Spring, Front - visualbits.net Stuff/Ford Ranger 1993-1999/04 - SUSPENSION… · Spring, Front...

REMOVAL AND INSTALLATION

Spring, Front

Removal

1. NOTE: Any time the steering linkage is disconnected from the steering knuckle, the steering system must be placed in the "on-center" position.

Place the steering wheel and steering system in the "on-center" position.

2. Raise vehicle on a hoist. Remove wheel and tire assembly.

3. Disconnect stabilizer bar link nut from front suspension lower arm (3078).

4. Remove the front shock absorber as described in Removal and Installation, Shock Absorber, Front in this section.

Front Suspension, Aerostar E-4WD

Section 04-01C: Suspension and Wheel Hubs, Front, Aerostar E-4WD

1997 Aerostar E-4WD Vehicles Workshop Manual

SPECIAL SERVICE TOOL(S) REQUIRED

Description Tool Number

Pitman Arm Puller T64P-3590-F

Coil Spring Compressor D78P-5310-A

of 121997 Aerostar/Ranger

2011-04-27file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK41C03.HTM~gen~ref.HTM

Item Part Number Description

1 3083 Front Suspension Upper Arm

2 18198 Insulator

3 N805348-S56 Nut and Washer Assembly

4 N605905-S101 Bolt, M8-1.25 x 20

5 N800237-S101 Nut, M16-2.0

6 4A462 Shaft Assembly

7 N804806-S160 Bolt, M10-1.5 x 55



8 N801206-S2 Nut, M10-1.5

9 3B305 Steering Knuckle Assembly (RH)

10 3B306 Steering Knuckle Assembly (LH)

11 N801338-S101 Washer, M20-40 x 5.13

12 N804199-S191 Nut, M20-1.25

13 N642567-S36 Cotter Pin, 3.2 x 25

14 390924-S36 Nut, 9/16-18

15 N800895-S56 Nut, M14-1.5

16 5415 Upper Insulator

17 3A130 Tie Rod End

18 N803637 Nut, M14-1.5

19 5414 Lower Insulator

20 3078 Front Suspension Lower Arm (RH)

21 3079 Front Suspension Lower Arm (LH)

22 18045 Front Shock Absorber

23 N620481-S2 Nut, M8-1.25

24 5C491 Nut (Part of Stabilizer Bar Bushing Repair Kit)

25 N803702-S Stabilizer Bar Bushing

26 5310 Front Coil Spring

27 N805537-S100 Bolt and Retainer, M16-2.0 x 117.5

28 3020 Front Suspension Bumper

29 5K483 Front Stabilizer Bar Link

30 5482 Front Stabilizer Bar

31 5484 Stabilizer Bar Insulator

32 N806497-S2 Bolt, M8-1.25 x 25.7

33 5486 Stabilizer Bar Bracket

34 3C156 Damper (RH)

35 3C157 Damper (LH)

36 N605905-S101 Bolt, M8-1.25 x 20

37 3C162 Clamp, Damper (RH)

38 3C163 Clamp, Damper (LH)

A — Tighten to 34-47 Nm (25-35 Lb-Ft)

B — Tighten to 17-23 Nm (13-17 Lb-Ft)

C — Tighten to 136-190 Nm (100-140 Lb-Ft)

D — Tighten to 37-50 Nm (27-37 Lb-Ft)

E — Tighten to 230-285 Nm(170-210 Lb-Ft)



5. If the vehicle is on a twin-post hoist, support the vehicle with safety stands under the jacking pads and lower the hoist but maintain working room.

6. Using Coil Spring Compressor D78P-5310-A, install one plate with the pivot ball seat facing downward into spring coils. Rotate the plate until flush with the upper surface of the front suspension lower arm.

7. Install the other plate with the pivot ball seat facing upward into spring coils.

8. Insert the upper ball nut through the spring coil so nut rests in the upper plate.

9. Insert the compression rod into front suspension lower arm opening, through the upper and lower plate and upper ball nut.

10. Insert the securing pin through the upper ball nut and compression rod.

� This pin can only be inserted one way into the upper ball nut because of a stepped hole design.

11. With the upper ball nut secured, turn the upper plate to walk up the coil until it contacts the upper spring seat; then, back off one-half turn.

F — Tighten to 80-110 Nm (59-81 Lb-Ft)

G — Tighten to 70-100 Nm (52-74 Lb-Ft)

H — Tighten to 61-88 Nm (45-65 Lb-Ft)

J — Tighten to 22-33 Nm (16-24 Lb-Ft)

K — Tighten to 8-12 Nm (71-107 Lb-In)

L — Tighten to 30-39 Nm (22-29 Lb-Ft)




1 — Compression Rod (Part of D78P-5310-A)

2 — Forcing Nut (Part of D78P-5310-A)

3 — Thrust Washer (Part of D78P-5310-A)

4 — Lower Ball Nut (Part of D78P-5310-A)

5 — Lower Plate (Part of D78P-5310-A)

6 — Upper Plate (Part of D78P-5310-A)

7 — Pin (Part of D78P-5310-A)

8 — Upper Ball Nut (Part of D78P-5310-A)



12. NOTE: 4x2 shown in illustrations; E-4WD similar.

Install lower ball nut and thrust washer to compression rod and screw on forcing nut.



13. NOTE: 4x2 shown in illustration; E-4WD similar.

Tighten the forcing nut until the front coil spring (5310) is compressed enough to move in seat.



14. Loosen the two lower arm pivot bolts. Remove the cotter pin and loosen but do not remove the nut attaching the front suspension lower arm ball joint (3050) to the knuckle.

15. Using Pitman Arm Puller T64P-3590-F loosen the front suspension lower arm ball joint.

16. Remove the puller tool. Support the front suspension lower arm with a jack and remove the ball joint nut.

17. NOTE: 4x2 shown in illustration; E-4WD must be pressed from bottom.

Separate the knuckle from the front suspension lower arm ball joint, lower the control arm and remove the front coil spring.



18. If a new front coil spring is installed:

a. Mark position of upper and lower plates on the spring with chalk. b. Measure the compressed length of the old front coil spring.

19. Loosen the forcing nut to relieve spring tension. Remove the tools from the front coil spring.



Installation

1. Assemble Coil Spring Compressor D78P-5310-A, and locate in the same positions indicated in Removal, Step 18a.

2. Before compressing the front coil spring, make sure upper ball nut securing pin is inserted properly.

3. Compress front coil spring until spring height reaches the dimension obtained in Removal, Step 18b.

4. Position the front coil spring assembly into the front suspension lower arm.

5. Verify the front coil spring is properly indexed in the front suspension lower arm.

6. To install front coil spring, reverse removal procedures.

7. NOTE: Vehicle must be in the normal ride position.

NOTE: 4x2 shown in illustration; E-4WD similar.

Tighten front suspension lower arm to No. 1 crossmember retaining nuts to 136-190 Nm (100-140 lb-ft).




Knuckle, Front Wheel

Removal

1. Put steering gear in "on-center" position.

2. Put transmission in PARK and set hand brake.

3. Remove wheelcover.

4. Raise vehicle on hoist.

5. Remove wheel and tire.

6. Remove hub nut and washer.

7. Remove spring tension from upper and lower control arms. Compress spring using spring compressor tool until all spring tension is removed from control arms.

8. Remove brake rotor and disc brake caliper (2B120) as described in Section 06-03 . Do not let disc brake caliper hang by hose.

9. Remove cotter pin and tie rod nut. Using Pitman Arm Puller T64P-3590-F, disconnect tie rod end (3A130) from steering knuckle.



SPECIAL SERVICE TOOL(S) REQUIRED

Description Tool Number

Pitman Arm Puller T64P-3590-F

Front Hub Replacer T81P-1104-A

Hub Remover Adapters Front Hub Bearing Service Set

T81P-1104-B, T86P-1104-A1

Front Hub Remover/Replacer T81P-1104-C

Page 1 of 41997 Aerostar/Ranger


10. NOTE: Make sure adapters are fully threaded onto the hub studs and positioned opposite the other adapter.

Install Front Hub Remover/Replacer T81P-1104-C with Front Hub Replacer T81P-1104-A, Hub Remover Adapters T81P-1104-B and Front Hub Bearing Service Set T86P-1104-A1.

11. Free the hub, bearing, and knuckle assembly from the halfshaft by pushing in the CV joint outer shaft until it is loose from the assembly.

CV Joint-to-Hub Removal


1 3A130 Tie Rod End

2 T64P-3590-F Pitman Arm Puller

3 3078 Front Suspension Lower Arm

4 5482 Front Stabilizer Bar

5 5019 Front Crossmember



12. Remove retaining nut and bolt and push up on front suspension upper arm (3083) until ball joint stud is out of knuckle.

13. Remove cotter pin and nut from front suspension lower arm ball joint (3050), using Pitman Arm Puller T64P-3590-F.

14. Remove ball joint stud from knuckle.

15. Remove knuckle from vehicle.

Installation

1. Put knuckle assembly onto lower and upper ball joint studs. Install nut and bolt clamping upper ball joint stud into knuckle and tighten to 37-50 Nm (27-37 lb-ft).

2. Install lower ball joint nut and tighten to 80-110 Nm (59-81 lb-ft). If necessary, advance nut to next slot. Install cotter pin.

3. Put CV joint shaft into hub and install washer and nut finger-tight.

4. Install tie rod end and nut. Tighten nut to 70-100 Nm (52-74 lb-ft). If necessary advance nut to next slot. Install cotter pin.

5. Install disc brake caliper and front disc brake hub and rotor (1102) ; refer to Section 06-03 .



6. Install wheel and tire assembly.

7. Remove spring compressor.

8. Tighten hub nut to 230-285 Nm (170-210 lb-ft).

9. Check alignment; refer to Section 04-00 .

10. Install wheelcover and lower the vehicle.




Shock Absorber, Front

WARNING: THE LOW-PRESSURE GAS SHOCK ABSORBERS ARE CHARGED WITH NITROGEN GAS TO 930 KPA (135 PSI). DO NOT ATTEMPT TO OPEN, PUNCTURE OR APPLY HEAT TO THE SHOCK ABSORBERS.






1 N805348 Nut

2 18198 Insulator

3 3B305 Steering Knuckle Assembly (RH)

4 3B306 Steering Knuckle Assembly (LH)

5 N605905-S2 Shock Absorber Lower Mounting Studs

6 — Front Shock Absorber



Removal and Installation

1. Remove the nut and washer assembly retaining the front shock absorber to the coil spring upper bracket.

2. Remove the two nuts retaining the front shock absorber to the bottom of the front suspension lower arm (3079).

3. Remove the front shock absorber through the front suspension lower arm.

4. Inspect the insulator in the coil spring upper bracket. If required, remove and replace the insulator.

For installation, follow removal procedures in reverse order. Tighten shock absorber-to-lower control arm nuts to 22-33 Nm (16-24 lb-ft). Tighten shock absorber-to-upper spring bracket nut to 34-47 Nm (25-35 lb-ft).

7 3078 Front Suspension Lower Arm

8 N620481 Nut






Ball Joint and Arm Assembly, Upper

Removal

WARNING: WHEN SERVICING ANY COMPONENT IN THE UPPER CONTROL ARM AND BALL JOINT SYSTEM, ONLY ONE SIDE OF THE VEHICLE IS SERVICED AT A TIME. NEVER SERVICE BOTH SIDES AT THE SAME TIME.

1. NOTE: Any time the steering linkage is disconnected from the steering knuckle, the steering system must be placed in the "on-center" position.


2. Raise the vehicle on a frame hoist. Place safety stands under the lower control arm. Slowly lower the hoist to maintain coil spring compression.

Front Drive Axle Crossmember and Control Arm Mounting






1 38380 Bolt Bracket Retainer, If Equipped

2 N611175 Screw

3 — Shim (Part of 3393)

4 3B204 Mounting Plate

5 — Mounting Brackets (Part of 3393)

6 N804431 Nut

7 3C137 Front Drive Axle Crossmember Assembly


9 N804618 Bolt

10 N804386 Bolt

11 N611194-S Screw



C — Tighten to 47-64 Nm



3. Remove upper ball joint-to-knuckle bolt and nut. Disengage upper ball joint from knuckle.

4. Remove the bolt retainer plate screw. Remove plate.

5. Mark the position of the control arm mounting brackets on the flat plate.

6. Remove the front bolt and washer retaining the front mounting bracket to the mounting plate.

7. From beneath the rail, remove the three nuts from bolts retaining two front suspension upper arm mounting brackets to the body rail.

8. Remove the three long bolts retaining the mounting brackets to the body rail by rotating the front suspension upper arm (3083) out of position.

9. Remove the front suspension upper arm, mounting bracket assembly and mounting plate from the vehicle.

10. If required, remove and replace the upper ball joint boot seal.

Note the exact position and number of shims on each control arm stud. These shims control caster and camber.

11. NOTE: The pivot shaft and mounting brackets are serviced as an assembly. The front suspension upper arm and front suspension upper ball joint (3049) are serviced as an assembly.

To service front suspension upper arm and front suspension upper ball joint assembly or the mounting brackets and adjusting arm assembly, remove the nuts retaining the front suspension upper arm to the adjusting arm.

12. Remove the front suspension upper arm from the adjusting arm.

Control Arm Damper

(35-47 Lb-Ft)



13. If required, remove the damper assembly from the front suspension upper arm by removing the three retaining bolts.


1 3043 Alignment Shims

2 3C156 Damper Assembly (RH)

3 3C157 Damper Assembly (LH)


5 3049 Front Suspension Upper Ball Joint

6 — Rear Mounting Bracket (Part of 3393)

7 — Front Mounting Bracket (Part of 3393)



Installation

1. If removed, install the front suspension upper arm and ball joint in the pivot shaft.

2. Install the shims on the control arm studs with the same number of shims in the exact position as marked during removal.

3. Install and tighten the nuts retaining the upper arm and ball joint plus the shims to the front suspension upper arm.

4. If removed, install the boot seal on the upper and/or lower ball joint and lubricate ball joint.

5. If removed, install the damper assembly to front suspension upper arm. Tighten damper retaining bolts to 30-39 Nm (22-29 lb-ft).

6. Place the flat plate for the mounting brackets in position on the body rail. Install screw and tighten to 14-19 Nm (10-14 lb-ft).

7. Place the mounting brackets and front suspension upper arm assembly in position on the flat plate.

8. Install the three long bolts and washers retaining the mounting brackets to the body rail.

9. Rotate or rock the front suspension upper arm and mounting bracket until the bolt heads rest against



the mounting bracket and the studs extend through the body rail.

10. NOTE: Make sure the mounting brackets do not move from the marked positions on the flat plate. This minimizes corrections.

Move mounting brackets into position marked on mounting plate during removal.

11. CAUTION: The torque required for the mounting bracket-to-body rail nuts and bolts is critical. They must be tightened to the specified torque.

If present, place the bolt retainer plate in position on the mounting bracket and flat plate assembly. Install and tighten the screw to 14-19 Nm (10-14 lb-ft).

12. Install and tighten the nuts retaining the mounting bracket bolts to the body rail to 196-264 Nm (145-195 lb-ft).

13. Install and tighten the front bolt retaining the front mounting bracket to the mounting plate, 47-64 Nm (35-47 lb-ft).

14. Connect the front suspension upper ball joint to steering knuckle. Install the bolt and nut and tighten to 37-50 Nm (27-37 lb-ft).

15. Check and if required, adjust caster, camber and toe-in as described in Section 04-00 . Use service adjustment shims as required for caster and camber revisions.




Arm, Lower

Removal

1. NOTE: Any time the steering linkage is disconnected from the steering knuckle the steering system must be placed in the "on-center" position.


2. WARNING: MAKE SURE THE VEHICLE IS SECURELY SUPPORTED ON THE SAFETY STANDS.

Raise the vehicle on a twin post hoist. Place safety stands under the frame to support the vehicle. During service procedures, the front post hoist is lowered to remove coil spring.

3. Remove the coil spring as described in Removal and Installation, Spring, Front this section.

4. NOTE: Prior to removing the front suspension lower arm, the front post of the hoist should be rotated to support the vehicle under the No. 1 crossmember.

Remove the bolts and nuts retaining the front suspension lower arm to the No. 1 crossmember. Remove the front suspension lower arm.

5. Replace entire front suspension lower arm assembly to service bushings.

Installation

1. Position the front suspension lower arm in No. 1 crossmember.

2. Install but do not tighten the bolts in the direction shown in Views A and B in the illustration labeled Front Suspension, Aerostar E-4WD in the Removal and Installation portion of this section.

3. Inspect the lower ball joint boot seal for damage and replace if required.

4. Install the coil spring as described in this section.

5. With the vehicle in the normal ride position, tighten the front suspension lower arm-to-No. 1 crossmember retaining nuts to 136-190 Nm (100-140 lb-ft).

6. Remove safety stands and lower vehicle.






Bumper, Front

Removal and Installation

1. Remove the bolt retaining the front suspension bumper (3020) to the No. 1 crossmember. Remove the front suspension bumper.

2. Place the front suspension bumper in position on the crossmember. Install the bolt and tighten to 17-23 Nm (13-17 lb-ft).





SPECIFICATIONS

SPECIFICATIONS

FRONT SUSPENSION, AEROSTAR E-4WD



TORQUE SPECIFICATIONS

Description Nm Lb-Ft Lb-In

Crossmember to Frame Rail Bolts (M16 Bolts Through Front and Rear Upper Control Arm Mounts)

196-264

145-195

—

Front Mounting Bracket Bolt (M10 Bolts Through Front Upper Control Arm Front Mount Only)

47-64 35-47 —

Bolt Retainer Bracket to Frame Screw 14-19 10-14 —

Front Suspension Bumper to Frame Bolt 17-23 13-17 —

Lower Control Arm to No. 1 Crossmember Nut and Bolt. Tighten to the Specified Torque with the Vehicle in the Normal Ride Position with All Other Fasteners Tightened to Specifications.

136-190

100-140

—

Shock Absorber to Lower Control Arm Nuts 22-33 16-24 —

Shock Absorber to Upper Spring Bracket Nut 34-47 25-35 —

Knuckle to Lower Ball Joint Nut. Tighten to Specifications and If Required, Advance the Nut to the Castellation to Install the Cotter Pin.

80-110

59-81 —

Knuckle to Upper Ball Joint Nut 37-50 27-37 —

Stabilizer Link to Lower Control Arm Link Nut 8-12 — 71-107

Stabilizer Bar Mounting Bracket to Frame Bolts 22-33 16-24 —

Stabilizer Link to Stabilizer Bar Nut 8-12 — 71-107

Tie Rod End to Steering Knuckle Nut. Tighten to Specifications and If Required, Advance the Nut to the Castellation to Install the Cotter Pin.

70-100

52-74 —

Upper Control Arm Alignment Adjustment Nuts 95-135

70-100

—

Hub Nut 230-285

170-210

—

Damper Bolts 30-39 22-29 —

Toe Set Jam Nut 61-88 45-65 —



Spring, Front - visualbits.net Stuff/Ford Ranger 1993-1999/04 - SUSPENSION… · Spring, Front...

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