessary correction or parts replacement if

wear, damage, corrosion or any other abnormal

conditions are found through inspection.

Check the following parts :

• Shock absorber

• Rubber bushing

Installation

1. Install rubber bushing and washer.

2. Install shock absorber.

3. Install rubber bushing and washer.

4. Install nut (1), then tighten it to the specified

torque.

Torque: 20 N⋅m (2.0kg⋅m/14 lb ft)

5. Install bolt and nut (3), then tighten to the specified

torque.

Torque: 93 N⋅m (9.5kg⋅m/69 lb ft)

Stabilizer Bar

Stabilizer Bar and Associated Parts

RTW340MF000401

Legend

(1) Rubber Bushing

(2) Bracket and Bolt

(3) Link

(4) Nut

(5) Stabilizer Bar

(6) Nut

Removal

1. Raise the vehicle and support the frame with

suitable safety stands.

2. Remove the stone guard.

3. Remove wheel and tire assembly. Refer to Wheel

Replacement in this section.

4. Remove nut (4) and (6).

CAUTION: Be careful not to break the ball joint

boot.

5. Remove link.

6. Remove bracket.

7. Remove stabilizer bar.

8. Remove rubber bushing.

Inspection and Repair

Make necessary correction or parts replacement if

wear, damage, corrosion or any other abnormal

conditions are found through inspection.

Check the following parts :

• Stabilizer bar

• Rubber bushing

• Link ball joint

Installation

1. Install rubber bushing.

2. Install stabilizer bar.

3. Install bracket and bolt (2), then tighten it to the

specified torque.

Torque: 25 N⋅m (2.5kg⋅m/18 lb ft)

4. Install link.

5. Install nut (4), (6), then tighten it to the specified

torque.

Torque: 50 N⋅m (5.1kg⋅m/37 lb ft)

Torsion Bar

Torsion Bar and Associated Parts

RTW340MF000501

Legend

(1) Adjust Bolt, End Piece and Seat

(2) Height Control Arm

(3) Torsion Bar

Removal

1. Raise the vehicle and support the frame with

suitable safety stands.

2. Apply the setting marks (1) to the adjust bolt and

end piece, then remove adjust bolt, end piece and

seat.

410RS004

pply the setting marks (2) to the height control

arm and torsion bar, then remove height control

arm.

NOTE: “Besco chassis grease” shall be applied on

contact area of height control arm with frame.

(RH & LH Both side)

410RS005

4. Apply the setting marks (3) to the torsion bar and

lower control arm, then remove torsion bar.

RTW340SH000301

Inspection and Repair

Make necessary correction or parts replacement if

wear, damage, corrosion or any other abnormal

conditions are found through inspection.

Check the following parts:

• Torsion bar

• Height control arm

• Adjust bolt

• Rubber seat

Installation

pply grease to the serrated portions, then install

torsion bar. Make sure the bars are on thei

correct respective sides and align the setting

marks (3).

410RS007

RTW340SH000301

2. Apply grease to the portion that fits into the

bracket then install height control arm and align

the setting marks (2).

410RS005

3. Apply grease to the bolt portion of the end piece

(4). Apply grease to the portion of the seat (5) that

fits into the bracket.

410RS008

4. Apply grease to the serrated portions.

5. Install adjust bolt and seat, then turn adjust bolt to

the setting mark (1) applied during disassembly.

NOTE: Adjust the trim height. Refer to Front End

Alignment Inspection and Adjustment in Steering

section.

410RS004

Knuckle

Knuckle and Associated Parts

RTW340LF001301

Legend

(1) Torsion Bar

(2 )Lower Ball Joint, Nut and Cotter Pin

(3) Back Plate

(4) Knuckle Assembly

(5) Knuckle

(6) Needle Bearing (4×4 Model Only)

(7) Thrust Washer (4×4 Model Only)

(8) Oil Seal (4×4 Model Only)

(9) Upper Ball Joint, Nut and Cotter Pin

(10) Speed Sensor harness

Removal

1. Raise the vehicle and support the frame with

suitable safety stands.

2. Remove wheel and tire assembly. Refer to Wheel

in this section.

3. Remove the brake caliper. Refer to Disc Brakes

in Brake section.

4. Remove the hub assembly. Refer to Front Hub

and Disc in this section.

5. Remove tie-rod end from the knuckle. Refer to

Power Steering Unit in Steering section.

6. Remove the speed sensor from the knuckle.

7. Loosen torsion bar, by removing height control

arm adjust bolt, then remove torsion bar. Refer to

Torsion Bar in this section.

8. Remove speed sensor harness.

9. Remove back plate.

10. Remove lower ball joint by using remover 5-8840-

2005-0.

CAUTION: Be careful not to damage the ball joint

boot.

901RW271

11. Remove upper ball joint by using remover 5-8840-

2121-0.

CAUTION: Be careful not to damage the ball joint

boot.

901RW272

12. Remove knuckle assembly.

13. Remove oil seal. If replacement required.

(4×4 Model Only)

14. Remove thrust washer. If replacement required.

(4×4 Model Only)

15. Remove needle bearing by using remover 5-8840-

2000-0 and sliding hammer 5-8840-0019-0.

If replacement required. (4×4 Model Only)

(4×4 Model Only)

RTW340SH00401

Inspection and Repair

Make necessary correction or parts replacement if

wear, damage, corrosion or any other abnormal

conditions are found through inspection.

Check the following parts:

• Knuckle

• Knuckle arm

• Thrust washer (4×4 Model Only)

Installation

pply appropriate amount of multipurpose type

grease to the new bearing (Approx. 5 g) and

install needle bearing by using installer 5-8840-

2128-0 and grip 5-8840-0007-0. (4×4 Model Only)

(4×4 Model Only)

901RW275

pply multipurpose type grease to the thrust

washer, and install washer with chamfered side

facing knuckle. (4×4 Model Only)

3. Use a new oil seal, and apply multipurpose type

grease to the area surrounded by the lip (approx.

2 g). Then use installer 5-8840-2127-0 and grip 5-

8840-0007-0 to install oil seal. After fitting the oil

seal to the installer, drive it to the knuckle using a

hammer or bench press until the tool front face

contacts with the thrust washer. (4×4 Model Only)

(4×4 Model Only)

901RW274

4. Install knuckle assembly.

5. Install upper ball joint and tighten the nut to the

specified torque, with just enough additional

torque to align cotter pin holes. Install new cotte

pin (9).

Torque: 98 N⋅m (10.0kg⋅m/72 lb ft)

6. Install lower ball joint and tighten the nut to the

specified torque, with just enough additional

torque to align cotter pin holes. Install new cotte

pin (2).

Torque: 147 N⋅m (15.0kg⋅m/108 lb ft)

7. Install back plate.

8. Install speed sensor harness.

9. Install torsion bar. Refer to Torsion Bar in this

section.

NOTE: Adjust the trim height. Refer to Front End

Alignment Inspection and Adjustment in Steering.

Upper Control Arm

Upper Control Arm and Associated Parts

RTW440LF001301

Legend

(1)Bolt and Plate

(2)Camber Shims

(3)Caster Shims

(4)Nut Assembly

(5)Upper Control Arm Assembly

(6)Fulcrum Pin

(7)Bushing

(8)Plate

(9)Nut

(10)Speed Sensor harness

(11)Nut and Cotter Pin

(12)Upper Ball Joint, Bolt and Nut

Removal

1. Raise the vehicle and support the frame with

suitable safety stands.

2. Remove wheel and tire assembly. Refer to Wheel

in this section.

3. Remove the brake caliper and disconnect brake

pipe. Refer to Disc Brakes in Brake section.

4. Support lower control arm with a harness.

5. Remove speed sensor harness.

6. Remove nut and cotter pin then remove knuckle

using remover 5-8840-2121-0.

CAUTION: Be careful not to damage the ball joint

boot.

RTW340SH000401

7. Remove upper ball joint.

8. Remove bolt and plate.

9. Remove nut assembly.

10. Remove camber shims and note the positions and

number of shims.

11. Remove caster shims and note the positions and

number of shims.

12. Remove upper control arm assembly.

13. Remove nut (9).

14. Remove plate (8).

15. Remove bushing (7) by using remover 5-8840-

0256-0.

RTW340SH000501

RTW340SH000601

16. Remove fulcrum pin (6).

Inspection and Repair

Make necessary parts replacement if wear, damage,

corrosion or any other abnormal conditions are found

through inspection.

Check the following parts:

• Upper control arm

• Bushing

• Fulcrum pin

Installation

1. Install fulcrum pin.

2. Install bushing by using installer 5-8840-0256-0

and 5-8840-2307-0.

RTW340SH000701

RTW340SH000801

3. Install upper ball joint and tighten it to the specified

torque (12).

Torque: 57 N⋅m (5.8kg⋅m/42 lb ft)

4. Install nut and cotter pin then tighten the nut to the

specified torque, with just enough additional

torque to align cotter pin holes. Install new cotte

pin (11).

Torque: 98 N⋅m (10.0kg⋅m/72 lb ft)

5. Install plate (8).

6. Install nut (9) and tighten fulcrum pin nut finger-

tight.

NOTE: Apply oil to the thread.

NOTE: Tighten the nut with the parts in the position

shown in the illustration below.

Buffer clearance: 29.7 mm (1.17 in)

Torque: 108 N⋅m (11.0kg⋅m/80 lb ft)

450R100002

7. Install upper control arm assembly with the

fulcrum pin projections turned inward.

RTW340SH000901

Legend

(1) Projection

(2) Outward

8. Install the caster shims (2) between the chassis

frame and fulcrum pin.

9. Install the camber shims (1) between the chassis

frame and fulcrum pin.

450R100004

10. Install nut assembly.

11. Install bolt and plate (1), then tighten the bolt to

the specified torque.

Torque: 152 N⋅m (15.5kg⋅m/112 lb ft)

NOTE: Apply oil to the thread.

12. Install speed sensor harness.

Lower Control Arm

Lower Control Arm and Associated Parts

RTW33CLF000201

Legend

(1) Cam Bolt

(2)Bush, Front

(3) Cam Plate and Nut

(4) Nut, Rear

(5) Bush, Rear

(6) Bolt, Rear

(7) Bolt, Lower Ball Joint

(8) Bolt, Torsion Bar Arm

(9) Torsion Bar Arm Bracket and Nut

(10) Torsion Bar

(11) Lower Control Arm

(12) Lower Ball Joint and Nut

(13) Shock Absorber, Bolt and Nut

(14) Stabilizer Link and Nut

Removal

1. Raise the vehicle and support the frame with

suitable safety stands.

2. Remove wheel and tire assembly. Refer to Wheel

in this section.

3. Remove the tie-rod end from the knuckle. Refer to

Power Steering Unit in Steering section.

4. Remove the retaining ring from the front axle drive

shaft to release the shaft from hub. Refer to

Front Hub and Disc in Driveline/Axle section.

5. Support lower control arm with a jack.

6. Remove cam plate and nut.

7. Remove rear nut.

8. Remove torsion bar, refer to Torsion Bar in this

section.

9. Remove torsion bar arm bracket.

10. Disconnect the stabilizer link at the lower control

arm.

11. Remove the shock absorber lower end from the

lower control arm.

12. Remove the lower ball joint from the lower control

arm.

13. Remove cam bolt.

14. Remove rear bolt.

15. Remove lower control arm.

16. Remove torsion bar arm bolt.

17. Remove lower ball joint bolt.

18. Remove front bushing by using remover 5-8840-

2123-0.

Front

901RW154

Front

901RW155

19. Remove rear bushing by using remover 5-8840-

2124-0.

Front

901RW051

Front

901RW052

Inspection and Repair

Make necessary correction or parts replacement if

wear, damage, corrosion or any other abnormal

conditions are found through inspection.

Check the following parts:

• Lower control arm

• Bushing

Installation

1. Install rear bushing by using installer 5-8840-

2124-0.

Front

901RW053

2. Install front bushing by using installer 5-8840-

2123-0.

Front

901RW156

3. Install lower ball joint bolt.

4. Install torsion bar arm bolt.

5. Install lower control arm.

6. Install rear bolt.

7. Install cam bolt the hole and projection are

upward.

8. Install lower ball joint and tighten it to the specified

torque (12).

Torque: 127 N⋅m (12.9kg⋅m/94 lb ft)

9. Install shock absorber and tighten it to the

specified torque (13).

Torque: 93 N⋅m (9.5kg⋅m/69 lb ft)

10. Install stabilizer link and tighten it to the specified

torque (14).

Torque: 50 N⋅m (5.1kg⋅m/37 lb ft)

11. Install torsion bar arm bracket and tighten it to the

specified torque.

Torque: 116 N⋅m (11.8kg⋅m/85 lb ft)

12. Install Torsion bar, refer to Torsion Bar in this

section.

13. Install rear nut and tighten lower link nut finger-

tight (4).

NOTE: Apply oil to the thread.

NOTE: Tighten the nut or bolt with the parts in the

position shown in the illustration below.

Buffer clearance: 29.7 mm (1.17 in)

Torque: 235 N⋅m (24.0kg⋅m/174 lb ft)

450R100002

14. Install cam plate and nut then tighten lower link

nut finger-tight.

NOTE: Apply oil to the thread.

NOTE: Tighten the nut (3) or bolt with the parts in the

position shown in the illustration below.

Buffer clearance: 29.7 mm (1.17 in)

Torque: 186 N⋅m (19.0kg⋅m/137 lb ft)

NOTE: Adjust the trim height. Refer to Front End

Alignment Inspection and Adjustment in Steering

section.

450R100002

Upper Ball Joint

Upper Ball Joint and Associated Parts

RTW440LF001401

Legend

(1) Bolt and Nut

(2) Upper Ball Joint

(3) Nut and Cotter Pin

Removal

1. Raise the vehicle and support the frame with

suitable safety stands.

2. Remove the speed sensor from the knuckle.

3. Remove upper ball joint nut and cotter pin, then

use remover 5-8840-2121-0 to remove the uppe

ball joint from the knuckle.

CAUTION: Be careful not to damage the ball joint

boot.

RTW340SH000401

4. Remove bolt and nut.

5. Remove upper ball joint.

Inspection and Repair

Make necessary parts replacement if wear, damage,

corrosion or any other abnormal conditions are found

through inspection.

• Inspect the lower end boot for damage or grease

leak. Move the ball joint as shown in the figure to

confirm its normal movement.

• Inspect screw/taper area of ball for damage.

• If any defects are found by the above inspections,

replace the ball joint assembly with new one.

450RS023

• After moving the ball joint 4 or 5 times, attach nut

then measure the preload.

Starting torque: 1.3–3.2 N⋅m (0.13-0.33kg⋅m/0.9-

2.4 lb ft)

450RS024

If the above limits specified are exceeded, replace the

ball joint assembly.

Installation

1. Install upper ball joint.

2. Install bolt and nut (1), then tighten them to the

specified torque.

Torque: 57 N⋅m (5.8kg⋅m/42 lb ft)

3. Install nut and cotter pin, then tighten the nut to

the specified torque with just enough additional

torque to align cotter pin holes. Install new cotte

pin (3).

Torque: 98 N⋅m (10.0kg⋅m/72 lb ft)

Lower Ball Joint

Lower Ball Joint and Associated Parts

RTW340LF001601

Legend

(1) Bolt

(2) Lower Ball Joint

(3) Nut

(4) Nut and Cotter Pin

Removal

1. Raise the vehicle and support the frame with

suitable safety stands.

2. Remove wheel and tire assembly. Refer to Wheel

in this section.

3. Remove the tie-rod end from the knuckle. Refer to

Power Steering Unit in Steering section.

4. Remove the retaining ring from the front axle drive

shaft to release the shaft from hub. Refer to

Front Hub and Disc in Driveline/Axle section.

5. Support lower control arm with a jack.

6. Remove lower ball joint nut and cotter pin, then

use remover 5-8840-2005-0 to remove the lowe

ball joint from the knuckle.

CAUTION: Be careful not to damage the ball joint

boot.

901RW271

7. Remove nut.

8. Remove bolt.

9. Remove lower ball joint.

Inspection and Repair

Make necessary parts replacement if wear, damage,

corrosion or any other abnormal conditions are found

through inspection.

• Inspect the lower end boot for damage or grease

leak. Move the ball joint as shown in the figure to

confirm its normal movement .

• Inspect screw/taper area of ball for damage.

• If any defects are found by the above inspections,

replace the ball joint assembly with new one.

450RS026

•

fter moving the ball joint 4 or 5 times, attach nut

then measure the preload.

Starting torque: 2.5-6.4 N⋅m (0.25-0.65kg⋅m/1.8-

4.7 lb ft)

450RS024

• If the above limits specified are exceeded, replace

the ball joint assembly.

Installation

1. Install lower ball joint.

2. Install bolt.

3. Install nut (3) and tighten it to the specified torque.

Torque: 127 N⋅m (12.9kg⋅m/94 lb ft)

4. Install ball joint nut, then tighten it to the specified

torque with just enough additional torque to align

cotter pin holes. Install new cotter pin (4).

Torque: 147 N⋅m (15.0kg⋅m/108 lb ft)

Bump Rubber

Bump Rubber and Associated Parts

RTW340MF001001

Legend

(1) Bolt

(2) Bump Rubber

Removal

1. Raise the vehicle and support the frame with

suitable safety stands.

2. Remove bolt.

3. Remove bump rubber.

Inspection and Repair

Make necessary correction or parts replacement if

wear, damage, corrosion or any other abnormal

condition are found through inspection.

Check the following parts :

• Bump Rubber

Installation

1. Install bump rubber.

NOTE: Arrow points to be vehicle outer side of after

assembly to vehicle.

2. Install bolt (1), then tighten it to the specified

torque.

Torque: 42 N⋅m (4.3kg⋅m/31 lb ft)

Special Tools (4×2 High Ride Suspension, 4×4)

ILLUSTRATION PART NO.

PART NAME ILLUSTRATION PART NO.

PART NAME

5-8840-2000-0

(J-23907)

Remover; Needle bearing

5-8840-0019-0

Sliding hammer

5-8840-2123-0

(J-36833)

Remover and Installer kit;

Lower arm front bushing

5-8840-2128-0

(J-36838)

Installer; Needle bearing

5-8840-2124-0

(J-36834)

Remover and Installer kit;

Lower arm rear bushing

5-8840-0007-0

(J-8092)

Grip

5-8840-2121-0

(J-36831)

Ball joint remover

5-8840-2127-0

(J-36837)

Installer; Oil seal

5-8840-2005-0

(J-29107)

Tie-rod end remover

5-8840-2307-0

(J-39376)

Installer; Upper arm

bushing

5-8840-0256-0

(J-29775)

Remover and Installer

Upper arm bushing