204-01B Front Suspension - 4WD PICKUP JMC

204-01B-1 Front Suspension – 4WD 204-01B-1
Section 204-01B Front Suspension – 4WD

Applicable Model: Boomday
CONTENTS PAGE
Specifications
Specifications ..............................................................................................................................204-01B-2
Descriptions and Operations
Front Suspension – 4WD ............................................................................................................204-01B-3
Diagnosis and Testing
Front Suspension – 4WD. ...........................................................................................................204-01B-4
Removal and Installation
Shock Absorber ...........................................................................................................................204-01B-5
Upper Arm ...................................................................................................................................204-01B-6
Upper Arm Bushing .....................................................................................................................204-01B-8
Upper Arm Ball Joint ..................................................................................................................204-01B-10
Lower Arm ................................................................................................................................. 204-01B-11
Lower Arm Bushing ...................................................................................................................204-01B-13
Lower Arm Ball Joint ..................................................................................................................204-01B-15
Stabilizer Bar .............................................................................................................................204-01B-16
Torsion Bar ................................................................................................................................204-01B-17
Knuckle, Oil Seal, Inner Bearing................................................................................................204-01B-19
2009.06 Boomday
Specifications
Material Specifications
Item Specification
Grease -
Torque Parameters
Item Nm
Upper retaining nut of shock absorber 20 ± 5
Lower retaining nut of shock absorber 84 ± 8
Retaining nut of support pin and upper arm 110 ± 15
Connecting bolt between support pin and bracket 155 ± 15
Lower retaining bolt of upper arm ball joint 33 ± 3
Retaining bolt of torsion bar bushing 118 ± 10
Retaining nut between stabilizer bar and lower arm 10
Rear connecting bolt of lower arm 200 ± 20
Front connecting bolt of lower arm 160 ± 20
Retaining bolt of lower arm ball joint 105 ± 10
Retaining bolt for U-shaped junction plate of stabilizer bar 28 ± 7
Retaining nut of upper arm ball joint and knuckle 100 ± 10
Retaining nut of lower arm ball joint and knuckle 130 ± 10
Connecting nuts between knuckle and tie rod 100 ± 10
2009.06 Boomday
Descriptions and Operations
Front Suspension – 4WD

ATTENTION: The suspension fasteners
are critical parts which may influence
the vehicle performance. Their failure
will cause high maintenance costs. Use
components of identical part drawing
number when replacement is necessary
during maintenance. Do not use subs-
titutive parts or parts of poor quality. During
assembly, strictly tighten the components
up to the given torque so as to guarantee
that they are under correct holding force.
The front suspension system is in the form of an
independent double-overarm torsion bar spring
suspension. Both ends of the torsion bar spring
are splines, with the front end supported by
lower arm and the rear end supported by height-
adjustable arm. The wheel knuckle and swing
arm is connected with a ball joint. Longitudinal
movement of the vehicle is controlled by the
swing arm.
The front suspension system is composed of the
following components:
● Shock Absorber
● Upper Arm
● Lower Arm
● Torsion Bar
● Stabilizer Bar
● Knuckle
2009.06 Boomday
Diagnosis and Testing
Front Suspension – 4WD

Refer to section 204-00 for more information.
2009.06 Boomday
Shock Absorber
Removal and Installation ● During installation, tighten them up to 84 ± 8 Nm.

during maintenance. Do not use
substitutive parts or parts of poor quality.
During assembly, strictly tighten the
components up to the given torque so as
to guarantee that they are under correct
holding force.
5. Remove the shock absorber.
ATTENTION: The following operations
are for components on the right side, and 6. For installation, reverse the removal procedures.
those for components on the left side are
similar.
1. Jack up the vehicle.
2. Remove wheels and tires.
3. Remove the upper retaining nut of shock
absorber, and take off the washer and
rubber bushing.
● During installation, tighten it up to 20 ± 5 Nm.
4. Remove the lower retaining bolt and nut of

shock absorber.
2009.06 Boomday
Upper Arm
Removal and Installation Use a suitable plug to block the brake pipe to prevent the
brake fluid from running out.

holding force.
ATTENTION: The following operations 5. Disconnect the brake hose.

are for components on the right side, and
those for components on the left side are Remove the hose clamp.
similar.
3. If equipped, disconnect the wheel speed
sensor harness.
The harness of the wheel speed sensor is
secured on the upper arm. Remove the sensor
harness first before removing the swing arm. 6. Disconnect the connection between the upper
arm ball joint and knuckle.
Remove the cotter pin and nut, and discard the
cotter pin.
● During installation, tighten them up to 100 ±
10 Nm.
4. Disconnect the brake pipe from the brake

pipe bracket.
2009.06 Boomday
7. Remove the connecting bolt, shim, and nut

of the support pin and bracket.
Pay attention to the position and quantity of
the shims during removal so as to restore them
upon installation.
● During installation, tighten them up to 155
± 15 Nm.
8. Remove the upper arm from the frame.
ATTENTION: Do not damage the wheel speed

sensor and brake hose during removal.
9. For installation, reverse the removal procedures.
● Check the condition of the upper arm ball joint
and bushing, and replace them if necessary.
● After installation, check the position parameters
of the four wheels. Make adjustment if
necessary.
● After installation, evacuate the braking
system, and refill it if necessary.
2009.06 Boomday
Upper Arm Bushing

Special Tool ● Special tool: 5-8840-0256-0
Removal
holding force.
1. Remove the upper arm. Refer to this section
for more information.
2. Remove the nut and washer of support pin.
● Make marks on the support pin, and
remember the mark orientation.
3. Remove the upper arm bushing with special

tools.
2009.06 Boomday
Installation
1. Install support pin.
● During installation, pay attention to the
orientation of the support pin mark.
2. Install a new upper arm bushing with sp-
ecial tools.
● Special tool: 5-8840-0256-0
ATTENTION: The new upper arm bushing
can not be applied with grease, oil fluid,
or other foreign matter.
ATTENTION: the upper arm bushing
flange should be installed on the outer
edge of the upper arm.
3. Install washer and nut.

● Screw up the nut by hand. Then tighten
it up to 110 ± 15 Nm when the position
parameters are adjusted well.
2009.06 Boomday
Upper Arm Ball Joint

holding force.
those for components on the left side are
similar.
1. Remove the four connecting bolts of the

ball joint and upper arm.
3. Detach the ball joint from the upper arm.
4. For installation, reverse the removal pro-

cedures.
2009.06 Boomday
Lower Arm
Removal and Installation ● During installation, tighten it up to 10 Nm.
holding force.
7. Remove the rear connecting bolt of lower arm.
those for components on the left side are ● During installation, screw up the nut first.
similar. When the position parameters are adjusted
1. Jack up the vehicle. well, tighten it up to 200± 20 Nm.
2. Remove the wheels and tires.
3. Remove the shock absorber.
Refer to this section for more information.
4. Remove the torsion bar.
5. Remove torsion bar bushing.
Remove two nuts.
± 10 Nm. 8. Remove the front connecting bolt of lower arm.
● During installation, screw up the nut first.
When the position parameters are adjusted
well, tighten it up to 160 ± 20 Nm.
6. Disconnect the connection between the sta-

bilizer bar and lower arm.
Remove one nut.
2009.06 Boomday
9. Remove the four bolts from the lower arm

joint.
10. Remove the lower arm.

cedures.
● After installation, check the position param-
eters of the four wheels. Make adjustment if
necessary.
2009.06 Boomday
Lower Arm Bushing

Special Tool ● Special tool: 5-8840-2123-0
Installation
1. Install a new front bushing of lower arm
Removal with special tools.
1. Remove the lower arm. ● Special tool: 5-8840-2123-0
Refer to this section for more information. ATTENTION: The new lower arm bushing
2. Remove the rear bushing of lower arm with or other foreign matter.
special tool.
● Special tool: 5-8840-2124-0
3. Remove the front bushing of lower arm with

special tools.
2009.06 Boomday
2. Install the rear bushing of lower arm with

special tools.
● Special tool: 5-8840-2124-0
ATTENTION: The new lower arm bushing
or other foreign matter.
3. Install the lower arm.

Refer to his section for more information.
2009.06 Boomday
Lower Arm Ball Joint

during maintenance. Do not use substitutive
parts or parts of poor quality. During
assembly, strictly tighten the components
up to the given torque so as to guarantee
that they are under correct holding force.
1. Remove the lower arm.
2. Disconnect the connection between the
lower arm ball joint and knuckle.
Remove the cotter pin and nut, and discard the
cotter pin.
± 10 Nm.
3. Remove the lower arm ball joint.

2009.06 Boomday
Stabilizer Bar
holding force.
1. Remove one nut, and disconnect the stab-
ilizer bar from the lower arm.
● During installation, tighten it up to 10 Nm.
2. Remove the four retaining bolts, and detach

the stabilizer bar.
● During installation, tighten them up to 28 ± 7 Nm.

● Check the stabilizer bar bushing, and replace it if
necessary.
2009.06 Boomday
Torsion Bar
Material 2 Remove the adjusting bolts.
Item Specification
● Apply a moderate amount of grease during
installation.
Grease -

will cause high maintenance costs.
Use components of identical part
drawing number when replacement is
necessary during maintenance. Do not use
to guarantee that they are under correct 2. Remove the height-adjusting arm.
holding force. ● Before removal, make alignment marks on
the height-adjusting arm and torsion bar for
ATTENTION: The following operations the purpose of alignment during installation.
those for components on the left side are ● Apply a moderate amount of grease on
similar. the spline hole of the height-adjusting arm
during installation.
1. Remove the torsion bar adjusting bolts.
1 Before removal, make alignment marks on
the adjusting bolt and adjusting block for the
purpose of alignment during installation.
Item Description
1 Height adjusting arm
2 Alignment mark
Item Description
3 Torsion bar
1 Alignment mark
2 Adjusting bolt
3 Adjusting block
2009.06 Boomday
3. Remove the torsion bar spring.

● Before removing the torsion bar and torsion
bar bushing, make alignment marks for the
purpose of alignment during installation.
Item Description
1 Lower arm
2 Alignment mark
3 Torsion bar bushing
4 Torsion bar
● During installation, apply a moderate amount of

grease on splines on both ends of the torsion
bar, and make sure to have marks on the left
and right.

cedures.
● After accomplishing installation, check the
body height of the vehicle.
2009.06 Boomday
Knuckle, Oil Seal, and Inner Bearing

Material
Item Specification
Grease -
Special Tool
Item Description
1 Upper ball joint
2 Steering linkage
3 Knuckle module
4 Lower ball joint

will cause high maintenance costs.
Use components of identical part
drawing number when replacement is
necessary during maintenance. Do not use
holding force.
Refer to relevant contents in Section 100-02.
3. Remove the wheel hub and brake disk module.
2009.06 Boomday
4. Remove one bolt from the wheel speed 7. Remove the retaining nut and cotter pin of
sensor, and put aside the sensor posit- upper arm ball joint, and discard the cotter pin.
ioning unit.
● During installation, tighten it up to 8 Nm. ± 10 Nm.
5. Remove the cotter pin and nut of the 8. Remove the upper arm ball joint retaining nuts
knuckle and steering linkage ball joint. and cotter pins, and discard the cotter pins.
● Discard the cotter pin. ● During installation, tighten to 130 ± 10 Nm.
± 10 Nm.
10. Remove the knuckle, oil seal, and bearing

assembly.
6. Disconnect the steering linkage ball joint
CAUTION: Do not damage the ball joint
with special tools.
dust cover and front axle shaft dust
● Special tool: 5-8840-2121-0. cover.
2009.06 Boomday
11. Remove the oil seal and washer from the ● During installation, use special tools:
knuckle assembly. 5-8840-2128-0 and 5-8840-0007-0.
● Change a new oil seal during installation,
and apply stationary grease around the
flange.
● After installing the oil seal into the installer,
force it into the knuckle with a hammer or
bench press until it sits tightly against the
thrust washer.
● During installation, use special tools:
5-8840-2127-0 and 5-8840-0007-0.

cedures.
● After installation, check the position
par-ameters of the four wheels. Make
adjustment if necessary.
12. Remove the knuckle inner bearing with

special tools.
● During removal, use special tool:
5-8840-2000-0.
● During installation, install with special tools,

and apply a certain amount of grease.
2009.06 Boomday

204-01B Front Suspension - 4WD PICKUP JMC

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

204-01B Front Suspension - 4WD PICKUP JMC

Uploaded by

Copyright:

Available Formats

204-01B-1 Front Suspension – 4WD 204-01B-1

Section 204-01B Front Suspension – 4WD

Front Suspension – 4WD

Front Suspension – 4WD

ATTENTION: The suspension fasteners

4. Remove the lower retaining bolt and nut of

ATTENTION: The suspension fasteners

ATTENTION: The following operations 5. Disconnect the brake hose.

4. Disconnect the brake pipe from the brake

7. Remove the connecting bolt, shim, and nut

8. Remove the upper arm from the frame.

ATTENTION: Do not damage the wheel speed

Upper Arm Bushing

3. Remove the upper arm bushing with special

3. Install washer and nut.

Upper Arm Ball Joint

1. Remove the four connecting bolts of the

3. Detach the ball joint from the upper arm.

4. For installation, reverse the removal pro-

6. Disconnect the connection between the sta-

9. Remove the four bolts from the lower arm

10. Remove the lower arm.

Lower Arm Bushing

1. Remove the lower arm. ● Special tool: 5-8840-2123-0

3. Remove the front bushing of lower arm with

2. Install the rear bushing of lower arm with

3. Install the lower arm.

Lower Arm Ball Joint

3. Remove the lower arm ball joint.

2. Remove the four retaining bolts, and detach

3. For installation, reverse the removal procedures.

Removal and Installation

3. Remove the torsion bar spring.

● During installation, apply a moderate amount of

4. For installation, reverse the removal pro-

Knuckle, Oil Seal, and Inner Bearing

Removal and Installation

10. Remove the knuckle, oil seal, and bearing

13. For installation, reverse the removal pro-

12. Remove the knuckle inner bearing with

● During installation, install with special tools,

You might also like