1998 Sec 3-Suspension

Section 3
Suspensio n
S u s p e n s io n G e n e ra l D ia g n o s is ....... ..............3 -3 W h e e l A lig n m e n t ............ .....................................3-18

S p e c ific a tio n s ....... ..... ........ ...................3 -3 S p e c ific a tio n s ........... ............... .............................. 3-18
Trim Height Specifications........... ........................3-3 Wheel Alignment Specifications
Diagnostic Inform ation and Procedures .......... 3-3 (C Model) .......................... ................... .............3-18
Suspension Genera l Diagnosis .............,.....,.,...3 -3 Wheel Alignment Specifications
(K Model) ............ .................... ............... ......... 3-18
Vehicle Leads/Pu lls
(Leads to Either Side) ...................................... 3-3 Fastener Tightening Specifications ............... .3-18
Vehicle Leads/Pulls GM SPO Group N u m b ers..................... ............3-18
(Pulls to One Side-No Braking) ............. .......3-3 Diagnostic Inform ation and Procedures .......3-19
Abnormal or Excessive Tire W ear Preliminary Alignment Inspection
(G e n e ra l)................................ ...................... .....3-4 (C M o d e l)........................................................... 3-19
Abnorma l or Excessive Tire W ear Preliminary Alignment Inspection
(Heel and Toe W ear) .................................. ....3-4 (K 1, 2 M o d e l)................................. .................3-19
Abnormal or Excessive Tire W ear Preliminary Alignment Inspection
(Tire Edges Wear) .................................. .........3 -4 (K Model) ....... ......... ................................... ......3-20
Abnormal or Excessive Tire W ear Repair In s tru c tio n s ......... .............................. ...3-21
(Uneven) ........................ .....................................3-4 Measuring Wheel Alignment (C Model) .........3-21
Abnormal or Excessive Tire W ear Measuring W hee l Alignment (K Model) .........3-21
(Excessive or Uneven) ..................... ............... 3-5
Frame Bracket Knock Out Removal
Abnormal or Excessive Tire W ear (C M o d e l).......................................... ............... 3-23
(Scuffed T ire s ).............. ...................................... 3-5
Abnormal or Excessive Tire W ear (K Model) ......................................... ................3-25
(Cupped Tires) ...................................................3-5
Description and O p e ra tio n ...................... .........3-27
Abnormal or Excessive Tire Wear
General Description (2W D) .............................. .3-27
(Center of Tread) ............................................... 3-5
General Description (4W D) ............................... 3-28
Trim Height Inspection P roced u re..................... 3-6
Trim Height ................. ........................................... 3-8 Special Tools and E q u ip m e n t..................... ......3-29
Wheel T ra m p .................. ....................................... 3-9 F ro n t S u s p e n s io n ............................. .............. .....3-30
Noisy Front Suspension ......... .............................. 3-9 S p e c ific a tio n s .................. ...... .3-30
Poor Directional S tability................ ......... ............3-9 Fastener Tightening Specifications ................. 3-30
Tire Hop or Poor Handling GM SPO Group N u m b ers................................ .3-31
(Radial Tire W ad d le)................. ..................... 3-10
Com ponent L o c a to r..... ......... .....3-32
Noise Diagnosis - Front Suspension ..............3-10
Front Suspension Components .......... ............3-32
Excessive Road Shock ......................................3-11
Diagnostic Inform ation and Procedures ........ 3-36
Struts or Shock Absorbers Weak
(F ro n t)......................... ...................................... 3-11 Ball Joint W ear C h e c k .......................................3-36
Struts or Shock Absorbers Noisy Repair In s tru c tio n s ............................. ..................3-37
(F ro n t)........................ ................................ .......3-11 Wheel Hub Bolt Replacement
Struts or Shock Absorbers Leak (RWD-All Except C3500HD) ........................ 3-37
(Front) ................................................................3-11 Wheel Hub Bolt Replacement
Struts or Shock Absorbers Bench Test (R W D -C 35 00 H D )...... .......................................3-38
(Non-Spiral Groove-Pliacell) ..........................3-12 Wheel Hub Bolt Replacement (S4W D) .......... 3-39
Front Wheel Shimmy ............ ........ ................... .3-12 Stabilizer Shaft Replacement
Hard Steering ....................... ...............................3-12 (2WD-AII Except C3500HD) ..........................3-40
Wheel Bearings Diagnosis ...... s........... ..........3-13 Stabilizer Shaft Replacement (C3500HD) ..... 3-41
Low or Uneven Trim H e ig h t........................... ..3-17 Stabilizer Shaft Replacement (S4WD) ........... 3-42
Upper Ball Joint Replacement (RW D) ........... 3-43 Leaf Spring Replacement
Upper Ball Joint Replacement (S 4 W D ).......... 3-45 (Dual Wheel Spring Assembly) ....................3-97
Lower Ball Joint Replacement (RW D) ........... 3-47 Leaf Spring Replacement (HD Chassis) ....... 3-99
Lower Ball Joint Replacement (S 4 W D ).........,3-49 Spring Shackle Replacement
Steering Knuckle Replacement (CK Model) .................... ................................. 3-100
(RWD-AII Except C3500HD) .........................3-51 Spring Shackle Replacement
Steering Knuckle Replacement (Heavy Duty C h as sis ).................................. 3-101
(C350QHD) .........................................................3-54 Wheel Stud Replacement
Upper Control Arm Replacement (RW D) .........3-55 (Semi-Floating Axle) .....................................3-102
Upper Control Arm Replacement (S 4 W D )....... 3-56 W heel Stud Replacement
Lower Control Arm Replacement (RW D) .........3-58 (Full-Floating A x le )............ ........................... 3-103
Lower Control Arm Replacement (S 4 W D )........3-59 Description and O peration ............................... 3-103
Front Coil Springs R eplacem ent...................3 -6 2 General Description...........................................3-103
Leaf Springs Replacement ............. ........... .... .3-64 T ire s a n d W h e e l s .......... ............ ........... .3-104
W heel Hub, Bearing, and Seal Specifications ...................... ..........................3-104
Replacement Fastener Tightening Specifications ...............3-104
(RWD-AII Except C3500HD) ..... ...................3-67
GM SPO Group Numbers ........................... .3-104
Wheel Hub, Bearing, and Seal
Diagnostic Inform ation and
Replacement (S4WD) .................:............... . 3-68 P ro c e d u re s ...................... .........3-105
W heel Hub, Bearing, and Seal Wheel Mounting Surface C h e c k ................ ...3-105
Replacement (RW D-C3500HD) ...... .............3-70
Radial Tire Lead/Pull Correction .................... 3-106
Torsion Bar and Support Assembly
R epair Instructions .......... ...... .............. 3-107
Replacement (All Except 4 Door U tility)....... 3-72
Aluminum Wheel Porosity R e p a ir.................3-107
Torsion Bar and Support Assemb ly
Aluminum Wheel Refinishing .......................... 3-107
Replacement (4 Door U tility)...................... ,.3-74
W heel Bearing Adjustment (2 W D) ......... ........3-75 Wheel Removal (Single Wheels) ...................3-107
Wheel Removal (Dual Rear Wheels) ............3-108
Wheel Bearing Adjustment (C 3 5 0 0 H D ).......... 3-76
Shock Absorber Replacement Wheel Installation
(RWD-AII Except C3500HD) ....... ........ ........3-77 (Single Wheels-Front or Rear) ...................3-109
Shock Absorber Replacement (4W D) ...... .....3-78 Wheel I nstallation (Dual Rear Wheels) ....... 3-109
Shock Absorber Replacement Tire R ep a ir............... ................................. ......... 3-110
(R W D -C 3500H D )....... .................................... ..3-79 Tire Mounting and Dismounting....... ...........3 -1 1 0
Front Axle R eplacem ent..................... .......... 3-80 Tire Rotation ................ ......... .......................... ..3-111
D escription and O p e ra tio n .................................3-83 Spare Tire Carrier Replacement
General Description ............................................ 3-83 (Suburban Models) .................................... ..3-112
Special Tools and E q u ip m e n t........................... 3-84 Spare Tire Carrier Replacement
(2 Door Utility M o d e ls )............ .................3 -1 1 3
R e a r S u s p e n s io n .................................. ....... . 3-87
Tire Hoist and Shaft Replacement
S p e c ific a tio n s ................................................... .....3-87 (All Pickup Mode ls ) .................. .............. .3-115
Fastener Tightening Specifications ..... .3-87 Tire Hoist and Shaft Replacement
GM SPO Group Numbers ..................... ...........3-87 (4 Door U tility)............ ........ ..........................3-116
C om ponent Locator .......... ............................ 3-88 Description and O p e ra tio n .............................3-118
Rear Suspension C om ponents.......... ......... ...3-88 General Description..... ............................ ........3-118
R epair In s tru c tio n s ................................ ..... 3-91
Metric Wheel Nuts and Bolts
Stabilizer Shaft Replacement (C M o d e l)....... 3-91 Description ................................................ .....3-118
Stabilizer Shaft Replacement (K Model) ....... 3-91 Jire Inflation Description ............................... ...3-118
Stabilizer Shaft Link Bracket Replacement
Tire Chain Usage Description......................3 -11 8
(All Models Except C/K 3) ..................... ........3-91
Tire Description .................................................. 3-119
All Seasons Tires Description........................ 3-119
(C/K 3 M o d e ls )........... ............................... .......3-91
Shock Absorber Replacement (C Model) ......3-92 P-Metric Sized Tires Description .....,.....,...,3-1 19
Shock Absorber Replacement (K Model) ......3-93 Tire Placard Description .................... ......... ,...3-120
W heel Bolt R eplacem ent................................. .3-94 Wheels Description ................................. ......... 3-120
Spring Bushing Replacement .......................... .3-94 Steel Wheel Repair Description .........,3-120
Leaf Spring Replacement Aluminum Wheels D escription....................... 3-120
(Single Wheel Spring A ssem bly)....... .........3-95 Special Tools and E q u ip m e n t...... .....3-120
Suspension Genera! Diagnosis
Specifications
___ _______ Trim Height Specifications
Z Trim Height Specifications
Model Service Allowed Service Preferred
C1, 2, 3 89.0 to 101 mm (3.5 to 4.0 in) 95 mm (3.7 in)
K1, 2 (except K10906 with L65 157 mm (6.2 in)
or K20906 with C6P) 151 to 163 mm (5.9 to 6.4 in)
K1, 2 (K10906 with L65 139 to 151 mm (5.5 to 5.9 in) 145 mm (5.7 in)
or K20906 with C6P)
K3 139 to 151 mm (5.5 to 5.9 in) 145 mm (5.7 in)
Diagnostic Information and Procedures

Suspension General Diagnosis Proceed with the following preliminary checks. Correct
any substandard conditions found.
The problems in steering, suspension, and in tires and Inspect for the following:
wheels involve several systems. Therefore, all must • Inspect for improper tire pressure.
be considered when diagnosing a complaint. • Inspect for uneven wear on tires.
Always road test the vehicle first to avoid using the • Inspect the power steering fluid level.
wrong symptom. Allow for road surface imperfections • Inspect for wear on joints from the steering
and allow for road crown when road testing a column to the steering gear.
vehicle. The test route chosen must resemble the • Inspect for loose or damaged parts on the front
average surface the customer utilizes in order suspension.
to duplicate the complaint. • Inspect for loose or damaged parts on the rear
suspension.
• Inspect for loose or damaged parts on the
steering gear.
• Inspect for loose or damaged parts on the
steering linkage.
• Inspect for components that are out-of-round.
• Inspect for tire imbalance.
• Inspect for wheel damage.
Ve hicle Leads/Pulls (Leads to Either Side)

Checks Action
Keep in mind the wind and the road Test the vehicle, going in both directions, on a flat road.
conditions
Front end misaligned Adjust to specifications. Refer to Measuring Wheel Alignment (C Model) or
Measuring Wheel Alignment (K Model) in Wheel Alignment.
Unbalanced steering gear valve (if Replace the gear valve.
this is the cause, steering effort will
be very light in direction of lead and
heavy in the opposite direction)
Steering shaft rubbing the inside Align or replace the steering column.
diameter of the shaft tube
Vehicle Leads/Pulls (Pulls to One Side-No Braking)

Checks Action
Low or uneven tire pressure Inflate the tires to the recommended pressure. Refer to Tire Inflation Description in
Tires and Wheels.
Front or rear brakes dragging Adjust the brakes.
Broken or sagging front spring Replace the spring. Refer to Front Coil Springs Replacement or Leaf Springs
Replacement in Front Suspension.
Incorrect front wheel Check and align the front suspension. Refer to Measuring Wheel Alignment (C Model)
alignment (camber) or Measuring Wheel Alignment (K Model) in Wheel Alignment.
Abnormal or Excessive Tire Wear (General)
Checks Action
Failure to rotate the tires Refer to Tire Rotation in Tires and Wheels.
Damaged shock absorbers Replace the shock absorber.
• For 2WD, refer to Shock Absorber Replacement (RWD-AII Except C3500HD)
in Front Suspension.
• For 4WD, refer to Shock Absorber Replacement (4WD) in Front Suspension.
• ForC3500HD, refer to Shock Absorber Replacement (RWD-C3500HD)
Improper tire pressure Refer to Tire Inflation Description in Tires and Wheels.
Incorrect wheel alignment Align the wheels. Refer to Measuring Wheel Alignment (C Model) or Measuring
Wheel Alignment (K Model) in Wheel Alignment.
Overloaded or improperly loaded Avoid overloading the vehicle. Refer to Label - Vehicle Certification \n General
vehicle Information.
Broken or sagging springs Replace the springs.
• For 2WD, refer to Front Coil Springs Replacement \n Front Suspension.
• For C3500HD, refer to Leaf Springs Replacement in Front Suspension.
Loose or worn stabilizer bushings Tighten the stabilizer bushing brackets or replace the stabilizer bushings.
• For 2WD, refer to Stabilizer Shaft Replacement (2WD-AII Except C3500HD)
• For 4WD, refer to Stabilizer Shaft Replacement (2WD-AII Except C3500HD)
• For C3500HD, refer to Stabilizer Shaft Replacement (C3500HD) in Front
Suspension.
Abnormal or Excessive Tire Wear (Heel and Toe Wear)

Checks Action
Hard cornering Inform the operator of proper driving techniques.
Incorrect alignment (excessive toe) Set to the correct specifications. Refer to Measuring Wheel Alignment (C Model)
or Measuring Wheel Alignment (K Model) in Wheel Alignment.
Abnormal or Excessive Tire Wear (Tire Edges Wear)

Checks Action
Underinflated tires Inflate the tires to the recommended pressure. Refer to Tire Inflation Description in
Tires and Wheels.
Vehicle overloaded Refer to Label - Vehicle Certification in General Information.
Hard cornering Inform the driver about proper driving techniques.
Incorrect toe setting Set to the correct specifications. Refer to Measuring Wheel Alignment (C Model)
Abnormal or Excessive Tire Wear (Uneven)

Checks Action
Improper tire pressure Inflate the tires to the recommended pressure. Refer to Tire Inflation Description in
Tires and Wheels.
Incorrect tire and wheel usage Install the correct tire and wheel combination.
Front end out of alignment Align the front end. Refer to Measuring Wheel Alignment (C Model) or Measuring
Wheel Alignment (K Model) in Wheel Alignment.
Loose, worn, or damaged steering Inspect, repair, or replace the components as required.
linkage, joints, or suspension
components, bushings, or ball joints
Abnormal or Excessive Tire Wear (Excessive or Uneven)
Checks Action
Underinflated or overinflated tires Inflate the tires to the recommended pressure. Refer to Tire Inflation Description
in Tires and Wheels.
Improper toe-in Adjust the toe-in setting. Refer to Measuring Wheel Alignment (C Model) or
Measuring Wheel Alignment (K Model) in Wheel Alignment.
Wheels are out of balance Balance the wheels. Refer to Balancing Tires and Wheels in Vibration Diagnosis
and Correction.
Hard driving Instruct driver about proper driving techniques.
Overloading the vehicle Do not exceed the maximum recommended payload rating. Refer to Label -
Vehicle Certification in General Information.
Abnormal or Excessive Tire Wear (Scuffed Tires)

Checks Action
Incorrect toe-in Adjust the toe-in setting. Refer to Measuring Wheel Alignment (C Model)
Excessive speed on turns Instruct operator about proper driver techniques.
Improper inflation of the tires Inflate the tires to the recommended pressure. Refer to Tire Inflation Description
in Tires and Wheels.
Suspension arm is bent or twisted Replace the suspension arm.
Abnormal or Excessive Tire Wear (Cupped Tires)

Checks Action
Front shock absorbers are worn Replace the shock absorbers.
• For C3500HD, refer to Shock Absorber Replacement (RWD-C3500HD) in Front
Suspension.
Worn ball joints Replace the ball joints.
• For the upper ball joint, refer to Upper Ball Joint Replacement (RWD) or
Upper Ball Joint Replacement (S4WD) in Front Suspension.
• For the lower ball joint, refer to Lower Ball Joint Replacement (RWD) or
Lower Ball Joint Replacement (S4WD) in Front Suspension.
Incorrectly adjusted or worn wheel Adjust or replace the wheel bearings.
bearings • For 2WD, refer to Wheel Hub, Bearing, and Seal Replacement (RWD-AII
Except C3500HD) in Front Suspension.
• For 4WD, refer to Wheel Hub, Bearing, and Seal Replacement (S4WD) in
Front Suspension.
• For C3500HD, refer to Wheel Hub, Bearing, and Seal
Replacement (RWD-C3500HD) in Front Suspension.
Wheel and tire is out of balance Balance the wheel and tire. Refer to Balancing Tires and Wheels in Vibration
Diagnosis and Correction.
Excessive tire or wheel runout Check and compensate for runout. Refer to Tire and Wheel Runout Measurement in
Vibration Diagnosis and Correction.
Abnormal or Excessive Tire Wear (Center of Tread)

Problem Action
The tires are overinflated. Deflate the tire to the recommended pressure. Refer to Tire Inflation Description in
Tires and Wheels.
The vehicle is overloaded. Refer to Label - Vehicle Certification in General Information.
The operator is using hard driving Inform the operator about proper driving techniques.
techniques such as rapid acceleration
or excessive braking.
Trim Height Inspection Procedure
Z Height
Trim height is a predetermined measurement relating
to vehicle ride height. Incorrect trim heights may
cause symptoms similar to alignment problems. Check
the trim heights when you diagnose steering or
vibration complaints.
The Z dimension measurement determines the proper
ride height for the front end. The Z dimension is different
for RWD vehicles and S4WD or F4W D vehicles. The
S4W D and F4WD vehicles have different points of
measurement to determine Z height. Use the torsion
bar adjusting arm in order to adjust Z height.
RWD vehicles have no adjustment and could require
replacement of suspension components.
On S4W D and F4W D vehicles, measure Z height from

the center line of the pivot bolt (1) down to the
lowest inboard edge of the steering knuckle (2).
88
On RWD vehicles, measure Z height from the center
line of the bolt of the front lower control arm down
to the lower inboard corner of the ball joint. Trim all
Z heights at 89.0-101 mm (3.5-4.0 in).
For S4W D and F4W D vehicles, use the following

measurements:
• K1 and K2 models (except K10906 with L65 or
K20906 with C6P) trim the Z height at
151.0-163.0 mm (5.9-6.4 in).
• K1 and K2 models (K10906 with L65 or
K20906 with C6P) trim the Z height at
139.0-151.0 mm (5.5-5.9 in).
• K3 models trim the Z height at
139.0-151.0 mm (5.5-5.9 in).
Z Height Measurement
Measure the Z height using the following procedure:
o t
93
D Height Measurement
130874 Measure the D height using the following procedure:
1. Lift the front bumper of the vehicle up around
38 mm (1.5 in).
2. Gently remove your hands. Let the vehicle settle
by itself.
3. Repeat the jounce operation two more times for a
total of three times.
4. Measure the Z dimension.
5. Push the front bumper of the vehicle down about
38 mm (1.5 in).
6. Gently remove your hands. Let the vehicle rise
by itself.
Important; True trim height is the average of the high
and low measurements.
8. Measure the Z dimension.
130875
9. Find the average of the high and low
measurements. This is the true Z dimension. 1. Lift the rear bumper of the vehicle up around
38 mm (1.5 in).
D Height 2. Gently remove your hands. Let the vehicle settle
The D dimension measurement determines the proper by itself.
rear end ride height. There is no adjustment 3. Repeat the jounce operation two more times for a
procedure. Repair may require replacement of total of three times.
suspension components. : 4. Measure the D dimension.
5. Push the front bumper of the vehicle down about
38 mm (1.5 in).
6. Gently remove your hands. Let the vehicle rise
by itself.
Important: True trim height is the average of the high
and low measurements.
8. Measure the D dimension.
9. Find the average of the high and low
measurements. This is the true D dimension.
Trim Height 6. Push the front bumper of the vehicle down about
38 mm (1.5 in).
Z Height Measurement 7. Gently remove your hands.
1. Lift the front bumper of the vehicle up about 8. Allow the vehicle to rise.
38 mm (1.5 in).
9. Repeat the operation twice for a total of
2. Gently remove your hands. Let the vehicle settle. three times.
3. Repeat this operation for a total of three times. 10. Measure the Z dimension.
The true Z dimension number is the average of
the high and low measurements.
• For C1, 2, and 3 vehicles, the Z measurement
should be between 89-101 mm (3.5-4.0 in).
• For K models, use the following
Z measurements:
- K1,2 models
(except K10906 + L65 and K20906 + C6P)
— 151-163 mm (5.9-6.4 in)
- K models
(10906 + L65 and 20906 + C6P + 3)
-1 3 9 -1 5 1 mm (5.5-5.9 in)
- K3 models— 139-151 mm (5.5-5.9 in)
D Height Measurement
4. For 2WD vehicles, measure from the pivot bolt

center line (2) down to the lower ball joint
extrusion (4) in order to obtain the Z height
dimension (3).
156342
1. Lift the rear bumper of the vehicle 38 mm (1.5 in).

2. Gently remove your hands. Let the vehicle settle.
3. Repeat this operation for a total of three times.
4. Measure the D dimension (2). Measure from
the bottom surface of jounce bracket (6) to the
top of the axle jounce pad (3).
5. Push the rear bumper of the vehicle downward
156339
38 mm (1.5 in).
5. For 4WD vehicles, measure from the pivot bolt 6. Gently remove your hands. Let the vehicle rise.
center line (2) down to the lower corner (5) of
the steering knuckle (1) in order to obtain the 7. Repeat this operation for a total of three times.
Z height measurement (4). For torsion bar 8. Measure the D dimension.
adjustment, refer to Torsion Bar and Support The true D dimension is the average of the high
Assembly Replacement (All Except 4 Door Utility) and the low measurements.
or Torsion Bar and Support Assembly
Replacement (4 Door Utility) in Front Suspension.
Wheel Tramp
Checks Action
DEFINITION: Abnormal bounce or hop of the wheel under normal driving conditions
Tire and wheel are out of balance Balance the wheels. Refer to B a l a n c i n g T ir e s a n d W h e e ls in Vibration Diagnosis
and Correction.
Tire and wheel are out of round Replace the tire. Refer to T i r e D e s c r i p t i o n in Tires and Wheels.
Blister or bump on the tire Replace the tire. Refer to T ir e D e s c r ip t io n in Tires and Wheels.
Improper shock absorber action Replace the shock absorber.
• For 2WD, refer to S h o c k A b s o r b e r R e p l a c e m e n t ( R W D - A I I E x c e p t C 3 5 0 0 H D )
• For 4WD, refer to S h o c k A b s o r b e r R e p l a c e m e n t ( 4 W D ) in Front Suspension.
. • For C3500HD, refer to S h o c k A b s o r b e r R e p l a c e m e n t ( R W D - C 3 5 0 0 H D ) in
Front Suspension.
Excessive wheel or tire runout Refer to T ir e a n d W h e e l R u n o u t S p e c if ic a t io n s in Vibration Diagnosis and Correction.
Tire lead Refer to R a d ia l T ir e L e a d / P u ll C o r r e c t io n in Tires and Wheels.
Noisy Front Suspension

Checks Action
Worn tie rod ends Replace the tie rod ends. Refer to T i e R o d R e p l a c e m e n t ( A l l E x c e p t C 3 5 0 0 H D )
or T i e R o d R e p l a c e m e n t ( C 3 5 0 0 H D ) in Steering Linkage.
Loose suspension bolts Refer to F a s t e n e r T i g h t e n i n g S p e c i f i c a t i o n s in Front Suspension.
Lack of proper lubrication Refer to F l u i d a n d L u b r i c a n t R e c o m m e n d a t i o n s in Maintenance and Lubrication.
Loose shock absorbers Tighten the bolts. Refer to F a s t e n e r T ig h te n in g S p e c if ic a t io n s in Front Suspension.
Worn shock absorber bushings Replace the bushings.
• For 2WD, refer to S h o c k A b s o r b e r R e p l a c e m e n t ( R W D - A I I E x c e p t C 3 5 0 0 H D )
• For 4WD, refer to S h o c k A b s o r b e r R e p l a c e m e n t ( 4 W D ) in Front Suspension.
• For C3500HD, refer to S h o c k A b s o r b e r R e p l a c e m e n t ( R W D - C 3 5 0 0 H D ) in
Front Suspension.
Loose stabilizer shaft Tighten the bolts. Refer to F a s t e n e r T i g h t e n i n g S p e c i f i c a t i o n s in Front Suspension.
Worn stabilizer shaft insulators Replace the insulators.
• For all except C3500HD, refer to S t a b i l i z e r S h a ft R e p la c e m e n t ( 2 W D - A II
E x c e p t C 3 5 0 0 H D ) in Front Suspension.
• For C3500HD, refer to S t a b i l i z e r S h a f t R e p la c e m e n t ( C 3 5 0 0 H D ) in
Front Suspension.
Poor Directional Stability

Checks Action
Lack of lubrication of the steering Lubricate the linkage. Refer to F l u i d a n d L u b r i c a n t R e c o m m e n d a t i o n s in
linkage Maintenance and Lubrication.
Low or uneven tire pressure Inflate the tires to the recommended pressure. Refer to T i r e I n f l a t i o n D e s c r i p t i o n in
Tires and Wheels.
Loose wheel bearings Adjust or replace the wheel bearings.
• For 2WD, refer to W h e e l H u b , B e a r i n g , a n d S e a l R e p l a c e m e n t ( R W D - A I I
E x c e p t C 3 5 0 0 H D ) in Front Suspension.
• For 4WD, refer to W h e e l H u b , B e a r i n g , a n d S e a l R e p l a c e m e n t ( S 4 W D ) in
Front Suspension.
• For C3500HD, refer to W h e e l H u b , B e a r i n g , a n d S e a l
R e p l a c e m e n t ( R W D - C 3 5 0 0 H D ) in Front Suspension.
Incorrect front wheel Check and align the front suspension. Refer to M e a s u r i n g W h e e l A l i g n m e n t ( C M o d e l)
alignment (caster) or M e a s u r i n g W h e e l A l i g n m e n t ( K M o d e l ) in Wheel Alignment.
Broken springs Replace the springs.
• For 2WD, refer to F r o n t C o i l S p r i n g s R e p l a c e m e n t in Front Suspension.
• For C3500HD, refer to L e a f S p r i n g s R e p l a c e m e n t in Front Suspension.
Poor Directional Stability (cont’d)
Cheeks Action
Malfunctioning shock absorber Check and replace the shock absorber.
• For C3500HD, refer to Shock Absorber Replacement (RWD-C3500HD) in
Front Suspension.
Broken stabilizer shaft or a Replace the stabilizer shaft or link.
missing link • For all except C3500HD, refer to Stabilizer Shaft Replacement (2WD-AII
• For C3500HD, refer to Stabilizer Shaft Replacement (C3500HD) in
Front Suspension.
Tire Hop or Poor Handling (Radial Tire Waddle)

Problem Action
DEFINITION: Side to side movement at speeds between 8-24 km/h (5-15 MPH)
The wheel has excessive lateral Replace the wheel. Refer to Wheel Removal (Single Wheels) or Wheel
runout. Removal (Dual Rear Wheels) and Wheel Installation (Single Wheels-Front or Rear)
or Wheel Installation (Dual Rear Wheels) in Tires and Wheels.
The tire has excessive lateral runout. Replace the tire. Refer to Tire Mounting and Dismounting in Tires and Wheels.
Noise Diagnosis - Front Suspension

Checks i Action
Steering linkage needs lubrication Lubricate at the recommended intervals. Refer to Fluid and Lubricant
Recommendations in Maintenance and Lubrication.
Loose shock absorber Tighten the bolts. Refer to Fastener Tightening Specifications in Front Suspension.
Worn shock absorber bushings Replace the shock absorber.
Front Suspension.
Worn control arm bushings Replace the bushings or the control arm.
• For the upper control arm, refer to Upper Control Arm Replacement (RWD)
or Upper Control Arm Replacement (S4WD) in Front Suspension.
• For the lower control arm, refer to Lower Control Arm Replacement (RWD)
or Lower Control Arm Replacement (S4WD) in Front Suspension.
Worn or loose wheel bearings Adjust or replace the wheel bearing.
• For 2WD, refer to Wheel Hub, Bearing, and Seal Replacement (RWD-AII
• For 4WD, refer to Wheel Hub, Bearing, and Seal Replacement (S4WD) in
Front Suspension.
• For C3500HD, refer to Wheel Hub, Bearing, and Seal
Replacement (RWD-C3500HD) in Front Suspension.
Loose stabilizer shaft Tighten all of the stabilizer shaft attachments. Refer to Fastener Tightening
Specifications in Front Suspension.
Loose wheel nuts Tighten the wheel nuts. Refer to Fastener Tightening Specifications in Tires
and Wheels.
Spring is improperly positioned Reposition the spring. Refer to Front Coil Springs Replacement or Leaf Springs
Replacement in Front Suspension.
Loose suspension bolts Tighten to specifications or replace. Refer to Fastener Tightening Specifications
Worn king pins and bushings Replace the bushings and the king pins. Refer to Steering Knuckle
Replacement (C3500HD) in Front Suspension.
Excessive Road Shock
Checks Action
DEFINITION; Vehicle ride unsteady and harsh.
Tire air pressure is too high Deflate the tire to the correct pressure. Refer to Tire Inflation Description in Tires
and Wheels.
Loose wheel bearings Adjust the bearings. Refer to Wheel Bearing Adjustment (2WD) or Wheel Bearing
Adjustment (C3500HD) in Front Suspension.
Camber adjustment incorrect Adjust camber. Refer to Measuring Wheel Alignment (C Model) or Measuring Wheel
(Negative camber contributes to Alignment (K Model) in Wheel Alignment.
road shock)
Weak or broken front spring Replace the spring. Refer to Front Coil Springs Replacement or Leaf Springs
Replacement in Front Suspension,
Loose suspension components Inspect, repair, and adjust the components as necessary. Refer to Fastener
Tightening Specifications in Front Suspension.
Struts or Shock Absorbers Weak (Front)

Checks Action
Worn out shocks Replace the shock absorbers.
Front Suspension.
Loss of shock fluid Replace the shock absorbers.
Front Suspension.
Struts or Shock Absorbers Noisy (Front)

Checks Action
Loose mounting fasteners Check all mounting bolt and nut torques. Refer to Fastener Tightening Specifications
in Front Suspension or Fastener Tightening Specifications in Rear Suspension.
Broken mounts Replace the shock absorber. Refer to Shock Absorber Replacement (RWD-AII
Except C3500HD), Shock Absorber Replacement (4WD), or Shock Absorber
Replacement (RWD-C3500HD) in Front Suspension or Shock Absorber
Replacement (C Model) or Shock Absorber Replacement (K Model) in |
Rear Suspension.
Extreme bushing wear Replace the shock absorber. Refer to Shock Absorber Replacement (RWD-AII
Except C3500HD), Shock Absorber Replacement (4WD), or Shock Absorber
Replacement (RWD-C3500HD) in Front Suspension or Shock Absorber
Replacement (C Model) or Shock Absorber Replacement (K Model) in
Rear Suspension.
Struts or Shock Absorbers Leak (Front)

Checks Action
Worn out seals Replace the shock absorber.
Front Suspension.
Struts or Shock Absorbers Bench Test 3. Pump the shock at various rates of speed.
(Non-Spiral Groove-Pliacell) Observe the rebound force.
• The rebound force normally is stronger than
Testing Procedure the compression force (approximately
It is not necessary to purge air from non-spiral groove two to one).
shock absorbers. These shock absorbers contain a
• The rebound force should be smooth and
gas filled cell within the shocks reservoir. These
shocks differ from spiral groove shocks. Spiral groove constant for each stroke rate.
shocks contain an air filled cell within the reservoir. 4. Compare this shock with a good shock absorber.
1. Remove the shock absorber from the vehicle. 5 If you observe any of the following conditions,
• For 2WD vehicles, refer to Shock Absorber replace the shock absorber:
Replacement (RWD-AII Except C3500HD)
in Front Suspension. • A skip, or a lag, at reversal near mid-stroke
• For 4WD vehicles, refer to Shock Absorber • A seizing (except at the extreme ends of travel)
Replacement (4WD) in Front Suspension. • A noise, a grunt or a squeal, after completing
• For the C3500HD, refer to Shock Absorber one full stroke in both directions
Replacement (RWD-C3500HD) in Front
Suspension. • A clicking noise at fast reversal
Important: Do not clamp the vise jaws on the shock
upper stem threads or the reservoir.
2. Place the shock absorber in a vise.
• Clamp the jaws on the top mounting stud of
the shock.
• Hold the shock vertically in the vise with the
bottom end up.
Front Wheel Shimmy
Checks Action
DEFINITION: Vehicle front wheel shimmy or shake while driving on a smooth road
Tire and wheel are out of balance Balance the tires. Refer to Balancing Tires and Wheels in Vibration Diagnosis and
Correction.
Tire and wheel are out of round Check runout. Refer to Tire and Wheel Runout Measurement in Vibration Diagnosis
and Correction.
Worn or loose wheel bearings Adjust the wheel bearings. Refer to Wheel Bearing Adjustment (2W D) or Wheel
Bearing Adjustment (C3500HD) in Front Suspension.
Worn or loose king pin or king pin Replace the worn parts or adjust the king pin bearing. Refer to Steering Knuckle
bearing Replacement (C3500HD) in Front Suspension.
Worn ball joints Replace the ball joints.
• For the upper ball joint, refer to Upper Ball Joint Replacement (RW D) or
Upper Ball Joint Replacement (S4W D) in Front Suspension.
• For the lower ball joint, refer to Lower Ball Joint Replacement (RW D) or
Lower Ball Joint Replacement (S4W D) in Front Suspension.
Malfunctioning shock absorber Check and replace the shock absorber.
• For 2WD, refer to Shock Absorber Replacement (RWD-AII Except C3500HD) in
Front Suspension.
• For 4WD, refer to Shock Absorber Replacement (4W D) in Front Suspension.
• For C3500HD, refer to Shock Absorber Replacement (RW D-C3500HD ) in
Front Suspension.
Hard Steering
Checks Action
Ball joints and steering linkage need Lubricate the ball joints and the steering linkage. Refer to Fluid and Lubricant
lubrication Recommendations in Maintenance and Lubrication.
Low or uneven front tire pressure Inflate the tires to the recommended pressure. Refer to Tire Inflation Description in
Tires and Wheels.
Incorrect front wheel alignment Check and align the front suspension. Refer to Measuring Wheel Alignment (C Model)
Worn ball joints Check ball joint free play.
Worn or loose king pin or king pin Replace any worn parts or adjust the king pin bearing. Refer to Steering Knuckle
bearing Replacement (C3500HD) in Front Suspension.
Wheel Bearings Diagnosis Abrasive Step Wear
Tapered Roller Bearing Diagnosis
Consider the following factors when diagnosing
bearing condition:
• General condition of all parts during disassembly
and inspection.
• Classify the failure with the aid of the illustrations.
• Determine the cause.
• Make all repairs following recommended
procedures.
Abrasive Roller Wear
1453
The pattern on the roller ends is caused by fine

abrasives.
1. Clean all of the parts and the housings.
2. Check the seals and the bearings.
3. Replace any leaky, rough, or noisy bearings.
Galling
1452
The pattern on the races and the rollers is caused by

fine abrasives.
1. Clean all of the parts and the housings.
2. Check the seals and the bearings.
3. Replace any leaky, rough, or noisy bearings.
The metal smears on the roller ends are due to

overheating, lubricant failure, or lubricant overload.
1. Replace the bearing.
2. Check the seals.
3. Check for proper lubrication.
Etching Cage Wear
1456 1457
The bearing surfaces appear gray or grayish black in The wear around the outside diameter of the cage and
color, with related etching away of material usually the roller pockets is caused by abrasive material or
at roller spacing. inefficient lubrication.
1. Replace the bearings. 1. Clean the related parts and the housings.
2. Check the seals. 2. Check the seals.
3. Check for proper lubrication. 3. Replace the bearings.
Bent Cage Indentations
1648 1458
When a cage is damaged due to improper handling or The surface depressions on the race and the rollers
improper tool usage. are caused by hard particles of foreign matter.
Replace the bearing. 1. Clean all the parts and the housings.
2. Check the seals.
3. Replace rough or noisy bearings.
Frettage If this condition occurs, perform the following:
1. Replace the bearings.
2. Clean the related parts.
3. Check for proper fit and lubrication.
Stain Discoloration
1459
The corrosion caused by small relative movement of
parts with no lubrication.
3. Check the seals. The discoloration on the bearings is caused by
4. Check for proper lubrication. incorrect lubrication or moisture and ranges in color
from light brown to black. Reuse the bearing if you can
Smears remove the stains with light polishing and there is
no evidence of overheating. Check the seals and the
related parts for damage.
Heat Discoloration
The smearing of the metal is due to slippage. Slippage

can be caused by the following factors:
• Poor fits 1462
• Lubrication The discoloration on the bearings ranges from faint
yellow to dark blue and results from overload or
• Overheating an incorrect lubricant. Excessive heat causes softening
• Overloads of the races or the rollers. In order to check for loss
• Handling damage of temper on the races and the rollers, perform a
file test. A file drawn over a tempered part will grab
and cut the metal and fail the file test. A file drawn over
a hard part will glide readily with no metal cutting.
If overheating damage is indicated, perform the Fatigue Spalling
following:
1. Replace the bearings.
2. Check the seals and the other related parts.
Misalignment
1465
The surface is flaked with metal due to bearing

fatigue.
2. Clean all related parts.
1463
Brinelling
The outer race is misaligned due to a foreign object.
3. Ensure the races are properly sealed.
Cracked Inner Race
1466
The surface indentations in the race way are caused

by the rollers under impact loading or from vibration
while the bearing is not rotating. Replace a rough
or noisy bearing.
The race is cracked due to improper fit, cocking, or

poor bearing seats.
2. Correct bearing seats.
Low or Uneven Trim Height
Checks Action
Broken or sagging springs Replace the springs.
• For 2WD, refer to Front Coil Springs Replacement in Front Suspension.
• For C3500HD, refer to Leaf Springs Replacement in Front Suspension.
Overloaded or improperly Avoid overloading the vehicle. Refer to Label - Vehicle Certification in General
loaded vehicle Information.
Wheel Alignment
Specificatio ns
____________ ___________ Wheel Alignment Specifications (C Model)
Operation Service Allowable j Service Preferred
C Truck (Exc C3500HD)
Caster 2.75 to 4.75 3.75
Cross Caster 0.5 —
Camber j 0 to 1 0.5
Cross Camber 0.5 —
Steering Angle -5.0 to 5.0 0
Toe (Total) 0.04 to 0.44 0 24
C Truck (C3500HD)
Caster (non adjustable, for Not Adjustable Not Adjustable
reference only)
Cross Caster (non adjustable, for Not Adjustable —
reference only)
Camber (non adjustable, for 0.75 to 1.75 1.25
reference only)
Cross Camber (non adjustable, for Not Adjustable —
reference only)
Toe (Total Degrees) 0 to 0.24 0.12
Toe (Total mm/inches) 0 to 0.12 in 0.06 in
Wheel Alignm ent Specifications (K Model)

Operation | Service Allowable j| Service Preferred
K Truck (Below 8600 GVW)
Caster 2.0 to 4.0 3.0
Cross Cast€. 0.5 —
Camber 0.15 to 1.15 0.65
Cross Camber 0.5 —
Steering Angle 5.0 to 5.0 0
Toe (Total) 0.04 to 0.44 0.24
K Truck (8600 GVW And Above)
Caster 2.0 to 4.0 3.0
Cross Caster 0.5 —
Camber Oto 1.0 0.5
Camber — 0.5
Toe (Total) 0.04 to 0.44 0.24
Fastener Tightening Specifications

Specification
Application Metric English
Tie Rod Adjuster Sleeve Nuts 19 N-m 141b ft
Upper Control Arm Nuts 190 N-m 140 Ib ft
GM SPO Group Numbers

Application GM SPO Group Number
Steering Knuckle Upper Control Arm Bolt and Cam Kit 6.172
Diagno stic Information and Procedures
Preliminary Alignment Inspection 11 . Inspect the level of the vehicle.
(C Mode!) The vehicle must be on a level surface fore and
aft and side to side.
1. Before making any adjustments affecting the
caster, the camber, or the toe-in, inspect the 12. Inspect for excess drag or poor return of the
front end. steering wheel due to stiff or rusty suspension
or linkage, components.
2. Inspect the tires for the proper inflation pressure.
Refer to Tire inflation Description in Tires and
Wheels. Preliminary Alignment Inspection
3. Inspect the front wheel bearing for proper (K 1, 2 -Model)
adjustment. Refer to Wheel Bearing Important: Before making any adjustments affecting
Adjustment (2WD) in Front Suspension. the caster, the camber, or the toe-in, inspect
4. Correct any excessive looseness before adjusting the front end.
the ball joints, the tie rod ends, and the relay 1. Inspect the tires for the proper inflation pressure.
rods. Refer to Steering Linkage Inspection Refer to Tire Inflation Description in Tires and
in Steering Linkage. Wheels.
5. Inspect the wheels and tires for runout. Refer to 2. Inspect the front wheel bearing for proper
Tire and Wheel Runout Measurement in Vibration adjustment. Refer to Wheel Bearing
Diagnosis and;;Correction. Adjustment (C3500HD) Front Suspension.
3. Correct any excessive looseness before adjusting
the following parts:
• The ball joints
• The tie rod ends
• The relay rods.
Refer to Steering Linkage Inspection in
Steering Linkage.
4. Inspect the wheels and tires for runout. Refer to
Tire and Wheel Runout Measurement in Vibration
Diagnosis and Correction.
6. The correct specification is 95.0 ± 6.0 mm. If not

within specifications, make the correction before
adjusting the caster.
7. Inspect the steering gear for looseness at
the frame.
8. Inspect the shock absorbers for leaks or
noticeable noise. Refer to Shock Absorber
Replacement (RWD-AII Except C3500HD) in
Front Suspension.
9. Inspect the control arms or the stabilizer shaft
attachments for looseness. Refer to Stabilizer 156339
Shaft Replacement (2WD-AII Except C3500HD) 5. The correct specification is 157.0 ± 6.00 mm. If
in Front Suspension and Axle. not within specifications, make the correction
10. Inspect the alignment equipment. before adjusting the caster.
Follow the manufacturer’s instructions. 6. Inspect the steering gear for looseness at
the frame.
Replacement (4WD) in Front Suspension.
8. Inspect the control arms or the stabilizer shaft
attachments for looseness. Refer to Stabilizer
Shaft Replacement (2WD-AII Except C3500HD) in
Front Suspension.
9. Inspect the alignment equipment.
Follow the manufacturer’s instructions.
10. Inspect the level of the vehicle.
The vehicle must be on a level surface fore and
11. Inspect for excess drag or poor return of the
steering wheel due to stiff or rusty suspension
or linkage components.
Preliminary Alignment Inspection

(K Model)
Important: Before making any adjustments affecting
the caster, the camber, or the toe-in, inspect
the front end. 156339
1. Inspect the tires for the proper inflation pressure.
Refer to Tire Inflation Description in Tires and 5. The correct specification is 10906 ± L65 and
20906 + C6P ± 3 145.0 ± 6.0 mm. If not within
Wheels.
specifications, make the correction before
2. Inspect the front wheel bearing for proper adjusting the caster.
adjustment. Refer to Wheel Bearing
6. Inspect the steering gear for looseness at
Adjustment (2WDj in Front Suspension.
the frame.
3. Correct any excessive looseness before adjusting
the following parts:
• The ball joints Replacement (4WD) in Front Suspension.
• The tie rod ends 8. Inspect the control arms or the stabilizer shaft
• The relay rods attachments for looseness. Refer to Stabilizer
Refer to Steering Linkage Inspection in Shaft Replacement (2WD-AII Except C3500HD)
Steering Linkage. in Front Suspension.
4. Inspect the wheels and tires for runout. Refer to 9. Inspect the alignment equipment.
Tire and Wheel Runout Measurement in Vibration Follow the manufacturer’s instructions.
Diagnosis and Correction. 10. Inspect the level of the vehicle.
The vehicle must be on a level surface fore and
11. Inspect for excess drag or poor return of the
steering wheel due to stiff or rusty suspension
or linkage components.
Repair Instructions
Measuring Wheel Alignment (C Model) 12. Correct the caster as follows:
1. Satisfactory vehicle operation may occur over a 12-1 - A down-in-the-rear frame angle must be
wide range of front wheel alignment settings. If subtracted from a positive caster reading.
the settings vary beyond the tolerances, 12.2. An up-in-the-rear frame angle must be
adjustments are needed. Refer to Wheel added to a positive caster reading.
Alignment Specifications (C Model). 12.3. A down-in-the-rear frame angle must be
As originally installed, the upper control arm added to a negative caster reading.
cannot be adjusted for the camber or the caster. 12.4. An up-in-the-rear frame angle must be
However, if the camber or the caster is out of subtracted from a negative caster reading.
tolerance, the alignment can be reset to
13. If the caster angle is wrong, remove the frame
specifications by removing the knockouts in the
bracket knockouts. Refer to Frame Bracket
upper control arm frame brackets. Refer to Frame
Bracket Knock Out Removal (C Model). Knock Out Removal (C Model).
Upon removal of the control arm, remove the 14. Reset the caster angle by turning the cam bolts.
inserts outboard from the inside of the bracket with Refer to Wheel Alignment Specifications
the J 38794. Refer to Frame Bracket Knock Out (C Model).
Removal (C Model). Important: In order to make the caster or the camber
Important: Set the front wheel alignment to the adjustments, remove the frame bracket knockouts.
specifications while the vehicle is in its normally loaded Refer to Frame Bracket Knock Out Removal (C Model).
condition. For vehicles which are consistently 15. Determine the camber from the alignment
operated with heavy loads, adjust the toe-in with the equipment.
vehicle under heavy load. Following this procedure 16. If the camber angle is wrong, remove the frame
prolongs the life of the tires. bracket knockouts. Refer to Frame Bracket
2. Measure the front alignment angles. Knock Out Removal (C Model).
3. Install the alignment equipment according to the 17. Reset the camber angle by turning the cam bolts.
manufacturer’s instructions. Refer to Wheel Alignment Specifications
4. Measure the alignment angles and record the (C Model).
readings. 18. Determine the toe-in from the alignment
5. Make any required adjustments in the equipment.
following order: 19. Change the length of both tie rod sleeves in order
5.1. Caster to affect a toe-in change. The toe-in can be
5.2. Camber increased or decreased by changing the length of
the tie rod ends. A threaded sleeve is provided
5.3. Toe-in for this purpose. When the tie rod ends are
Important: Ail of the caster specifications are given mounted ahead of the steering knuckle they must
with the vehicle frame level (zero angle). be decreased in length in order to increase the
toe-in. When the tie rod ends are mounted behind
In order to make the caster or the camber adjustments, the steering knuckle they must be lengthened
the frame bracket knockouts must be removed. Refer to in order to increase the toe-in. Refer to Wheel
Frame Bracket Knock Out Removal (C Model). Alignment Specifications (C Model).
6. Position the vehicle on a smooth, level surface.
7. Correct the Z dimension specification. Refer Measuring Wheel Alignment (K Model)
to Trim Height in Suspension General Diagnosis.
1. Satisfactory vehicle operation may occur over a
8. Measure the frame angle, using a bubble wide range of front wheel alignment settings. If
protractor or inclinometer. the settings vary beyond the tolerances,
The frame angle is the tilt (in degrees) of the adjustments are needed. Refer to Wheel
frame from the level position. Alignment Specifications (K Model).
9. Note the frame angle as being either up in the As originally installed, the upper control arm
rear or down in the rear. cannot be adjusted for the camber or the caster.
10. Determine the caster angle from the alignment However, if the camber or the caster is out of
equipment. tolerance, the alignment can be reset to
specifications by removing the knockouts in the
11. Determine the caster reading. Refer to Wheel
upper control arm frame brackets. Refer to Frame
Alignment Specifications (C Model).
Bracket Knock Out Removal (K Model).
Upon removal of the control arm, remove the
inserts outboard from the inside of the bracket with
the J 38794. Refer to Frame Bracket Knock Out
Removal (K Model).
Important: Set the front wheel alignment to the 12. Correct the caster as follows:
specifications while the vehicle is in its normally loaded 12.1. A down-in-the-rear frame angle must be
condition. For vehicles which are consistently subtracted from a positive caster reading.
operated with heavy loads, adjust the toe-in with the >12.2. An up-in-the-rear frame angle must be
vehicle under heavy load. Following this procedure added to a positive caster reading.
prolongs the life of the tires. 12.3. A down-in-the-rear frame angle must be
2. Measure the front alignment angles. added to a negative caster reading.
12.4. An up-in-the-rear frame angle must be
3. Install the alignment equipment according to the
subtracted from a negative caster reading.
manufacturer’s instructions.
13. If the caster angle is wrong, remove the frame
4. Measure the alignment angles and record the bracket knockouts. Refer to Frame Bracket
readings. Knock Out Removal (K Model).
5. Make any required adjustments in the 14. Reset the caster angle by turning the cam bolts.
following order: 9 . Refer to Wheel Alignm ent Specifications
(K Model).
5.1. Caster
Important: In order to make the caster or the camber
5.2. Camber adjustments, remove the frame bracket knockouts.
5.3. Toe-in Refer to Frame Bracket Knock Out Removal (K Model).
Important: All of the caster specifications are given 15. Determine the camber from the alignment
with the vehicle frame level'(zero’angle).
equipment.
16. If the camber angle is wrong, remove the frame
In order to make the caster or the camber adjustments,, bracket knockouts. Refer to Frame Bracket
the frame bracket knockouts must be removed. Refer to Knock Out Removal (K Model).
Frame Bracket Knock Out Removal (K Model). 17. Reset the camber angle by turning the cam bolts.
6. Position the vehicle on a smooth, level surface. Refer to Wheel Alignment Specifications
7. Correct the Z dimension specification. Refer (K Model).
to T r im Height in Suspension General Diagnosis. 18. Determine the toe-in from the alignment
equipment.
8. Measure the frame angle, using a bubble
19. Change the length of both tie rod sleeves in order
protractor or inclinometer.
to affect a toe-in change. The toe-in can be
The frame angle is the tilt (in degrees) of the increased or decreased by changing the length of
frame from the level position. the tie rod ends. A threaded sleeve is provided
9. Note the frame angle as being either up in the for this purpose. When the tie rod ends are
rear or down in the rear. mounted ahead of the steering knuckle they must
be decreased in length in order to increase the
10. Determine the caster angle from the alignment toe-in. When the tie rod ends are mounted behind
equipment. the steering knuckle they must be lengthened
11. Determine the caster reading. Refer to Wheel in order to increase the toe-in. Refer to Wheel
Alignment Specifications (K Model). Alignment Specifications (K Model).
(C Model)
Removal Procedure
Tools Required
J 38794 Knockout Removal Tool
Important: As originally installed, the upper control
arm cannot be adjusted for the caster or the camber.
However, if the caster or the camber is measured
and is out of tolerance, the caster and the camber can
be set to the proper specifications.
1. Raise the vehicle.
2. Suitably support the vehicle. Refer to Lifting and
Jacking the Vehicle in General Information.
Important: The jack or the jack stand must remain
under the lower control arm during the removal and the
installation procedure in order to retain the lower
control arm position. 156347
3. Support the lower control arms with a jack or the
jack stands.
4. Remove the tire and the wheel assembly.
5. Remove the following parts from the upper control
arm bracket (4):
® The nuts (6)
• The cams (5)
8 The bolts (1)
6. Lift the upper control arm (3) up and to the side in
order to gain access to the inner portion of the
frame bracket.
7. Use the J 38794 in order to remove the frame
bracket knockout as follows:
• Do not distort the frame bracket when
removing the knockout.
;• Apply extreme pressure lubricant to the
threads of the T-bolt.
• Insert the bolt through the knockout hole in the
bracket support.
• Install the bridge onto the T-bolt.
The forward bracket requires the bridge to be
installed between the legs of the bracket
due to access problems.
Notice: Do not subject the tool to more than 3
100 N-m (75 Ib ft) torque. Exceeding the recommended
torque may damage the tool and/or the bracket.
• Assemble the following parts in order: 156346
7.1. The bridge
7.2. The bearing with the chamfered
side out
7.3. The washer
7.4. The nut
• The T-bolt head and the bridge must line up
horizontally with the knockout.
The bridge should span the knockout without
interfering with the knockout procedure.
• Tighten the T-bolt head against the knockout
by turning the nut at the opposite end using
a socket and torque wrench.
• An open end wrench or adjustable wrench
may be needed in order to prevent the
T-bolt from losing the horizontal alignment with
the knockout.
• If the torque limit on the T-bolt is met and the
knockout does not break free, use a die
grinder of appropriate size.
Using the stamped outline as a guide, remove
the knockout.
Remove the wax coating in the knockout
area in order to make the perforation lines
more visible.
• If the outline is not visible, use the T-bolt head
installed horizontally, as a template, and
scribe the frame bracket.
• Repeat the procedure on the other upper
control arm frame bracket.
Installation Procedure
1. Install the upper control arm (3) into the frame
brackets (2).
2. Install the bolts (1) and the cams (6) through the
frame brackets (2) and through the control arm (3).
3. Install the cams (6) and the nuts (4).
Install the cams with the radius toward the frame
brackets.
4. Partially tighten the nut (4).
5. Install the front wheel assemblies.
6. Install the alignment machine heads.
Notice: Refer to Fastener Notice in Cautions and
Notices.
Important: Verify alignment specifications before
proceeding. Refer to Wheel Alignment Specifications
(C Model) in Wheel Alignment.
7. Adjust the caster and the camber to the correct
specifications by rotating the bolt head installed
through the adjuster cam.
Tighten
7.1. Tighten the front upper control arm nuts (4)
to 190 N-m (1401b ft).
7.2. Tighten the rear upper control arm nuts
to 190 N-m (1401b ft).
8. Set the steering wheel on center with the wheels
straight.
9. Loosen the adjuster sleeve nuts.
10. Adjust the toe-in. Refer to Fastener Tightening
Specifications.
Tighten
Tighten the tie rod adjuster sleeve nuts
to 19 N-m (14 Ib ft).
11. Ensure that the clamps are properly positioned.
Refer to Tie Rod Adjuster Replacement in
Steering Linkage.
12. Recheck the alignment specifications.
13. Lower the vehicle.
(K Model)
Removal Procedure
Tools Required
J 3 8 7 9 4 Knockout Removal Too!
2. Suitably support the vehicle. Refer to Lifting and
Jackin g the Vehicle in General Information.
Important: The jack or the jack stand must remain

under the lower control arm during the removal and the
installation procedure in order to retain the lower
control arm position.
3. Support the lower control arms with a jack or the
jack stands.
4. Remove the tire and the wheel assembly.
5. Remove the following parts from the upper control
arm bracket (2):
• The nuts
• The cams (4)
• The bolts (3)
6. Lift the upper control arm (2) up and to the side in
order to gain access to the inner portion of the
frame bracket.
7. Use the J 3 8 7 9 4 in order to remove the frame
bracket knockout as follows:
• Do not distort the frame bracket when
removing the knockout.
• Apply extreme pressure lubricant to the
threads of the T-bolt.
• Insert the bolt through the knockout hole in the
bracket support.
• Install the bridge onto the T-bolt.
The forward bracket requires the bridge to be
installed between the legs of the bracket
due to access problems.
Notice: Do not subject the tool to more than
100 N-m (75 Ib ft) torque. Exceeding the recommended
torque may damage the tool and/or the bracket.
• Assemble the following parts in order:
7.1. The bridge
7.2. The bearing with the chamfered
side out
7.3. The washer
7.4. The nut
• The T-bolt head and the bridge must line up
horizontally with the knockout.
The bridge should span the knockout without
interfering with the knockout procedure.
• Tighten the T-bolt head against the knockout
by turning the nut at the opposite end using
a socket and torque wrench.
• An open end wrench or adjustable wrench
may be needed in order to prevent the
T-bolt from losing the horizontal alignment with
the knockout.
• If the torque limit on the T-bolt is met and the
knockout does not break free, use a die
grinder of appropriate size.
Using the stamped outline as a guide, remove
the knockout.
Remove the wax coating in the knockout
area in order to make the perforation lines
more visible.
• If the outline is not visible, use the T-bolt head
installed horizontally, as a template, and
scribe the frame bracket.
• Repeat the procedure on the other upper
control arm frame bracket.
1. Install the upper control arm (2) into the frame
brackets.
2. Install the bolts and the cams (4) through the
frame brackets and through the control arm (2).
3. Install the cams (4) and the nuts.
Install the cams with the radius toward the frame
brackets.
4. Partially tighten the nut.
5. Install the tire and the front wheel assemblies.
6. Install the alignment machine heads.
Notice: Refer to F a s te n e r N o tice in Cautions and
Notices.
Important: Verify alignment specifications before
proceeding. Refer to W h e e l A lig n m e n t Specifications
(C M o d e l) or W h e e l A lig n m e n t Specifications (K M o d e l)
in Wheel Alignment.
7. Adjust the caster and the camber to the correct
specifications by rotating the bolt head installed
through the adjuster cam.
Tighten
7.1. Tighten the front upper control arm nuts to
190 N-m (140 Ib ft).
7.2. Tighten the rear upper control arm nuts to
190 N-m (1401b ft).
8. Set the steering wheel on center with the wheels
straight.
9. Loosen the adjuster sleeve nuts.
10. Adjust the toe-in. Refer to F a s te n e r Tightening
Specifications.
Tighten
Tighten the tie rod adjuster sleeve nuts to
19 N-m (141b ft).
11. Ensure that the clamps are properly positioned.
Refer to Tie H o d A d ju s te r R e p la c e m e n t in
Steering Linkage.
12. Recheck the alignment specifications.
Description and Operation
General Description (2WD)
The front wheel alignment refers to the angular
relationship between the front wheels, the front
suspension attaching parts, and the ground. Proper
front wheel alignment must be maintained in order to
ensure efficient steering, good directional stability,
and prevent abnormal tire wear. Following are
the most important factors of the front wheel alignment:
• The wheel toe-in
• The wheel camber
• The axle caster
156644
The camber is the inward or outward tilting of the front
wheels from the vertical (2). When the wheels tilt
outward at the top, the camber is positive (3). When
the wheels tilt inward at the top, the camber is
negative. The amount of tilt measured in the degrees
from the vertical is called the camber angle. The
camber is designed into the front axle assembly of all
the vehicles and is intended to be non-adjustable.
However, if the camber is measured and found to be
out of tolerance, the camber can be set to proper
specifications.
If the camber is extreme, or unequal between the
wheels, improper steering and excessive tire wear will
The caster is the tilting of the steering axis either result. The negative camber causes wear of the
inboard side of the tire, while the positive camber
forward or backward from vertical (1) when viewed from
causes wear to the outboard side.
the side of the vehicle. A backward tilt is measured in
positive degrees (3) and a forward tilt in negative
degrees (2).
On the short and long arm type suspension, you
cannot see a caster angle without a special instrument.
However, if you look straight down from the top of
the upper control arm to the ground, the ball joints do
not line up (fore and aft) when a caster angle other
than 0 degrees is present. With a positive angle,
the lower ball joint center line would be slightly ahead
(toward the front of the vehicle) of the upper ball
joint center line. The caster is designed into the front
axle assembly on all vehicles, and is intended to
be non-adjustable. However, if the caster is measured
and found to be out of tolerance, the caster can be
set to proper specifications.
General Description (4WD)
The front wheel alignment refers to the angular
relationship between the front wheels, the front
suspension attaching parts, and the ground. Proper
front wheel alignment must be maintained in order to
ensure efficient steering, good directional stability,
and prevent abnormal tire wear. Following are
the most important factors of the front wheel alignment:
• The wheel toe-in
• The wheel camber
• The axle caster
156652
The linear sum toe-in results when the distance

between the front wheels is less at the front of the
axle than at the rear of the axle.
Angular toe-in (3) is the angle of the front wheel
centerlines (1), relative to the intersection of the
forward projected vehicle center line (2).
The actual amount of the toe-in is normally a fraction
of a degree. Toe-in is measured from the center of
the tire treads or from the inboard side of the tires. The
purpose of toe-in is to ensure parallel rolling of the
front wheels and to offset any small deflections of the
wheel support system which occur when the vehicle
is rolling forward. Incorrect toe-in can cause unstable The caster is the tilting of the steering axis either
steering and front tire wear. The toe-in is the last forward or backward from vertical (1) when viewed from
angle to be set in the front wheel alignment procedure. the side of the vehicle. A backward tilt is measured in
positive degrees (3) and a forward tilt in negative
degrees (2).
On the short and long arm type suspension, you
cannot see a caster angle without a special instrument.
However, if you look straight down from the top of
the upper control arm to the ground, the ball joints do
not line up (fore and aft) when a caster angle other
than 0 degrees is present. With a positive angle,
the lower ball joint center line would be slightly ahead
(toward the front of the vehicle) of the upper ball
joint center line. The caster is designed into the front
axle assembly on ail vehicles, and is intended to
be non-adjustable. However, if the caster is measured
and found to be out of tolerance, the caster can be
set to proper specifications.
156647 156652
The camber is the inward or outward tilting of the front The linear sum toe-in results when the distance
wheels from the vertical (2). When the wheels tilt between the front wheels is less at the front of the
outward at the top, the camber is positive (3). When axle than at the rear of the axle.
the wheels tilt inward at the top, the camber is Angular toe-in is the angle of the front wheel
negative. The amount of tilt measured in the degrees centerlines (1), relative to the intersection of the
from the vertical is called the camber angle. The forward projected vehicle center line.
camber is designed into the front axle assembly of all
The actual amount of the toe-in is normally a fraction
the vehicles and is intended to be non-adjustable.
of a degree. Toe-in is measured from the center of
However, if the camber is measured and found to be
out of tolerance, the camber can be set to proper the tire treads or from the inboard side of the tires. The
purpose of toe-in is to ensure parallel rolling of the
specifications.
front wheels and to offset any small deflections of the
If the camber is extreme or unequal between the wheel support system which occur when the vehicle
wheels, improper steering and excessive tire wear will is rolling forward. Incorrect toe-in can cause unstable
result. The negative camber causes wear of the steering and front tire wear. The toe-in is the last
inboard side of the tire, while the positive camber angle to be set in the front wheel alignment procedure.
causes wear to the outboard side.
Special Tools and Equipment
Illustration Tool Number/Description
J 38794
Knockout Removal Tool
Front Suspension
Specifications
Specification
Axle Shaft Nut (K Models) 225 N-m 165 Ib ft
Brake Hose Bracket Nuts (C Models) 18 N m 131b ft
Caps to Steering Knuckle (C3500HD) 17 N-m 121b ft
Hub and Bearing Assembly to Steering Knuckle Bolts (K Models) 180 N-m 133 Ib ft
Lock Pin to Steering Knuckle Nut (C3500HD) 40 N-m 29 Ib ft
Lower Ball Joint to Steering Knuckle Nut (C and K Models) 128 N-m - 94 lb ft
Lower Control Arm Bumper (C Models) 32 N-m 23 Ib ft
Lower Control Arm to Frame Nuts and Bolts (C and K Models) 165 N-m 1211b ft
Lower Shock Absorber Nut (C3500HD) 185 N-m 136 1b ft
Outer Tie Rod Nut (C and K Models) 62 N-m 46 Ib ft
Shackle to Frame Nut and Bolt (C3500HD) 95 N-m 701b ft
Shock Absorber Nuts (K Models) 90 N-m 66 Ib ft
Shock Absorber to Control Arm Bolts (C Models) 27 N-m 201b ft
Shock Absorber Upper Nut (C Models) 11 N-m 1001b in
Splash Shield to Anchor Plate Bolts (C3500HD) 16 N-m 12 1b ft
Splash Shield to Steering Knuckle Bolts (C and K Models) 26 N-m 19 1b ft
Spring Eye Bolts and Nuts (C3500HD) 95 N-m 70 Ib ft
Spring to Axle U-Bolts (C3500HD) 125 N-m 92 Ib ft
Stabilizer Bar Bracket to Frame Nuts and Bolts (C and K Models) 33 N-m 241b ft
Stabilizer Bracket Bolts (C3500HD) 7 N-m 60 Ib in
Stabilizer Clamp Bolts (C3500HD) 29 N-m 21 Ib ft
Stabilizer Link Nuts (C and K Models) 18 N-m 131b ft
Stabilizer to Link Nuts (C3500HD) 68 N-m 501b ft
Steering Arm to Knuckle Nut (C3500HD) 285 N-m 2101b ft
Steering Knuckle Nuts (C3500HD) 312 N-m 230 Ib ft
Suspension Bumper (C3500HD) 34 N-m 25 Ib ft
Torsion Bar Support Link Nuts (4 Door Utility K Models) 125 N-m 92 Ib ft
Torsion Bar Support Center Nuts (K Models) 24 N-m 181b ft
Torsion Bar Support Outside Nuts (K Models) 62 N-m 46 1b ft
Upper Ball Joint Nuts (C Models) 24 N-m 181b ft
Upper Ball Joint to Steering Knuckle Nut (C and K Models) 100 N-m 74 Ib ft
Upper Control Arm to Frame Nuts and Bolts (C and K Models) 190 N-m 140 Ib ft
Upper Shock Absorber Bolt and Nut (C3500HD) 50 N-m 37 Ib ft
Front Chassis Spring 7.412
Front Spring Bumper Bolt Stop 7,421
Front Spring Insulator 7.420
Front Wheel Bearing Cone 6.135
Front Wheel Bearing Retainer Seal 6.326
Front Wheel Hub Grease Cap 6.330
Front Wheel Inner Bearing and Cup 6,311
Front Wheel Outer Bearing 6.313
Shock Absorber Bolt Nut 7.347
Shock Absorber Bracket 7.380
Shock Absorber Insulator 7.388
Shock Absorber Retainer 7.389
Stabilizer Shaft 7.241
Stabilizer Shaft Clamp 7.243
Stabilizer Shaft Insulator 7.243
Stabilizer Shaft Link 7.240
Steering Knuckle 6.020
Steering Knuckle Lower Control Arm Bolt and Cam Kit 6.172
Steering Knuckle Lower Control Arm Bushing 6.170
Steering Knuckle Lower Control Arm Pivot Nut and Ball Joint Stud Kit and Washer 6 174
Steering Knuckle Spindle Nut 6.022
Steering Knuckle Spindle Washer 6.321
Steering Knuckle Upper and Lower Control Arm Bumper 6.176
Steering Knuckle Upper and Lower Control Arm Kit 6.168
Steering Knuckle Upper Control Arm Bushing and Ball Joint Stud Kit 6,164
Suspension Absorber 7.345
Component Locator
Front Suspension Components
Shook Absorber, Axle Tie Rod, and Components (C3500HD)
Legend
(1) Shock Absorber Upper Mounting Bolt (13) Spring Hanger to Frame Nut
(2) Shock Absorber Upper Mounting (14) Spring Hanger to Frame Washer
Bolt Washer (15) Axle Tie Rod
(3) Shock Absorber Upper Mounting Nut (16) Axle Tie Rod Lower Mounting Bolt
(4) Front Spring Mounting Bolt (17) Axle Tie Rod Lower Mounting Washer
(5) Front Spring Mounting Washer (18) Stabilizer Link Lower Mounting Washer
(6) Front Spring Mounting Nut (19) Stabilizer Link Lower Mounting Nut
(7) Shock Absorber Assembly (20) Stabilizer Shaft Clamp
(8) Shock Absorber Lower Mounting Washer (21) Stabilizer Shaft U-bolt
0 ) Shock Absorber Lower Mounting Nut (22) Stabilizer Shaft Insulator
(10) Axle Tie Rod Upper Mounting Bolt (23) Front Stabilizer Bracket Mounting Bolt
(11) Axle Tie Rod Lower Mounting Washer (24) Stabilizer Shaft
(12) Axle Tie Rod Upper Mounting Nut (25) Axle Tie Rod Lower Mounting Washer
(26) Axle Tie Rod Lower Mounting Nut (32) Stabilizer Link Retainers
(27) Front Axle (33) Stabilizer Link Insulator
(28) Front Stabilizer Bracket (34) Stabilizer Link Mounting Nut
(29) Front Stabilizer Mounting Bracket Washer (35) Spring Hanger to Frame Bolt
(30) Front Stabilizer Mounting Bracket Nut (36) Spring Hanger to Frame Washer
(31) Stabilizer Link
Control Arm and Components (2WD)
Legend
(1) Cam (14) Lower Ball Joint Cotter Pin

(2) Upper Control Arm Bushing (15) Lower Ball Joint
(3) Upper Control Arm (16) Lower Ball Joint Nut
(4) Nut (17) Lower Control Arm
(5) Upper Ball Joint (18) Lower Control Arm Bushing
(6) Brake Hose Bracket (19) Front Coil Spring
(7) Upper Control Arm to Frame Nut (20) Front Coil Spring Upper Insulator
(8) Upper Ball Joint Nut (21) Lower Control Arm to Frame Bolts
0) Brake Hose Bracket Screw (22) Lower Control Arm to Frame Nut
(10) Upper Control Arm (23) Upper Control Arm to Frame Nut
(11) Lower Control Arm Bushing (24) Cams
(12) Lower Control Arm Bumper
(25) Upper Control Arm to Frame Bolts
(13) Lower Control Arm Bumper Nut
157093
Legend
(1) Front Spring Spacer Cushion (17) Anchor Plate

(2) Front Spring U-bolt (18) Splash shield Bolt
(3) Front Spring (19) Wheel Hub Rotor Bolt Washer
(4) Spring Spacer (20) Bearing Seal
(5) Front Stabilizer Bracket Nut (21) Wheel Hub Bolt
(6) Front Stabilizer Bracket Washer (22) Wheel Hub
(7) Front Stabilizer Bracket (23) Hub Outer Bearing
(8) Steering Knuckle Nut (24) Washer
0) Steering Knuckle Washer (25) Retainer Cap Cotter Pin
(10) Steering Knuckle (26) Retainer Cap
(11) Steering Knuckle Nut (27) Wheel Bearing Nut
(12) Front Spring U-bolt Nut (28) Inner Bearing
(13) Front Spring U-bolt Washer (29) Hub Rotor
(14) Front Stabilizer Bracket Bolt (30) Wheel Hub Rotor Bolt
(15) Brake Caliper (31) Bearing Seal Shield
(16) Splash Shield (32) Front Stabilizer Bracket Bolt
(33) Spring Hanger Washers (36) Spring Hanger to Front Spring Nut
(34) Spring Hanger to Front Spring Bolt (37) Cushion Nut
(35) Spring Hanger (38) Spacer

Bail Joint Wear Check
4. Check the ball joints for vertical looseness. With the

vehicle on the jack stands, place a dial indicator (1)
Important: against the spindle to show vertical movement.
• The vehicle must rest on a level surface.
• The vehicle must be stable. Do not rock the
vehicle on the floor stands.
• The upper control arm bumper must not contact
the frame.
1. Raise the vehicle. Support the vehicle with safety
stands. Support the lower control arm with a floor
stand or jack, as far outboard as possible,
under the stabilizer shaft bracket.
important: If a seal is cut or torn, replace the
ball joint.
2. Wipe the ball joints clean. Check the seals for
cuts or tears.
3. Adjust the wheel bearings. Refer to Wheel
Bearing Adjustment (2WD).
Notice: Do not pry between the lower arm and the

drive axle (halfshaft) boot or in such a manner that the
ball joint seal is contacted. Damage to the drive
axle (halfshaft) boot will result (4WD).
5. Pry between the lower control arm and the outer
race (2) while reading the dial indicator. This
shows vertical looseness in the ball joints.
5.1. The indicator reading should be no more
than 2 mm (0.08 in).
5.2. If the reading is too high, replace the
ball joint.
Repair Instructions
Wheel Hub Bolt Replacement
(RWD-AII Except C3500HD)
Removal Procedure
Tools Required
J 9 7 4 6 - 0 2 Wheel Stud Remover
1. Raise the vehicle. Support the vehicle with
safety stands.
2. Remove the tire and wheel assembly. Refer to
W h e e l R e m o v a l (S in g le W h e els) in Tires and
Wheels.
Notice: Support the caliper with a piece of wire to
prevent damage to the brake line.
3. Remove the brake caliper. Refer to B ra k e C a lip e r
R e p la c e m e n t (F ro n t D e lc o ) or B ra k e C a lip e r
R e p la c e m e n t (F ro n t B end ix) in Disc Brakes.
4. Remove the hub/rotor. Refer to W h e el
Hub, B earing, a n d S e a l R e p la c e m e n t
(R W D -A II E x c e p t C 3 5 0 0 H D ).
5. Remove the wheel hub bolts with a press.
• Support the hub/rotor using the J 9 7 4 6 -0 2 and
the press bars.
• Do not damage the wheel mounting surface on
the hub/rotor flange.
1. Install the wheel hub bolts into the hub/rotor.
1.1. Place four washers and a nut on the bolt.
1.2. Tighten until the bolt is fully seated in
the hub/rotor.
2. Install the hub/rotor. Refer to W h e e l Hub,
B earing, a n d S e a l R e p la c e m e n t
3. Install the brake caliper. Refer to B ra k e C a lip e r
R e p la c e m e n t (F ro n t B endix) in Disc Brakes.
4. Install the wheel assembly. Refer to W h e e l
Installation (S in g le W h e e ls -F ro n t o r R e a r) in
Tires and Wheels.
179465
Wheel Hub Bolt Replacement
(RWD-C3500HD)
Removal Procedure
Tools Required
J 9746-02 Wheel Stud Remover
W h e e l R e m o v a l (S ing le W h eels) in Tires and
Wheels.
2. Remove the hub/rotor assembly. Refer to
Replacement (RWD-C3500HD).
Important: Place the J 9746-02 between the press
bars and the hub/rotor in order to protect the rotor
surfaces.
3. Remove the wheel hub bolts with a press.
• Using the J 9746-02 and the press bars,
support the hub/rotor.
• Do not damage the wheel mounting surface
on the hub/rotor flange.
1. Install the wheel hub bolts into the hub/rotor.
1.1. Place four washers onto the bolt. Fasten
a nut onto the bolt until the nut bottoms on
the washers.
1.2. Tighten the nut until the bolt fully seats into
the hub/rotor.
1.3. Remove the nut and the washers.
2. Install the hub/rotor to the vehicle. Refer to
W h e e l Hub, B earing, a n d S e a l R e p la c e m e n t
( R W D -C 3 5 0 0 H D ) in Front Suspension.
3. Install the tire and wheel assembly. Refer to W h e e l
Installation (S ing le W h e els-F ro n t o r R e a r) in
Tires and Wheels.
Wheel Hub Bolt Replacement (S4WD)
Removal Procedure
Tools Required
J 6 6 2 7 -A Wheel Stud Remover
safety stands.
2. Remove the tire and the wheel. Refer to W h e e l
R e m o v a l (S in g le W h eels) in Tires and Wheels.
R e p la c e m e n t (F ro n t B en d ix) in Disc Brakes.
4. Remove the rotor. Refer to B ra k e R o to r
R e p la c e m e n t (K M o d e ls B e lo w 8 6 0 0 G V W ) or
B ra k e R o to r R e p la c e m e n t ( K M o d e ls 8 6 0 0 G V W
a n d A b o v e ) in Disc Brakes.
Important: Do not hammer on a wheel bolt.

5. Remove the hub bolt using the J 6 6 2 7 -A .
1. Install the stud to the hub and bearing assembly.
2. Install four washers and the nut to the stud.
Tighten
2.1. Install the nut. Draw the stud in.
2.2. Remove the nut and the washers.
Notices.
3. Install the rotor. Refer to B ra k e R o to r R e p la c e m e n t
(K M o d e ls B e lo w 8 6 0 0 G V W ) or B ra k e R o to r
R e p la c e m e n t ( K M o d e ls 8 6 0 0 G V W a n d A b o v e )
in Disc Brakes.
4. Install the brake caliper. Refer to B rake C a lip e r
R e p la c e m e n t (F ro n t D e lc o ) or B rake C a lip e r
R e p la c e m e n t (F ro n t B e n d ix) in Disc Brakes.
5. Install the tire and the wheel. Refer to W h e e l
Installation (S in g le W h e e ls -F ro n t o r R e a r) in
Tires and Wheels.
Stabilizer Shaft Replacement
(2WD-AII Except C3500HD)
Removal Procedure
safety stands.
Important: When you remove parts from the right side
and the left side of the vehicle, keep the parts
separated.
2. Remove the nut from the link bolt assembly.
3. Remove the link bolt.
4. Remove the spacer assembly.
5. Remove the bolts.
6. Remove the bracket.
7. Remove the stabilizer shaft.
8. Remove the rubber bushing.
9. Inspect all of the parts for wear and damage.
156963
Important: Place the bushings on the stabilizer shaft
with the slits facing toward the front of the vehicle.
1. Install the rubber bushings to the stabilizer shaft.
2. Install the stabilizer shaft.
3. Install the brackets over the bushings and the
stabilizer shaft.
4. Install the bolts to the brackets and the frame.
Tighten
Tighten the bolts to 33 N-m (24 Ib ft).
Notice: Refer to Fastener Notice in Caution and
Notices.
5. Install the spacer assembly.
6. Install the link bolt assembly.
7. Install the nuts.
I Tighten
156963 7.1. Tighten until the nut meets the end of the
bolt threads for torque value.
7.2. Tighten the nut to 18 N-m (13 Ib ft).
Stabilizer Shaft Replacement (C3500HD)
Removal Procedure
Tools Required
J 6627-A Wheel Stud and Tie Rod Remover
suitable safety stands.
Wheel Removal (Single Wheels) in Tires and
Wheels.
3. Remove the nut and the washer.
4. Remove the stabilizer shaft from the stabilizer
link. Using the J 6627-A, separate the stabilizer
link from the stabilizer end.
5. Remove the nuts, the washers, the clamp bolts,
and the clamps.
6. Remove the stabilizer shaft from the axle.
7. Remove the insulator from the stabilizer shaft.
8. Remove the nut, the retainer, and the insulator.
9. Remove the stabilizer link from the frame bracket.
• Pull the link from the bracket.
• Another insulator and retainer will come off
of the link.
Notices.
1. Install the stabilizer link to the frame bracket.
1.1. Slide a retainer and an insulator onto
the link.
1.2. Insert the link into the proper hole in the
frame bracket.
2. Install the insulator, the retainer, and the nut.
Tighten
Tighten the nut until the distance between each
retainer is 38 mm (1.5 in).
3. Install the stabilizer shaft to the front axle.
4. Install the insulators onto the stabilizer shaft.
5. Install the clamps, the clamp bolts, the washers,
and the nuts.
Tighten
Tighten the nuts to 29 N-m (21 Ib ft).
6. Install the stabilizer shaft to the stabilizer link.
7. Install the washer and the nut.
Tighten
8. Install the tire and wheel assembly. Refer to Wheel
Installation (Single Wheels-Front or Rear) in
Tires and Wheels.
Stabilizer Shaft Replacement (S4WD)
Removal Procedure
ggf h
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle in General Information.
2. Remove the wheel and tire assembly. Refer to
Wheels.
^ >7 / 1
Important: Remove the parts from the right front and
the left front of the vehicle. Keep the parts separated.
3. Remove the stabilizer link nuts.
4. Remove the stabilizer link bolts.
|k 5. Remove the stabilizer link spacer assemblies.
6. Remove the stabilizer shaft clamp bolts.
7. Remove the stabilizer shaft clamp.
<8> } F
i 8. Remove the stabilizer shaft.
9. Remove the stabilizer shaft insulators.
319069 10. Inspect all of the parts for wear and damage.
1. Install the insulators to the stabilizer shaft. Face
the slit in the insulator forward.
2. Install the stabilizer shaft to the frame and to the
lower control arm.
3. Install the stabilizer shaft clamp to the insulator.
Notices.
J p fe i DJ-Bpfr— .1,
TT
4. Install the stabilizer shaft clamp bolts to the frame.
Tighten
5. Install the stabilizer link spacer assemblies.
|k
6. Install the stabilizer link bolts.
7. Install the stabilizer link nuts.
i ) * f 1
Tighten
319069 8. Install the wheel and tire assembly. Refer to Wheel
Tires and Wheels.
Upper Bail Joint Replacement (RWD)
Removal Procedure
Tools Required
J 23742 Ball Joint Separator
Caution: Floor jack must remain under the lower
control arm during removal and installation to
retain the lower control arm in position. Failure to
do so could result in personal injury.
1. Raise the vehicle. Support the lower control arm
with floor stands.
Wheels.
3. Remove the brake caliper. Refer to Brake Caliper
Replacement (Front Delco) or Brake Caliper
Replacement (Front Bendix) in Disc Brakes.
4. Remove the rivets from the upper ball joint.
5. Use a 3.175 mm (Va in) drill in order to cut a
6.35 mm (1/4 in) deep hole in the center of
each rivet.
6. Drill away the rivet heads. Use a
12.75 mm (1/2 in) drill.
7. Punch the rivets out. Use a small pin punch.
8. Remove the cotter pin.
9. Remove the stud nut from the upper ball joint.
157000
Important: Support the knuckle assembly so that the
knuckle weight does not damage the brake hose.
10. Use the J 23742 as shown.
11. Apply pressure on the tool until the stud
breaks loose.
12. Remove the J 23742.
13. Pull the stud away from the knuckle.
14. Remove the ball joint.
1. Install a new upper ball joint to the upper
control arm.
Notices.
2. Position four attaching bolts and nuts.
Tighten
3. Remove the support from the knuckle assembly.
4. Install the upper ball joint to the steering
knuckle.
5. Install the stud nut.
Tighten
• Tighten the nut to 100 N-m (74 Ib ft).
• Tighten the stud nut in order to align the slot in
the stud nut with the hole in the stud.
156985
6. Install a new cotter pin.
7. Install the brake caliper. Refer to Brake Caliper
installation (Single Wheels-Front or Rear) in
Tires and Wheels.
Important:
® Check the running clearance at all suspension
components.
• Check the front wheel alignment. Refer to
Measuring Wheel Alignment (C Model) in Wheel
Alignment.
Upper Ball Joint Replacement (S4WD)

Removal Procedure
Tools Required
Wheels.
Caution: Floor ja ck must remain under the lower
control arm during removal and Installation to
do b o could result in personal injury.
3. Place a floor jack under the control arm. Raise
the jack in order to support the control arm.
4. Remove the brake hose and the bracket
(upper control arm only).
5. Using a 3.17 mm (Vs in) drill, cut a 6.35 mm (Vi in)
deep hole in the center of each rivet.
6. Using a 12.7 mm (Vz in) drill bit, drill away the
rivet heads.
157000

9. Remove the stud nut from the upper ball joint.
10. Using the J 36607, remove the ball joint from the
knuckle. Support the knuckle.
11. Remove the ball joint.
157043
1. Install the ball joint to the control arm.
Notices.
2. Install the bolts and the nuts to the ball joint.
Tighten
• For K1 and K2, tighten the nuts to
23 N*m (17 1b ft).
• For K3, tighten the nuts to 70 N-m (52 Ib ft).
157044
3. Install the ball joint to the knuckle.
4. Install the ball joint stud nut.
Important; Tighten the nut with the control arm at the
proper Z height. Refer to Trim Height inspection
Procedure in Suspension General Diagnosis.
Tighten . v -
Tighten the nut to 100 N-m (74 Ib ft). Tighten the
nut in order to align the cotter pin. Do not
tighten more than 1/e turn.
5. Install the new cotter pin. Bend the pin ends
against the nut.
6. Install the brake hose and the bracket
(upper control arm only).
Tires and Wheels.
9. Check the front wheel alignment. Refer to 157043
Measuring Wheel Alignment (K Model) in Wheel
Alignment. , ■ ..
Low er Bail J o in t Replacement (RWD)

Removal Procedure / . \
For control arms and components, refer to Control
Arms and Components (2WD).
Tools Required
@J 9519-D Ball Joint Remover and Installer Set
• J 23742 Ball Joint Separator
1. Raise the vehicle. Support the frame with
safety stands.
Wheels.
3. Place a floor jack under the,control .arm spring -
seat. Raise the jack in order to support the
control arm.
5. Remove the cotter pin and the nut.
6. Break the ball joint loose from the knuckle using
the J 23742.
Important; Place a wooden block between the frame
and the upper control arm in order to block the
knuckle assembly out of the way.
7. Remove the lower control arm from the knuckle.
Guide the lower control arm out of the splash
shield with a screwdriver while lifting the upper
control arm with a pry bar.
8. Remove the lower ball joint from the lower control

arm using the tools as shown.
9. Inspect the tapered hole in the steering knuckle.
Remove any dirt. If the tapered hole is out of
round, deformed or damaged, replace the knuckle.
372053
1. Install a new ball joint into the lower control arm.
1.1. Press in the ball joint using the tools
as shown.
1.2. The ball joint will bottom on the control arm.
2. Install the ball joint stud into the steering knuckle.
Notices.
3. Install the stud nut onto the stud.
Tighten
Tighten the nut to 128 N*m (94 Ib ft). Tighten in
order to align the slot in the stud nut with the hole
in the stud.
4. Install a new cotter pin to the stud.
372042
Tires and Wheels.
8. Check the front wheel alignment. Refer to
Alignment.
Lower Ball Joint Replacement (S4WD)

Removal Procedure
Tools Required
• J 2 4 3 1 9 -B Steering Linkage Puller
• J 39549 Ball Joint/Tie Rod End Separator
• J 9 5 1 9 - E Ball Joint Remover/Installer Set
• J 4 1 4 3 5 Ball Joint Remover and Installer Kit,
consisting of: J 41435-1, 2, 3
• J 2 9 1 9 3 Steering Linkage Installer
W h e e l R e m o v a l (S in g le W h eels) in Tires and
Wheels.
Caution: Floor Jack must remain under the lower
retain the lower control arm in position. Failure to 157043
3. Place a floor jack under the control arm. Raise
the jack until the jack supports the control arm.
4. Remove the halfshaft. Refer to H a lfs h a ft A s s e m b ly
R e p la c e m e n t in Front Drive Axle.
R e p la c e m e n t (F ro n t B end ix) in Disc Brakes.
6. Remove the cotter pin and the nut from the lower
control arm ball joint.
7. Using J 39549, break the ball joint loose from the
knuckle.
8. Remove the lower control arm from the knuckle.
9. Remove the knuckle from the vehicle.
10. Remove the ball joint from the lower control arm.
J 4 14 3 5-3 Use the tools as shown.
11. Inspect the tapered hole in the steering knuckle
and remove any dirt. If this hole is out of round,
J 41805 deformed, or damaged, replace the knuckle.
J 41435 -1
372022
1. Using Loctite® Cleaning Solvent 755, or
equivalent, clean the mounting surfaces of the
lower control arm ball joint and the new ball joint
prior to installation. Do not apply solvent to
the ball joint seal.
2. Install the new ball joint into the lower control arm.
2.1. Apply a 6 mm (W in) bead of Loctite® 680
evenly to the serrations on the bail joint
prior to installation.
2.2. Position the ball joint in the control arm with
the grease fitting toward the rear of the
vehicle.
2.3. Press in the ball joint using the tools !
as shown.
• The ball joint will bottom on the ■
control arm.
• When installing the ball joint with the
372035 J 41435, make sure the notch in the tool
aligns with the grease fitting.
3. Install the ball joint into the steering knuckle.
Notice: Refer to Fastener Notice in Cautioins and
Notices.
4. Install the stud nut onto the stud.
Tighten
Tighten the nut to 128 N-m (94 Ib ft). Tighten in
order to align the slot in the stud nut with the hole
in the stud.
5. Install a new cotter pin to the stud.
6. Install the halfshaft. Refer to Halfshaft Assembly
Replacement in Front Drive Axle.
Tires and Wheels.
Important: Check the front wheel alignment. Refer to 157043
Measuring Wheel Alignment (K Model) in Wheel
Alignment.
Steering Knuckle Replacement

Removal Procedure
Tools Required
1. Raise the front of the vehicle.
* Place safety stands under the front lift points.
• Do not place floor stands under the lower
control arms because spring tension is needed
to assist in breaking loose the ball joint studs.
Wheels.
4. Remove the hub/rotor assembly. Refer to
Wheel Hub, Bearing, and Seal Replacement
(RWD-AII Except C3500HD).
5. Remove the three bolts that attach the splash
shield to the knuckle.
6. Remove the knuckle seal if the knuckle is to be
replaced. Do not damage the knuckle seal.
7. Remove the lower ball joint stud from the knuckle

using the J 23742.
8. Remove the upper ball joint stud from the knuckle

using the J 23742.
9. Position a floor jack under the lower control arm
near the spring seat.
• Raise the jack until the jack just supports the
lower control arm.
• Raise the upper control arm. Disengage the
ball joint stud from the knuckle.
10. Remove the knuckle from the lower ball joint stud.
10.1. Clean the steering knuckle.
10.2. Inspect the steering knuckle tapered hole.
If this tapered hole is out-of-round,
deformed, or damaged, replace the
knuckle.
1. Install the upper ball joint into the knuckle. Refer
to Upper Ball Joint Replacement (RWD).
2. Install the lower ball joint into the knuckle. Refer
to Lower Ball Joint Replacement (RWD).
3. Install the knuckle seal.
4. Install the splash shield to the knuckle.

Notices.
5. Install the bolts to the splash shield.
Tighten
6. Install the tie rod end into the knuckle.
7. Install the hub/rotor assembly. Refer to
Wheel Hub, Bearing, and Seal Replacement
8. Adjust the wheel bearings. Refer to Wheel
Bearing Adjustment (2WD).
Tires and Wheels.
10. Remove the floor stands.
Alignment.
Steering Knuckle Replacement (C3500HD) Installation Procedure
For steering arm, knuckle, and components, refer to
Removal Procedure Shock Absorber, Axle Tie Rod, and Components
For steering arm, knuckle, and components, refer to (C3500HD) or Front Spring and Components
Shock Absorber, Axle Tie Rod, and Components (C3500HD).
(C3500HD) or Front Spring and Components 1. Install the bushings. Ream the new bushings to
(C3500HD). between 29.982-30.022 mm (1.1804-1.1820 in)
1. Raise the vehicle. Support the vehicle with after installation.
suitable safety stands. 2. Install the steering knuckle.
2. Remove the tire and wheel assembly. Refer to 3. Install the thrust bearing shim and the dust seal.
Wheel Removal (Single Wheels) in Tires and Prelube the thrust bearing. Refer to Fluid and
Wheels. Lubricant Recommendations in Maintenance and
3. Remove the brake caliper. Refer to Brake Caliper Lubrication.
Replacement (Front Delco) or Brake Caliper 4. Install the king pin and the lock pin.
4.1. Prelube the king pin.
4. Remove the hub/rotor assembly. Refer to Wheel
Hub, Bearing, and Seal Replacement 4.2. Insert the spacers in the correct order.
(RWD-C3500HD). Notice: Refer to Fastener Notice in Cautions and
5. Remove the bolts, the washers, and the nuts. Notices.
6. Remove the anchor plate, the splash shield, and 5. Install the washer and the nut.
the steering arm. Tighten
6.1. Pull the anchor plate and the splash shield Tighten the nut to 40 N-m (29 Ib ft).
off of the knuckle. The steering arm hangs 6. Install the gaskets.
by the rods.
7. Install the caps to the steering knuckle.
6.2. Remove the bolts and the washers in order
to separate the anchor plate from the , 8. Install the stabilizer bracket and the bolts.
splash shield. Tighten
6.3. Refer to Tie Rod Replacement (All Except Tighten the bolts to 7 N-m (60 Ib in). -
C3500HD) and Tie Rod Replacement 9. Install the steering arm, the splash shield, and the
(C3500HD) in Steering Linkage in order to anchor plate.
separate the steering arm from the tie 10. Install the bolts and the washers that attach the
rod and the pitman arm. splash shield to the anchor plate.
7. Remove the bolts and the washers. 11. Install the bolts, the washers, and the nuts that
8. Remove the stabilizer bracket. attach the anchor plate and the steering arm to
9. Remove the gaskets. the steering knuckle.
10. Remove the caps from the steering knuckle. Tighten
11. Remove the nut and the washer. • Tighten the bolts to 16 N-m (12 Ib ft).
12. Remove the lock pin. • Tighten the nuts to 312 N-m (230 Ib ft).
13. Remove the king pin from the steering knuckle. 12. Install the steering arm to the steering linkage.
• Using a drift, drive out the king pin. 13. Install the hub/rotor assembly. Refer to Wheel
• The spacers and the bushings will also Hub, Bearing, and Seal Replacement
come out. (RWD-C3500HD).
14. Remove the steering knuckle from the axle. 14. Adjust the wheel bearings. Refer to Wheel
Bearing Adjustment (C3500HD).
15. Remove the dust seal, the shim, and the
thrust bearing. 15. Install the brake caliper. Refer to Brake Caliper
Tires and Wheels.
18. Check the front wheel alignment. Adjust as
necessary. Refer to Measuring Wheel Alignment
Upper Control Arm Replacement (RWD) Installation Procedure
Removal Procedure 1. Install the bushings.
For control arms and components, refer to Control 2. Install the upper control arm to the frame.
Arms and Components (2WD). Notice: Refer to F a s te n e r N o tic e in Cautions and
Caution: Floor jack must remain under the lower Notices.
control arm during removal and installation to Important:
• The pivot bolts must be installed in the proper
direction.
1. Raise the front of the vehicle.
• Tighten the front nut prior to tightening the
• Support the lower control arm with rear nut.
floor stands.
• Tighten the nuts with the control arm at Z height.
• Because the weight of the vehicle is used to Refer to Trim H e ig h t Inspection P ro c e d u re in
relieve the spring tension on the upper Suspension General Diagnosis.
control arm, position the floor stands between
the spring seats and the ball joints of the 3. Install the bolts and new nuts.
lower control arms in order to maintain Tighten
maximum leverage.
Wheel Removal (Single Wheels) in Tires and 4. Install the upper ball joint to the steering knuckle.
Wheels. Refer to U p p e r B a ll Joint R e p la c e m e n t (R W D ).
3. Remove the air cleaner extension, if necessary. 5. Install the brake hose bracket to the upper
control arm.
4. Remove the brake hose bracket from the
upper control arm. 6. Install the bracket screws and the nuts.
4.1. Remove the nuts and the screws. Tighten
4.2. Tie the hose out of the way. Tighten the nuts to 18 N-m (13 Ib ft).
5. Remove the upper ball joint from the steering 7. Install the brake hose to the bracket.
knuckle. Refer to Steering Knuckle Replacement 8. Install the air cleaner extension, if necessary.
6. Remove the attaching bolts and nuts of the upper
Installation (S in g le W h e els-F ro n t o r R e a r) in
control arm.
Tires and Wheels.
7. Remove the upper control arm.
8. Remove the bushings. M e a s u rin g W h e e l A lig n m e n t (C M o d e l) in Wheel
9. Inspect all of the parts for wear and damage. Alignment.
Upper Control Arm Replacement (S4WD)
Removal Procedure
Wheels.
3. Remove the air cleaner extension, if necessary.
4. Remove the brake hose.
4.1. Remove the nut and the screw.
4.2. Remove the bracket and the hose.
4.3. Tie the hose out of the way.
6. Remove the nut.
7. Disconnect the upper control arm from the
knuckle.
8. Remove the nuts.
10. Remove the upper control arm.
11. Remove the bushings.
1. Install the bushings.
2. Install the upper control arm to the frame.
157043
3. Install the bolts and the washers. Make sure the
bolt heads are opposed inside the bracket.
Notices.
Important: Tighten the front nut prior to tightening the
rear nut.
Tighten the nuts with the control arm at Z height.
Refer to Trim Height Inspection Procedure in
Suspension General Diagnosis.
4. Install the new nuts.
Tighten
5. Install the upper ball joint stud to the knuckle.

6. Install the nut to the upper ball joint stud.
Tighten
• Tighten the nut to 100 N-m (94 Ib ft).
• Tighten the nut in order to align the cotter pin.
Do not tighten more than V e turn.
7. Install the new cotter pin. Bend the pin ends
against the nut flats.
8. Remove the support from the knuckle.
9. Install the brake hose.
9.1. Install the bracket and the hose.
9.2. Install the screw and the nut.
10. Install the air cleaner extension, if necessary.
11. Install the tire and wheel assembly. Refer
to Wheel Installation (Single Wheels-Front
or Rear) in Tires and Wheels.
157043
Lower Control Arm Replacement (RWD)
Removal Procedure
Tools Required
2. Support the vehicle with safety stands.
W h e e l R e m o v a l (S in g le W h eels) in Tires and
Wheels.
4. Remove the hub and the rotor. Refer to
W h e e l Hub, Bearing, a n d S e a l R e p la c e m e n t
5. Remove the cotter pin and the nut.
6. Separate the ball joint using the J 2 3 7 4 2 .
7. Disconnect the control arm from the knuckle.
8. Remove the coil spring. Refer to F ro n t Coil
S prings R eplac em en t.
9. Remove the nuts from the pivot bolts.
10. Remove the pivot bolts from the lower control arm.
11. Remove the lower control arm.
12. Remove the bushings.
1. Install the control arm bushings.
2. Install the control arm to the frame.
Important: The pivot bolts must be installed in the
proper direction.
3. Install the pivot bolts and the nuts.
4. Install the coil spring. Refer to F ro nt C oil Springs
R e p lac em en t.
5. Install the control arm to the steering knuckle.
Notice: Refer to Fastener Notice in Cautions
and Notices.
Important: Tighten the nuts of the control arm at the
proper Z height. Refer to Trim H e ig h t Inspection
P ro ce d u re in Wheel Alignment.
6. Install the ball joint stud nut.
Tighten
• Tighten the nuts to 165 N-m (121 Ib ft).
• Tighten the ball joint stud nut to
128 N-m (94 Ib ft). Tighten the nut by aligning
the slot in the stud nut with the hole in
the stud.
7. Install a new cotter pin.
8. Install the hub and the rotor. Refer to W h e e l Hub,
B earin g, a n d S e a l R e p la c e m e n t (R W D -A II E x c e p t
C 3 5 0 0 H D ).
9. Install the tire and wheel assembly. Refer to W h e el
Installation (S ing le W h e els-F ro n t o r R e a r) in Tires
and Wheels.
10. Remove the safety stands.
Lower Control Arm Replacement (S4WD)
Removal Procedure
Tools Required
• J 2 4 3 1 9 - B Steering Linkage Puller
• J 3 6 2 0 2 Torsion Bar Loading/Unloading Tool
• J 3 6 6 0 7 Ball Joint Separator
• J 3 6 6 1 8 Lower Control Arm Bushing Service Set
(Series 30)
• J 9 5 1 9 -2 3 Ball Joint C-Clamp
W h e e l R e m o v a l (S ing le W h eels) in Tires and
Wheels.
3. Unload the torsion bar using the J 3 6 2 0 2 .
3.1. Mark the adjuster bolt for installation.
3.2. Slide the bar forward in order to remove the 156607
adjuster arm.
3.3. Remove the adjuster arm.
• Refer to Torsion B a r a n d S u p p o rt
A s s e m b ly R e p la c e m e n t (All E x c e p t
4 D o o r Utility).
• For the 4 Door Utility models, refer to
Torsion B a r a n d S u pport A s s e m b ly
R e p la c e m e n t (4 D o o r Utility).
4. Remove the outer axle shaft nut (2) and the
washer (3) from the hub assembly (4).
R e p la c e m e n t (F ro nt D e lc o ) or B rake C a lip e r
6. Remove the brake rotor. Refer to B ra k e R o to r
B ra k e R o to r R e p la c e m e n t (K M o d e ls 8 6 0 0 G V W
7. Remove the lower shock absorber bolt from the
control arm. Compress the shock. Refer to S h o c k
A b s o rb e r R e p la c e m e n t (4 W D ).
8. Using the J 2 4 3 1 9 -B , disconnect the inner tie rod
end from the relay rod.
9. Support the lower control arm with a jack.
10. Remove the stabilizer link from the control arm.
Refer to S ta b iliz e r S h a ft R e p la c e m e n t
(C 3 5 0 0 H D ).
11. Remove the halfshaft assembly (5). Refer to
H a lfs h a ft A s s e m b ly R e p la c e m e n t in Front
Drive Axle.
12. Remove the cotter pin and the nut from the upper
ball joint.
13. Using the J 36607, disconnect the upper ball joint
from the knuckle.
14. Remove the lower control arm nuts and the

washers.
16. Remove the lower control arm and the knuckle
as a unit.
17. Remove the front bushing.
17.1. Using a punch, unbend the crimps.
17.2. Remove the bushing using J 36618-2,
J 9519-23, J 36618-4, and J 36618-1.
18. Remove the rear bushing (no crimp).
18.1. Removing the bushing using J 36618-5,
J 36618-3, J 36618-2, and J 9519-23.
18.2. If the bushings on the K1 and K2 vehicles
are worn or damaged, replace the lower
control arm.
. 156934
Installation-Procedure
1. Using the J 36618 and the J 9519-23, install the
front bushing.
• This applies to the K3 vehicle only.
• After installing the bushing, crimp the bushing
in place.
2. Using the J 36618 and the J 9519-23, install the
rear bushing.
3. Install the lower control arm and the knuckle
assembly to the crossmember and the frame
bracket. Install the front leg of the lower control
arm into the crossmember before installing
the rear leg into the frame bracket.
4. Install the bolts in the direction shown.
Notices.
Important; Tighten the nuts with the control arm at
the proper Z height. Refer to Trim Height inspection
Tighten the front nut prior to tightening the rear nut.
5. Install the new nuts.
Tighten
6. Prelube the steering knuckle seal.
7. Start the drive axle through the hub.
8. Connect the ball joint to the knuckle.

9. Install the ball joint nut.
Tighten
Tighten the nut to 128 N-m (94 Ib ft).
10. Install the cotter pin. Bend the pin ends against
the side of the nut.
11. Install the torsion bar adjuster arm.
11.1. Slide the bar rearward in order to install
the sides of the nut.
11.2. Using the J 36202, load the torsion bar.
11.3. Install the adjuster bolt and screw the bolt
down to the installation mark.
• Refer to Torsion Bar and Support
Assembly Replacement (All Except
4 Door Utility).
• For the 4 Door Utility models, refer to
Torsion B a r a n d S u p p o rt A s s e m b ly
Replacement (4 Door Utility). 157043
12. Install the halfshaft assembly (5). Refer to
H a lfs h a ft A s s e m b ly R e p la c e m e n t in Front
Drive Axle.
13. Install the lower shock absorber bolt. Refer to
S h o c k A b so rb er R e p la c e m e n t (4 W D ).
14. Install the stabilizer link. Refer to S ta b ilize r S h a ft
R e p la c e m e n t (C 3 5 0 0 H D ).
Installation (Single W h e els-F ro n t o r R e a r) in
Tires and Wheels.
Front Coil Springs .Replacement

Removal Procedure
For control arms and components, refer to Control
Arms and Components (2WD).
Tools Required
J 23028-01 Coil Spring Remover and Installer
1. Raise the vehicle on a hoist so that the control
arms hang free.
Wheels.
3. Remove the shock absorber. Refer to Shock
Absorber Replacement (RWD-AII Except
C3500HD).
4. Cradle the lower control arm. Use the J 23028-01,
secured to the end of a suitable jack.
5. Remove the stabilizer shaft from the lower control
arm. Refer to Stabilizer Shaft Replacement
(2WD-AII Except C3500HD).
5.1. Raise the jack in order to relieve tension on
the lower control arm pivot bolts.
5.2. Secure the spring with a chain through the
spring and the control arm.
6. Remove the pivot bolts and nuts.
6.1. Take the rear pivot bolt out first.
6.2. Lower the control arm by lowering the jack.
6.3. When compression is removed from the
coil spring, take the chain away.
7. Remove the coil spring and the insulator.
8. Position the coil spring properly for easy removal.
1. Install the coil spring and the insulator on the
lower control arm.
• The coil spring is installed with the tape at
the lowest position, and a gripper notch at
the top (2).
• Inspection drain holes (3). One hole must be
covered by the end of the spring, and one
hole must be open.
• Secure the spring with a chain through spring
and the control arm.
• Make sure the spring insulator (1) is on top.
2. Support the control arm using the J 23028-01.

3. Install the lower control arm in place on the frame.
Guide the control arm into place with a pry bar.

Notices.
Important: The pivot bolts must be installed in the
proper direction.
The nuts must be tightened with the control arm at
Z height. Refer to Trim Height Inspection Procedure in
Suspension General Diagnosis.
The front nut must be tightened before the rear nut.
4. Install the pivot bolts and the new nuts.
4.1. Insert and tighten the front bolt first.
4.2. Remove the chain and the jack.
Tighten
5. Install the stabilizer shaft. Refer to Stabilizer Shaft
Replacement (2WD-AII Except C3500HD).
156979
6. Install the shock absorber. Refer to Shock
Absorber Replacement (RWD-AII Except
C3500HD).
Tires and Wheels.
Leaf Springs Replacement

Removal Procedure
Tools Required
1. Raise the vehicle. Support the axle separately in
order to eliminate any load on the springs.
Wheels.
4. Remove the shock absorber from the axle.
157010

6. Remove the stabilizer link from the stabilizer
shaft. Using the J 6627-A, separate the stabilizer
shaft from the stabilizer link.
8. Remove the stabilizer link from the axle. Pull
the link free from the axle. Do not lose the
other insulator and retainer.
157007
9. Remove the nuts, the washers, and the U-bolts.
10. Remove the spacer and the spring spacer.
11. Remove the leaf spring from the axle.
12. Remove the nut, the washer, the bolt, and the
washer in order to separate the spring from the
rear shackle.
13. Remove the nut, the washer, the bolt, and the
washer in order to separate the spring from the
front hanger.
14. Pull the leaf spring back and out.
15. Remove the leaf spring from the frame.
157019
1. Install the leaf spring to the frame.
® Line up each end of the spring with the spring
hangers.
• The double wrap end of the spring should be
toward the front of the vehicle.
2. Attach the spring to the front spring hanger with
the washers, the bolt, and the nut.
Notices.
3. Attach the spring to the spring hanger with the
washers, the bolt, and the nut.
Tighten
Tighten the nut to 95 N-m (70 ib ft).
4. Install the leaf spring to the axle.
• Position the spring spacer onto the axle.
® Either of the aligning pins may contact the
edge of the leaf spring after the assembly 157019
is complete.
5. Install the spacer, the U-bolts, the washers, and
the nuts.
6. Install the stabilizer link (with lower retainer and
insulator) to the frame.
7. Install the stabilizer link upper insulator, retainer,
and the nut.
Tighten
retainer is 38.0 mm (1.5 in).
157024
8. Install the stabilizer link to the stabilizer shaft.

Tighten
10. Install the shock absorber to the axle.

Tighten
Tires and Wheels.
14. Check the front wheel alignment. Adjust as
necessary. Refer to Measuring Wheel Alignment
157010
Replacement (RWD-AII Except C3500HD)
Removal Procedure
R e p la c e m e n t (F ro n t D e lc o ) or H a lfs h a ft A s s e m b ly
R e p la c e m e n t in Disc Brakes.
2. Remove the cap from the hub/rotor.
3. Remove the cotter pin, the nut, and the washer.
Important: Do not damage the outer bearing and
the spindle threads.
4. Remove the hub/rotor from the spindle.
5. Remove the outer bearing.
6. Remove the seal. Pry the seal out and discard
the seal.
7. Remove the inner bearing.
Notice: Do not spin the wheel bearings with
compressed air to dry them-the wheel bearings may
be damaged.
8. Clean all of the parts in a solvent, then air dry. Do
not spin the bearings with compressed air.
9. Inspect the hub/rotor. Refer to B ra k e R o to r
T hickness Variation C h e c k or B ra k e R o to r L a teral
R u n o u t C h e c k or B rake R o to r T o leran ce in
Disc Brakes.
10. Inspect the bearings and the races for wear or
damage. Replace the parts as necessary. Refer
to W h e e l B earin gs D iag n o s is in Suspension
General Diagnosis.
Important:
• Make sure all of the parts are clean and free
of grease.-
• Apply an approved high-temperature front wheel
bearing grease to the spindle at the inner and
outer bearing seat, the shoulder, and the
seal seat.
• Also, finger apply a small amount of grease
inboard of each bearing cup in the hub/rotor.
• Pressure pack the bearings with a greasing
machine, or hand pack the bearings. Make sure
the grease is worked thoroughly into the
rollers, the cone, and the cage.
1. Install the inner bearing to the hub/rotor.
2. Apply an additional quantity of grease outboard of
the inner bearing.
3. Install the seal.
3.1. Lubricate the seal lip.
3.2. Use a seal installation tool or a flat block in
order to press the seal down flush with
the hub.
3.3. Seat the outer bearing and the cup.
Important: Do not scuff the spindle threads.
4. Install the hub/rotor to the spindle.
5. Install the outer bearing to the hub/rotor.
6. Install the washer.
Notices.
Important: Adjust the wheel bearings. Refer to W heel
B e arin g A d ju s tm en t (2 W D ).
7. Install the nut.
Tighten
7.1. Tighten the nut to 16 N-m (12 Ib ft), while
turning the wheel assembly forward
by hand.
7.2. Apply grease to the outboard side of the
outer bearing.
8. Install the brake caliper. Refer to B rake C a lip e r
R e p la c e m e n t (F ro nt D e lc o ) or H a lfs h a ft A s s e m b ly
R e p la c e m e n t in Disc Brakes.

Replacement (S4WD)
Removal Procedure
Tools Required
• J 3 6 6 0 7 Bali Joint Separator
• J 3 6 6 0 5 Steering Knuckle Seal Installer
W h e e l R e m o v a l (S ing le W h e els) in Tires and
Wheels.
Important: Wrap shop towels around the inner and
the outer C/V joint boots in order to avoid damage to
the boots during removal and installation.
157043 3. Remove the brake caliper. Refer to B ra k e C a lip e r
4. Remove the brake rotor. Refer to B ra k e R o to r
B ra k e R o to r R e p la c e m e n t (K M o d e ls 8 6 0 0 G V W
5. Remove the drive axle nut.
6. Remove the washer.
7. Remove the tie rod nut.
8. Disconnect the tie rod end from the knuckle.
Refer to Tie R o d R e p la c e m e n t (All E x c e p t
C 3 5 0 0 H D ) in Steering Linkage.
Important: Lay the hub and bearing assembly on the
hub bolt (outboard) side. This will prevent damage
or contamination of the bearing seal.
9. Using a puller, remove the hub and bearing
assembly.
10. Remove the halfshaft. Refer to H a lfs h a ft A s s e m b ly
11. Remove the splash shield bolts.
12. Remove the splash shield.
13. Support the lower control arm with a jack stand.
14. Remove the upper ball joint nut.
15. Using the J 3 6 6 0 7 , remove the upper ball joint
from the knuckle. Refer to U p p e r B a ll Joint
R e p la c e m e n t (S 4 W D ).
16. Remove the lower ball joint nut.
17. Using the J 3 6 6 0 7 , remove the lower ball joint
from the knuckle. Refer to L o w e r B a ll Jo int
R e p la c e m e n t (S 4 W D ).
18. Remove the knuckle.
19. Remove the seal from the knuckle.
1. Using the J 3 6 6 0 5 , install the seal into the
knuckle.
2. Connect the knuckle to the upper and the lower
ball joint.
N o tic e : Refer to F a s te n e r N o tice in Cautions and
Notices.
3. Install the ball joint stud nuts.
Tighten
3.1. Tighten the lower stud nut to
128 N-m (94 Ib ft).
3.2. Tighten the upper stud nut to
100 N-m (74 Ib ft).
3.3. Tighten the nuts in order to align the cotter
pin. Do not tighten more than Ve turn.
4. Install new cotter pins. Bend the pin ends against
the nut.
5. Install the splash shield. Properly align the 157043
splash shield.
6. Install the splash shield bolts.
Tighten
7. Prelube the steering knuckle seal.
8. Install the halfshaft. Refer to H a lfs h a ft A s s e m b ly
9. Install the hub and bearing assembly. Align the
threaded holes.
10. Install the bolts.
Tighten
11. Connect the tie rod end to the knuckle. Refer to
Tie R o d R e p la c e m e n t (A ll E x c e p t C 3 5 0 0 H D ) in
Steering Linkage.
12. Install th e tie rod nut.
Tighten
T ig h ten th e nut to 4 8 N -m (3 5 Ib ft).
13. Install th e w a s h e r.
14. Install th e d rive a x le nut.
Tighten
T ig h ten th e nut to 2 2 5 N -m (1 6 5 Ib ft).
15. Install th e b ra k e rotor. R e fe r to Brake Rotor
Replacement (KModels Below 8600 GVW) o r
Brake Rotor Replacement (K Models 8600 GVW
and Above) in D isc B rakes.
16. Install th e b ra k e ca lip er. R e fe r to Brake Caliper
Replacement (Front Bendix) in D isc B rakes.
17. Install th e tire an d w h e e l assem b ly. R e fe r to Wheel
T ire s an d W h e e ls .
18. R e m o v e th e ja c k stand .
19. L o w er th e ve h ic le .
2 0 . C h e c k th e v e h ic le trim height. A djust if n ecessary.
R e fe r to Trim Height Inspection Procedure in
S u sp en sio n G e n e ra l D iag n osis.

Replacement (RWD-C3500HD)
Removal Procedure
F o r front spring an d co m p o n en ts, refer to Front Spring
and Components (C3500HD).
Tools Required
J 9746-02 W h e e l S tu d R e m o v e r
1. R a is e th e ve h ic le . S u pp o rt th e ve h icle with
su itab le s a fe ty stand s.
2. R e m o v e th e tire an d w h e e l assem b ly. R e fe r to
Wheel Removal (Single Wheels) in T ire s and
W h e e ls .
Notice: S u pp o rt th e c a lip e r w ith a p ie ce of w ire to
p rev en t d a m a g e to th e b rak e line.
3 . R e m o v e th e b ra k e calip er. R e fe r to Brake Caliper
Replacement (Front Bendix) in D isc B rakes.
4 . R e m o v e th e re tain e r/ca p .
5 . R e m o v e th e co tter pin, th e nut, an d th e w ash er.
6. R e m o ve th e w h e e l hub/rotor.
• Pull th e h ub /ro tor fre e from th e spindle. M a k e
su re th e o u te r w h e el b earin g co m es fre e.
• D o not d a m a g e th e steerin g knuckle
spindle th rea d s .
7 . R e m o v e th e in n er w h e e l b earing . P ry out th e seal.
8 . R e m o v e th e ra ce s. Using a b rass drift, drive out
e a ch race.
9 . C le a n a n y g re a s e from th e h ub /ro tor an d th e
steerin g kn uckle spind le. C le a n an y g re a s e
from insid e th e hub.
Notice: Do not spin the wheel bearings with Notice: Failure to completely pack the wheel bearing
compressed air to dry them-the wheel bearings may (cones, rollers, and cage) with grease will result in
be damaged. premature wheel bearing damage and/or wear.
10. Using clean solvent and a small brush with no 4. Fill each wheel bearing (cone and roller assembly)
loose bristles, clean any grease from the wheel full of grease.
bearings and the races. • Use a cone-type grease machine that forces
11. Inspect the wheel bearings and the races for grease into the bearing.
damage or wear. • If a cone-type grease machine is not available,
• Refer to W h e e l B earin gs D iag n osis in pack the wheel bearing by hand. When
Suspension General Diagnosis. packing the wheel bearing by hand, work the
• If a bearing or the race is damaged, replace grease into the bearings between the
both of these. rollers, the cones, and the cage.
12. Inspect the hub/rotor for damage or wear. 5. Install the inner wheel bearing into the hub/rotor.
Put an additional quantity of grease outboard of
• Check for out of round or scored conditions. this bearing.
• Check for pitting or cracks. 6. Install the new seal.
• If necessary, repair or replace the hub/rotor.
6.1. Using a seal installer or a block, install the
Installation Procedure seal in order to ensure that the seal is flush
For Front Spring and Components refer to F ro n t
with the hub/rotor flange.
S p ring a n d C o m p o n e n ts (C 3 5 0 0 H D ). 6.2. Lubricate the seal lip with a thin layer of
grease.
Notice: Start the races squarely inside the hub/rotor
to avoid distortion and possible cracking. 7. Install the hub/rotor. Do not damage the steering
1. Install the races into the hub/rotor. knuckle spindle threads.
1.1. Place the hub/rotor on the J 9 7 4 6 -0 2 . Rest 8. Install the outer wheel bearing. Slide the bearing
this assembly on the press bars. over the spindle until the wheel bearing fully seats
against the hub/rotor outer race.
1.2. Using a 7.6 cm (3 in) diameter bar, or
equivalent, press the outer bearing race Notice: Refer to F a s te n e r N o tice in Cautions and
into position. Notices.
1.3. Remove the J 9 7 4 6 -0 2 and use a 9. Install the washer, the nut, and the cotter pin. Do
7.6 cm (3 in) diameter bar, or equivalent, in not place the cotter pin through the hole in the
order to press the inner bearing race spindle until the wheel bearings are adjusted.
into position. If the bar is larger than Tighten
7.6 cm (3 in), the bar may damage the Tighten the nut to 16 N-m (12 Ib ft), while turning
bearing seal seat. the hub/rotor assembly by hand.
Important: 9.1. Apply an additional amount of grease
• Use an approved, high-temperature front wheel outboard of the wheel bearing.
bearing grease in order to lubricate the bearings. 9.2. Adjust the wheel bearings. Refer to W h e e l
Refer to F lu id a n d Lub ricant R e co m m e n d a tio n s B e arin g A d ju stm en t (C 3 5 0 0 H D ).
in Maintenance and Lubrication.
10. Install the cotter pin.
• Do not mix different greases because mixing may
change the grease properties, resulting in poor 11. Install the retainer/cap in place.
performance. 12. Install the brake caliper. Refer to B ra k e C a lip e r
2. Apply a thin film of grease to the steering knuckle
spindle at the outer wheel bearing seat and at the
inner wheel bearing seat, the shoulder, and the 13. Install the tire and wheel assembly. Refer to W h e e l
seal seat. Installation (Single W h e e ls -F ro n t o r R e a r) in
3. Apply a small amount of grease inboard of each Tires and Wheels.
wheel bearing retainer/cap. 14. Lower the vehicle.
Replacement (All Except 4 D oor Utility)
Removal Procedure
Tools Required
J 36202 Torsion Bar Unloading/Loading Tool
2. Remove the adjustment assemblies on both
torsion bars.
2.1. Mark the adjustment bolt setting.
2.2. Using the J 36202, increase the tension on
the adjustment arm.
2.3. Remove the adjustment bolt and the
retaining plate.
2.4. Move the tool aside.
2.5. Slide the torsion bars forward.
2.6. Remove the adjustment arms.
3. Remove the nuts and the bolts from the torsion
bar support crossmember. Slide the support
crossmember rearward.
4. Remove the torsion bars. Note the location and
the front ends of the torsion bars. The left side
and the right side torsion bars are different.
5. Remove the support crossmember.
6. Remove the retainer, the spacer, and the insulator
from the support crossmember.
157033
1. Install the insulator, the spacer, and the retainer
on the support crossmember.
2. Install the support crossmember assembly on the
frame, rearward of the mounting holes.
3. Install the torsion bars.
3.1. Make sure the bars are installed on the
proper sides.
3 .2 . Slide the support crossmember forward
until the torsion bars are supported.
4. Install the adjustment arms on the torsion bars.
N o tice: Refer to Fastener Notice in Cautions and
Notices.
5. Install the bolts and the nuts into the torsion bar
support crossmember.
Tighten
5.1. Tighten the center nut to 24 N-m (18 Ib ft).
5.2. Tighten the edge nuts to 62 N-m (46 Ib ft).
6 . Install the adjustment retainer plate and the bolt
on both torsion bars.
7. Using the J 36202, increase the tension on the
torsion bar.
8 . Install the retaining plate and the adjustment bolt.
141835
9. Set the adjustment bolt to 34 mm (1.3 in).
10. Release the tension on the torsion bar until the
load is taken up by the adjustment bolt.
13. Check the Z height, refer to Trim Height Inspection

Replacement (4 Door Utility)
Removal Procedure
Tools Required
J 3 6 2 0 2 Torsion Bar Unloading/Loading Tool
2. Remove the adjustment assemblies on both
torsion bars.
2.1. Mark the adjustment bolt setting.
2.2. Using the J 36202, increase the tension on
the adjustment arm.
2.3. Remove the adjustment bolt and the
retaining plate.
O)
2.4. Using the J 36202, decrease the tension on
the adjustment arm.
2.5. Move the tool aside.
2.6. Slide the torsion bars forward.
2.7. Remove the adjustment arms.
3. Remove the nuts and the bolts from the torsion
bar support crossmember link assembly.
4. Remove the torsion bars. Note the location and
the front ends of the torsion bars. The left side
and the right side torsion bars are different.
5. Remove the support crossmember.
6 . Remove the link assembly from the support
crossmember.
1 . Install the link assembly on the support
crossmember.
2. Install the support crossmember assembly to the
frame, rearward of the mounting holes.
3. Install the torsion bars.
3.1. Make sure the bars are installed on the
proper sides.
3 .2 . Slide the support crossmember forward
until the torsion bars are supported.
4. Install the adjustment arms on the torsion bars.
N o tice: Refer to Fastener Notice in Cautions and
Notices.
5. Install the bolts and the nuts into the torsion bar
support crossmember link assembly.
Tighten
Tighten the link assembly nuts to
125 N-m (92 Ib ft).
6 . Install the adjustment retainer plate and the bolt

on both torsion bars.
7. Using the J 36202, increase the tension on the
torsion bar.
8 . Install the retaining plate and the adjustment bolt.
9. Set the adjustment bolt to 34 mm (1.3 in).
10. Release the tension on the torsion bar until the
load is taken up by the adjustment bolt.
13. Check the Z height, refer to Trim Height Inspection
Wheel Bearing Adjustment (2WD)

Notice: Never preload the front wheel bearings.
Damage can result by the steady load on the roller
ends that comes from preloading.
Important:
• Adjust the front wheel bearings correctly in order
to ensure the front suspension functions properly.
• The bearings must be a slip fit on the spindle.
• Lubricate the bearings in order to ensure that the
roller bearings will roll and not skid.
• The spindle nut must have a free-running fit on
safety stands.
2. Remove the wheel cover, if used.
3. Remove the dust cap from the hub.
130890
N o tic e : Refer to F astener Notice in Cautions and
Notices.
Tighten
Tighten the hub/rotor bearing nut to
16 N-m (12 Ib ft), while turning the wheel
forward by hand. This will seat the bearings.
Important: Do not back the nut off more than 1A turn.
5. Adjust the nut to so that it is just loose. Then,
back the nut off until the hole in the spindle
aligns with a slot in the nut.
6 . Install a new cotter pin.
6.1. Make sure the cotter pin ends do not
interfere with the cap.
6.2. Bend the ends of the cotter pin against
the nut.
6.3. Cut off any extra pin length.
7. Measure the endplay in the hub/rotor assembly.
Proper endplay is 0 .03-0,20 mm (0.001-0.008 in).
8 . Install the cap to the hub/rotor.
9. Install the wheel cover, if used.
10. Remove the safety stands.
Wheel Bearing Adjustment (C3500HD)

N o tic e : Never preload the front wheel bearings.
Damage can result by the steady load on the roller
ends that comes from preloading.
Important:
• In order to maintain the continuous, smooth
functioning of the front suspension, the front wheel
bearings must be correctly adjusted.
• The bearings must be a slip fit on the spindle and
the wheel bearings must be lubricated in order to
ensure that the roller bearings will roll and
not skid.
• The spindle nut must have a free-running fit on
1 . Raise the vehicle. Support the vehicle with
suitable safety stands under the lower control arm.
2. Remove the retainer cap.
Notices.
Tighten
Tighten the nut to 16 N-m (12 Ib ft), while rotating
the wheel and tire assembly, or the hub/rotor.
This will seat the bearings.
4. Back off the nut one flat.
• If the hole in the spindle lines up with the slot
in the nut, insert the cotter pin.
• If these do not line up, back off the nut until
the hole and the slot line up. Do not back
off the nut more than one additional flat.
5. Measure the endplay in the hub/rotor. This
measurement should be between 0.013-0.20 mm
(0.0005-0.008 in) when properly adjusted.
6. Install the retainer cap.
Shock Absorber Replacement

Removal Procedure
Notice: The front shock absorbers of the vehicle are
multifunctional. In addition to contributing to a
smooth ride they also provide the only stop to the
front suspension when fully extended. Therefore, when
servicing the shock absorber, service replacement
shock absorbers must be equivalent to original shock
absorbers in both extended length and strength.
Use of shocks not complying to original equipment or
strength could result in suspension over-travel or
shock breakage. Suspension over-travel may result in
suspension component breakage.
safety stands.
2. Remove the nut. Hold the shock absorber stem
with a wrench while backing the nut off.
3. Remove the retainer.
4. Remove the grommet.
5.1. Pull the shock absorber out of the spring
from below.
5.2. The lower grommet and the retainer are on
the stem.
1. Install the retainer and the grommet on the stem.
Fully extend the stem.
2. Install the shock absorber up through the lower
control arm and the spring. Insert the stem end
through the hole in the upper control arm
frame bracket.
3. Install the grommet to the stem.
4. Install the retainer to the stem.
Notices.
5. Install the nut.
Tighten
Tighten the nut to 11 N-m (100 Ib in), while
holding the stem with a wrench.
6. Install the bolts through the pivot holes to the
lower control arm holes.
Tighten
Shock Absorber Replacement (4WD)

Removal Procedure
N o tic e : Original equipment shock absorbers serve
additionally as suspension drop cutoffs. Replacement
shock absorbers must have a built in suspension
cutoff feature and must not be longer than original
shocks when they are fully extended or serious vehicle
or component damage could result.
1 . Raise the vehicle on a hoist.
2. Remove the lower nut, the washer, and the bolt.
Collapse the shock absorber.
3. Remove the upper nut, the washer, and the bolt.
4. Remove the shock absorber.
157039
1. Install the shock absorber to the bracket.
2. Install the bolts. Fit the bolts in the
direction shown.
Notices.
3. Install the new nuts and the washers to the bolts.
Tighten
Tighten the upper and the lower nut to
90 N-m (66 Ib ft).
Shock Absorber Replacement

(RWD-C3500HD)
Removal Procedure
Wheels.
4. Remove the shock absorber from the leaf
spring spacer.
5. Remove the nut, the washer, and the bolt.
6. Remove the shock absorber from the frame.
7. Inspect the shock absorbers for damage
and leakage.
1. Install the shock absorber to the frame. Insert the
bolt through the upper shock bracket and the
shock absorber.
2. Install the washer and the nut. Do not tighten.
3. Install the shock absorber to the leaf spring
spacer. Position the lower shock mount
onto the stud.
Notices.
Tighten
• Tighten the upper nut to 185 N-m (136 Ib ft).
• Tighten the lower nut to 50 N-m (37 Ib ft).
5. Install the tire and wheel assembly. Refer to
Wheel Installation (Single Wheels-Front or
Rear) in Tires and Wheels.
Front Axle Replacement
Removal Procedure
Tools Required
suitable safety stands on the frame.
W heel R em oval (Single Wheels) in Tires and
Wheels.
3. Support the axle with a floor jack in order to
eliminate any load on the springs.
4. Remove the steering arm, the knuckle, and the
spindle. Refer to Steering Knuckle R eplacem ent
(C 3500H D ).
6. Remove the shock absorber from the axle. Refer
to Shock Absorber Replacem ent
(R W D -C 3500H D ).
8. Remove the stabilizer link from the stabilizer
shaft. Using the J 6627-A, separate the stabilizer
shaft from the stabilizer link.
10. Remove the stabilizer link from the axle. Pull
the link free from the axle. Do not lose the
other insulator and retainer.
157007
11. Remove the nuts, the washers, and the U-bolts.

12. Remove the spacer and the spring spacer.
13. Remove the leaf spring from the axle. Refer to
Leaf Springs Replacement.
14. Remove the steering damper from the axle. Refer
to Steering D am per R eplacem ent in Steering
Linkage.
15. Lower the floor jack and pull the axle clear of
the vehicle.
157019
1. Line up the axle under the leaf springs.
2. Using a floor jack, raise the axle into position.
3. Install the steering damper to the axle. Refer to
Steering Damper Replacement in Steering
Linkage.
4. Install the axle to the leaf springs.
157019
5. Install the stabilizer link to the axle.

6. Install the link into the hole on the spring spacer
and the axle.
157007

Notices.
7. Install the insulator, the retainer, and the nut.

Tighten
retainer is 38.0 mm (1.5 in).
157024
8. Install the stabilizer link to the stabilizer shaft.
Tighten
157007
10. Install the shock absorber to the axle.

Tighten
12. Install the steering arm, the knuckle, and the
spindle. Refer to Steering Knuckle Replacem ent
(C 3500H D ).
13. Adjust the wheel bearings. Refer to W heel
Bearing Adjustment (C 35 0 0 H D ).
14. Install the tire and wheel assembly. Refer to
W heel Installation (Single W heels-Front or
R ear) in Tires and Wheels.
Measuring W heel Alignment (C Model) in Wheel
Alignment.
157010
1
157081
Legend
(1) C Series (except C3500HD) (3) C Series (C3500HD)

(2) K Series
The front suspension allows each wheel to Special Tools and Equipment
compensate for changes in the road surface without
affecting the opposite wheel. Each wheel, except Illustration Tool Number / Description
C3500HD, independently connects to the frame with a
steering knuckle, ball joint assemblies, and upper
and lower control arms.
Two tie rods connect to steering arms on the knuckles
and to a relay rod. These operate the front wheels. J 6627-A
Two-wheel drive C Series models (1), except Wheel Stud and Tie Rod
C3500HD, have coil chassis springs. These springs Remover
are mounted between the spring housings on the
frame and the lower control arms. Shock absorbers
mount inside the coil springs. The coil springs attach to
the lower control arms with bolts and nuts. 130
The upper part of each shock absorber extends
through a frame bracket. Two grommets, two grommet
retainers, and a nut secure the upper part of the
shock to the frame.
A spring steel stabilizer shaft controls the side roll of
the front suspension on some models. This shaft cd J 8092
is mounted in rubber bushings that are held by Driver Handle
brackets to the frame Side rails. The ends of the
stabilizer shaft connect to the lower control arms with
link bolts. Rubber grommets isolate these link bolts.
A ball joint assembly is riveted to the outer end of the
upper control arm. A castellated nut and a cotter 2015
pin join the steering knuckle to the upper ball joint.
The inner ends of the lower control arm have
pressed-in bushings. The bolts pass through the
bushings and join the arm to the frame. The lower ball
joint assembly is a press fit in the lower control arm J9519-D
and attaches to the steering knuckle with a castellated
Bali Joint
nut and a cotter pin. Remover/Installer Set
Ball socket assemblies have rubber grease seals.
These seals prevent entry of moisture and dirt,
preventing damage to the bearing surfaces. And, all
ball joints have grease fittings for routine maintenance.
2016
Four-wheel drive (2) K Series models have a front
suspension that consists of the following components:
• Control arms
• Stabilizer shaft
• Shock absorber J9519-E
• Torsion bar (right and left side) Lower Control Arm Bushing
Remover
Torsion bars replace the conventional coil springs.
The front end of the torsion bar attaches to the lower
control arm. The rear of the torsion bar mounts
into an adjustable arm at the torsion bar crossmember.
This arm adjustment controls the vehicle trim height. 3286
K Series models have sealed front wheel bearings.
These bearings are pre-adjusted and need no
lubrication. Heat treatment may create darkened areas
on the bearing assembly. This discoloration does
not signal a need for replacement.
A heavy-duty front suspension (3) is standard on the J 9519-30
C3500HD model. This suspension is centered Ball Joint Remover/Installer
around a solid I-beam axle that includes taper leaf
springs, shock absorbers, and a stabilizer shaft.
156882
Illustration Tool Number / Description
J 21474-5
Receiver
3288
J 21474-8
Lower Control Arm Bushing
9 9 Remover
156915
J 21474-12
Installer Spacer
156905
J 21474-13
( 2 ^ Lower Control Arm Bushing
Installer
3289
J 21474-18
Special Nut
2018
Illustration Tool Number/Description
- J 36605
Steering Knuckle Seal
Installer
J 36607
Ball Joint Separator
J 36618
Service Set
J 41435
Lower Ball Joint
Remover/Installer Kit
(K Chassis)
Rear Suspension
Specifications
Specification
Leaf Spring to Bracket Nuts 95 N-m 70 Ib ft
Leaf Spring to Bracket Nuts (C3500HD) 415 N-m 306 Ib ft
Leaf Spring to Shackle Nuts 95 N-m 70 Ib ft
Leaf Spring to Shackle Nuts (C3500HD) 213 N-m 157 Ib ft
Shackle to Bracket Nuts 95 N-m 70 Ib ft
Shackle to Bracket Nuts (C3500HD) 213 N-m 1571b ft
Shock Absorber Lower Nuts 100 N-m 74 Ib ft
Shock Absorber Lower Nuts (C3500HD) 70 N-m 52 Ib ft
Shock Absorber Upper Nuts 17 N-m 131b ft
Shock Absorber Upper Nuts (C3500HD) 15 N-m 11 Ib ft
Stabilizer Clamp U-Bolt Nuts 30 N-m 22 Ib ft
Stabilizer Kit Nut 23 N-m 171b ft
Stabilizer Link Bracket to Frame Nut 45 N-m 33 Ib ft
Stabilizer Link Nut 45 N-m 33 Ib ft
U-Bolt Nuts (C/K 1,2) 110 N-m 81 ib ft
U-Bolt Nuts (C/K 3 without Dual Rear Wheels or 7.4L Engine) 110 N-m 81 Ib ft
U-Bolt Nuts (C/K 3 with Dual Rear Wheels or 7.4L Engine without
Dual Rear Wheels) 148 N-m 1091b ft
U-Bolts (C3500HD) 253 N-m 187 Ib ft

Auxiliary Spring Hanger 7.526
Leaf Spring 7.505
Rear Leaf Spring Insert 7.495
Rear Shock Absorber 7.345
Rear Spring and Axle Washer 7.529
Rear Spring Auxiliary 7.503
Rear Spring Bolt, Nut, Shackle and Washer 7.523
Rear Spring Bushing 7.504
Rear Spring Eye Nut 7.530
Rear Spring U Bolt, Nut and Washer 7.516
Rear Spring U Bolt, Plate and Spacer 7 518
Rear Stabilizer Shaft 7.241
Rear Stabilizer Shaft Insulator and Support 7.243
Spring Center Bolt 7.506
Spring Rebound Clip and Spacer 7 513
Component Locator
Rear Suspension Components
Axle Attaching Components (C 3500HD)
Legend
(1) U-bolt (10) Washer
(2) Bolt (1 1 ) Anchor Plate
(3) Washer (12) Spacer
(4) Shackle (13) Bolt
(5) Washer (14) Washer
(6 ) Nut (15) Front Bracket
(7) Spring Assembly (16) Washer
(8 ) Washer (17) Nut
(9) Nut (18) Spring Pad
Stabilizer Shaft and Components (C 3500HD)
Legend
(1) U-Bolt (7) Stabilizer Kit Bolt

(2 ) C lamp (8 ) Insulator
(3) Insulator (9) Spacer
(4) Stabilizer Shaft (10) Insulator
(5) Nut (11) Nut
(6 ) Insulator
23 1
156270
Legend
(1 ) Bracket (13) Insulator
(2 ) Nut (14) Bolt/Screw
(3) Bolt/Screw (15) Bolt/Screw
(4) Stabilizer Shaft (16) Insulator
(5) Bolt/Screw (17) Clamp
(6 ) Bracket (18) Bolt/Screw
(7) Nut (19) Washer
(8 ) Nut (2 0 ) Nut
(9) Washer (2 1 ) Nut
(1 0 ) Stabilizer Link (2 2 ) Washer
(1 1 ) Bolt/Screw
(23) Bolt/Screw
(1 2 ) Clamp
Repair Instructions N o tic e : Refer to Fastener Notice in Cautions and
Notices.
Stabilizer Shaft Replacement (C Model) 6. Install the nuts.
Tighten
Removal Procedure • Tighten the bolts to 34 N-m (25 Ib ft).
1 . Raise the vehicle on a hoist. • Tighten the nuts to 45 N-m (33 Ib ft).
2. Remove the following part from the stabilizer links:
• The lower nuts Stabilizer Shaft Link Bracket Replacement
• The washers (All Models Except C/K 3)
• The bolts
Removal Procedure
3. Remove the bolt/screws from the clamp.
1. Raise the vehicle on a hoist.
4. Remove the clamps and the insulators.
2. Remove the following parts from the
5. Remove the stabilizer shaft. stabilizer links:
Installation Procedure • The upper nuts
1 . Install the stabilizer shaft to the rear axle. • The washers
2. Install the insulators. • The bolts
3. Install the clamps. 3. Remove the bolts from the clamp insulators.
4. Install the bolt to the clamp. 4. Remove the nuts and bolts from the stabilizer
5. Install the lower bolts through the following bracket to the frame.
components: Installation Procedure
• The washer
N o tic e : Refer to Fastener Notice in Cautions and
• The stabilizer link Notices.
• The washer 1. Install the nuts and the bolts to the stabilizer
N o tice: Refer to Fastener Notice in Cautions and bracket and the frame.
Notices. Tighten
6 . Install the nuts. Tighten the nuts to 45 N-m (33 Ib ft).
Tighten 2. Install the bolts to the insulators and the clamps.
• Tighten the bolts to 34 N-m (25 Ib ft). Tighten
• Tighten the nuts to 45 N-m (33 Ib ft). Tighten the bolts to 34 N-m (25 Ib ft).
3. Install the nuts, the washers, and the bolts to the
Stabilizer Shaft Replacement (K Model) stabilizer links.
Removal Procedure Tighten
1 . Raise the vehicle on a hoist.
2 . Remove the following part from the stabilizer links:
• The lower nuts
(C/K 3 Models)
• The washers
• The bolts Removal Procedure
3. Remove the bolt/screws from the clamp. 1. Raise the vehicle on a hoist.
4. Remove the clamps and the insulators. 2. Remove the nuts.
5. Remove the stabilizer shaft. 3. Remove the insulators.
4. Remove the bolts from the spacer and the
Installation Procedure stabilizer shaft.
1. Install the stabilizer shaft to the rear axle. 5. Remove the nuts from the U-bolts.
2. Install the insulators. 6. Remove the following parts:
3. Install the clamps. • The U-bolts
4. Install the bolt to the clamp. • The clamps
5. Install the lower bolts through the following • The insulators
components:
7. Remove the stabilizer shaft.
• The washer
• The stabilizer link
• The washer
1. Install the stabilizer shaft to the rear axle.
2 . Install the following parts:
• The insulators
• The clamps
• The U-bolt
Notices.
3. Install the nuts to the U-bolt.
Tighten
4. Install the bolts through the following parts:
• The insulators
• The stabilizer shaft
• The spacers
5. Install the nuts.
Tighten
Tighten the nuts to 23 N-m (17 Ib ft)
Shock Absorber Replacement (C Model)

R e m o v a l P ro c e d u re
N o tic e : Original equipment shock absorbers serve
2. Remove the following parts from the frame
bracket:
• The upper shock nut (3)
• The bolt (1)
3. Remove the following parts from the axle bracket:
• The lower shock nut (6 )
• The washer (5)
• The bolt (2)
156191
4. Remove the shock absorber (4) from the vehicle.
1. Install the shock absorber (4) to the vehicle.
N o tice: Refer to Fastener Notice in Cautions
and Notices.
2.1. The upper shock bolt (2)
2.2. The washer (5)
2.3. The lower nut (6 )
Tighten
Tighten the lower nut to 70 N-m (52 Ib ft).
2.4. The upper shock bolt (1)
2.5. The upper nut (3)
Tighten
Tighten the upper nut to 15 N-m (11 Ib ft).
Shock Absorber Replacement (K Model)

Removal Procedure
N otice: Original equipment shock absorbers serve
2 . Remove the following parts from the frame
bracket:
• The upper shock nut (5)
• The bolt (6)
3. Remove the following parts from the axle bracket:
• The lower shock nut (1)
• The washer (2)
• The bolt (3)
4. Remove the shock absorber (4) from the vehicle.
1. Install the shock absorber (4) to the vehicle.
N o tic e : Refer to Fastener Notice in Cautions
and Notices.
2 .1 . The lower shock bolt (3)
2 .2 . The washer (2)
2.3. The lower nut ( 1 )
Tighten
Tighten the lower nut to 100 N-m (74 Ib ft).
2.4. The upper shock bolt (6 )
2.5. The upper nut (5)
Tighten
Tighten the upper nut to 17 N-m (13 Ib ft).
Wheel Bolt Replacement

Wheel bolts are serrated and may also be swaged in
place; however, the replacement procedure remains
the same for both types of installation.
1. Press the wheel bolts out of the hub flange.
2 . Press the new wheel bolts into place.
• Make sure of a tight fit.
® When replacing all of the wheel bolts, make
sure that the hub oil deflector is in position
under the wheel bolt heads.
Spring Bushing Replacement

Removal Procedure
1 . Remove the spring assembly. Refer to L eaf Spring
R eplacem ent (Single W heel Spring Assembly) or
L e a f Spring Replacem ent (D ual W heel Spring
Assembly) or L eaf Spring Replacem ent
(H D Chassis).
2. Remove the bushing from the leaf spring
as follows:
2 .1 . Place the leaf spring in a press.
Press the bushing out.
2 .2 . Clean the spring bushing bore of any
foreign material or old bushing.
1. Install the bushing to the leaf spring.
Place the leaf spring in a press.
Press the bushing in.
2 . Install the spring assembly. Refer to L eaf Spring
R eplacem ent (Single W heel Spring Assembly) or
L e a f Spring Replacem ent (D u al W heel Spring
Assembly) or L eaf Spring Replacem ent
(H D Chassis).
Leaf Spring Replacement
(Single Wheel Spring Assembly)
Removal Procedure
Support the rear axle independently in order to
relieve the tension on the leaf springs.
2 . Remove the U-bolt nuts (6 ).
3. Remove the washers (5).
4. Remove the anchor plate (7).
5. Remove the U-bolts (1),(4).
6 . Remove the spacer ( 8 ).
Loosen the shackle to spring nut.
7. Remove the following parts:
• The shackle (3)
• The shackle to rear bracket nut
• The washers
• The bolt
8 . Remove the spring to front bracket.
9. Remove the following spring to front bracket parts:
® The nut
® The washers
• The bolt
10. Remove the spring assembly from the vehicle.
156206
1. Install the spring assembly to the vehicle.
2. Install the following spring to front bracket parts:

• The bolt
• The washers
• The nut
Do not tighten the nut.
3. Install the following parts:
• The shackle (3)
• The shackle to rear bracket bolt
• The washers
• The nut
4. Install the spacer (8 ).
Important: Do not use old U-bolts.
5. Install the new U-bolts (1, 4) to the top of
the spring.
6 . Install the anchor plate (7).
7. Install the washers (5).

Notices.
8. Install the nuts (6).

Tighten
8.1. Tighten the U-bolt nuts in the
sequence shown.
8.2. Tighten the U-bolt nuts to 110 N-m (81 Ibft).
8.3. Adjust the spring height between the top
surface of the axle jounce pad and the
bottom surface of the frame jounce bracket.
8.4. Tighten the leaf spring to bracket nuts to
95 N-m (70 Ib ft).
8.5. Tighten the leaf spring to shackle nut to
95 N-m (70 Ib ft).
8.6. Tighten the shackle to bracket nuts to
95 N-m (70 Ib ft).
Leaf Spring Replacement
(Dual Wheel Spring Assembly)
Removal Procedure
2. Remove the U-bolt nuts (6).
3. Remove the washers (5).
4. Remove the anchor plate (7).
5. Remove the U-bolts (1),(4).
6. Remove the spacer (8).
• The shackle (3)
• The washers
156215
• The bolt
8. Remove the spring to front bracket.
• The nut
• The washers
• The bolt
156207

• The bolt
• The washers
• The nut
• The shackle (3)
• The washers
• The nut
4. Install the spacer (8).
5. Install the new U-bolts (1, 4) to the top of
the spring.
6. Install the anchor plate (7).
7. Install the washers (5).

Notices.
8. Install the nuts (6).

Tighten
sequence shown.
8.2. Tighten the U-bolt nuts to 110 N-m (81 Ib ft).
95 N-m (70 Ib ft).
95 N-m (70 Ib ft).
8.6. Tighten the shackle to bracket nuts to
95 N-m (70 Ib ft).
Leaf Spring Replacement (HD Chassis)
Removal Procedure
2. Remove the U-bolt nuts.
3. Remove the washers.
4. Remove the anchor plate.
5. Remove the U-bolts.
6. Remove the spacer.
• The shackle
• The washers
• The bolt
8. Remove the spring to front bracket.
• The nut
• The washers
• The bolt
• The bolt
• The washers
• The nut
• The shackle
• The washers
• The nut
4. Install the spacer.
5. Install the new U-bolts to the top of the spring.
6. Install the anchor plate.
7. Install the washers.
Notices.
8 . Install the nuts.
Tighten
sequence shown.
8.2. Tighten the U-bolt nuts to
148 N-m (109 Ib ft).
415 N-m (306 Ib ft).
213 N-m (157 Ib ft).
8 .6 . Tighten the shackle to bracket nuts to
213 N-m (157 Ib ft).
Spring Shackle Replacement (CK Model)

Removal Procedure
2. Loosen the shackle to spring nut.
3. Remove the shackle from the following parts:
• The rear bracket bolt
• The nut
• The washers
• The spring nut
• The washers
• The bolt
5. Remove the shackle from the vehicle.
1. Install the shackle to the vehicle.
Important: Do not tighten the fasteners until all the
parts have been assembled.
2. Install the shackle to the following parts:
• The spring bolt
• The washers
• The nut
Notices.
• The washers
• The nut
Tighten
• Tighten the leaf spring to bracket nuts to
95 N-m (70 Ib ft).
• Tighten the leaf spring to shackle nut to
95 N-m (70 Ib ft).
• Tighten the shackle to bracket nuts
95 N-m (70 Ib ft).
4. Adjust the spring height between the top surface
of the axle jounce pad (3) and the bottom surface
of the frame jounce bracket (6 ).
156342
Spring Shackle Replacement

(Heavy Duty Chassis)
Removal Procedure
2. Loosen the shackle to spring nut.
• The nut
• The washers
• The spring nut
• The washers
• The bolt
5. Remove the shackle from the vehicle.
1. Install the shackle to the vehicle.
Important: Do not tighten the fasteners until all the
parts have been assembled.
• The spring bolt
• The washers
• The nut
Notices.
• The washers
• The nut
Tighten
• Tighten the leaf spring to bracket nuts to
415 N-m (306 Ib ft).
• Tighten the leaf spring to shackle nut to
213 N-m (157 Ib ft).
• Tighten the shackle to bracket nuts
213 N-m (1571b ft).
4. Adjust the spring height between the top surface
of the axle jounce pad (3) and the bottom surface
of the frame jounce bracket (6).
Wheel Stud Replacement

J 6 6 2 7 -A
(Semi-Floating Axle)
Tools Required
J 6627-A Wheel Stud Remover
Removal Procedure
1. Raise the vehicle on a hoist and allow the axle to
hang free.
2. Remove the wheel, tire and brake drum.
3. Use the J 6627-A in order to remove the stud
from the axle flange.
1. Start the new stud into the axle flange hole by
J 6 6 2 7 -A
pressing firmly with your hand.
2. Thread the lug nut on the stud with the flat side of
the lug nut to the vehicle.
3. Tighten the lug nut in order to draw the stud into
the rear of the flange.
4. Thread the lug nut off the stud.
5. Install the wheel, tire and brake drum.
156430
Wheel Stud Replacement
(Full-Floating Axle)
Wheel studs are serrated and may also be swaged in
place; however, the replacement procedure remains
the same for both types of installation.
1. Press the wheel studs out of the hub flange.
156480
2. Press the new wheel studs into place.

• Make sure of a tight fit.
• When replacing all of the wheel studs, make
sure that the hub oil deflector (if equipped)
is in position under the wheel bolt heads.
156483

General Description
All of the C/K series vehicles use a leaf spring and a
solid rear axle suspension system. The rear axle
assembly is attached to the multi-leaf springs by the
U-bolts. The front ends of the springs are attached
to the frame at the front hangers through the rubber
bushings. The rear ends of the springs are attached to
the frame with the shackles that allow the springs in
order to change their length while the vehicle is
in motion.
The ride control is provided by two identical direct
double-acting shock absorbers angle-mounted
between the frame and the brackets attached to the
axle tubes.
Tires and Wheels
Specifications
Specification
Hoist to Crossmember Nuts (All Pickup Models) 25 N-m 18 1b ft
Hoist to Wheel Carrier Nuts (4 Door Utility Models) 47 N-m 35 Ib ft
Support Bolts (Suburban Models) 5 N-m 44 Ib in
Support Bolts (2 Door Utility Models) 44 N-m 32 Ib ft
Wheel Nut Stud (C1) (5 Studs) 170 N-m 125 Ib ft
Wheel Nut Stud (CK1, 2) (6 Studs) 170 N-m 125 Ib ft
Wheel Nut Stud (CK2, 3) (Single Wheel) (8 Studs) 170 N-m 125 Ib ft
Wheel Nut Stud (CK3) (Dual Wheel) (8 Studs) 170 N-m 125 1b ft
Wheel Nut Stud (C3500HD) (Dual Wheel) (10 Studs) 220 N-m 162 1b ft

Hub or Drum Wheel Bolt and Stud 5,812
Spare Wheel Guide, Hoist, Pin, Retainer and Shaft 7.629
Tire Valve and Cover Lock Cap and Stem 5.875
Wheel Balance Weight 5.805
Wheel Cap 5.858
Wheel Carrier Adapter and Stud 7.632
Wheel Cover Appearance Insert Ring 5.871
Wheel Front or Rear 5.803
Wheel Mounting Surface Check
It is necessary to replace any wheels which are bent,
dented, or which have excessive lateral or radial
runout. Also, wheels with runout greater than specified
I
may cause objectionable vibrations.
881
3. Inspect the mounting wheel/nut holes for damage
caused from over-torquing the wheel nuts. Inspect
for collapsed wheel/nut bosses. Inspect for
cracked wheel bosses.
1. Use a straight edge 203-229 mm (8-9 in) long.

Place the straight edge on the wheel inboard
mounting surface. Try to rock the straight edge up
and down within the mounting surface.
N otice: The use of non-GM original equipment wheels

may cause:
• Damage to the wheel bearing, the wheel fasteners
and the wheel
• Tire damage caused by the modified clearance to
2. Repeat this procedure on at least three or four the adjacent vehicle components
different positions on the inboard mounting • Adverse vehicle steering stability caused by the
surface. modified scrub radius
• The outer ring of the mounting surface • Damage to the vehicle caused by the modified
normally is raised above everything inside the ground clearance
mounting surface. • Speedometer and odometer inaccuracy
• The mounting surface will be raised above the
outer ring if the wheel mounting surface has
been bent on a tire changer.
Important: 4. Replace the wheel if the wheel is bent. Replace
• Replacement wheels must be equivalent to the the wheel if the wheel/nut boss area is cracked.
original equipment wheels in the following ways: Identify steel wheels with a 2 or 3 letter code stamped
- Load capacity into the rim near the valve stem. Aluminum wheels
- Wheel diameter have the code, the part number, and the manufacturer
- Rim width identification cast into the back side of the wheel.
- Wheel offset
- Mounting configuration
• A wheel of incorrect size or type may effect the
following conditions:
- Wheel and hub-bearing life
- Brake cooling
- Speedometer/odometer calibration
- Vehicle ground clearance
- Tire clearance to the body and the chassis
Radial Tire Lead/Pull Correction

Step Action Value Yes No
DEFINITION: Vehicle leads or pulls to either side while driving straight ahead.
1. Adjust the tire pressure to specifications. Refer to
Tire Inflation Description in Tires and Wheels.
2. Check for proper trim heights. Refer to Measuring
Wheel Alignment (C Model) or Measuring Wheel
1 Alignment (K Model) in Wheel Alignment. —
3. Check the brakes for drag.
4. Road test the vehicle.
Does the vehicle lead or pull to one side? Go to step 2 System OK
1. Interchange the front tire and wheel assemblies.
2 2. Road test the vehicle. —
Does the vehicle still pull to one side? Go to step 3 System OK
Check to see if the vehicle pulls in the same direction.
3 —
Does the vehicle pull in the same direction? Go to step 4 Go to step 5
Check the caster, camber, toe and the cross caster/cross
camber alignment settings. Refer to Measuring Wheel
4 Alignment (C Model) or Measuring Wheel Alignment —
(K Model) in Wheel Alignment.
Are the alignment settings within specifications? Go to step 6 Go to step 7
1. Check the tires.
2. Interchange the left front tire and wheel assembly
5 with the left rear tire and wheel assembly. —
3. Road test the vehicle. Replace the
Does the vehicle still pull to one side? Go to step 10 left rear tire
Change the caster setting.
6 —
Does the vehicle lead to the left? Go to step 8 Go to step 9
Adjust the front wheel alignment to specifications. Refer to
Measuring Wheel Alignment (C Model) or Measuring
7 Wheel Alignment (K Model) in Wheel Alignment. — —
Is the adjustment complete? Go to step 13
Set the left caster at the top specification, and set the right
8 caster at one degree less. — —
Set right caster at the top specification, and set the left
9 caster at one degree less. — —
Radial Tire Lead/Pull Correction (cont’d)
Step Action Value Yes No
1. Interchange the right front tire and wheel assembly
with the right rear tire and wheel assembly.
10 —
2. Road test the vehicle. Replace the
Does the vehicle still pull to one side? Go to step 6 right rear tire
Continue decreasing the right caster setting until the pull
11 is eliminated. Do not exceed 2 degrees cross caster. —
Is the pull eliminated? System OK Go to step 12
Continue decreasing the left caster setting until the pull is
12 eliminated. Do not exceed 2 degrees cross caster. — —
Is the pull eliminated? System OK
Road test the vehicle.
13 —
Does the vehicle still pull to one side? Go to Step 14 System OK
14 Does the vehicle pull to the left? — Go to Step 11 System OK
R e p a ir In s tr u c tio n s
Aluminum Wheel Porosity Repair Aluminum Wheel Refinishing

1. Remove the tire and wheel. A protective clear coating covers the surface of
• For vehicles with single wheels, front or rear, original equipment cast aluminum wheels. A surface
refer to W heel R em oval (Single W heels) degradation may develop if frequent automatic
car wash cleaning wears off the factory applied
• For vehicles with dual rear wheels, refer to protective clear coating. This can happen at some
W heel R em oval (D ual R e a r Wheels)
automatic car wash facilities that use aggressive
2. Inflate the tire to 275 kPa (40 psi). brushes to clean whitewalls and tires. Once you
3. Submerge the tire/wheel into a water bath in order damage the protective clear coating, exposure
to locate the leak. to caustic cleaners and road salt can cause further
4. Make a mark on the wheel in order to record the surface deterioration. Damage to the protective clear
leak areas. coating is corrected by replacing the damaged
wheel; refinishing is no longer recommended.
5. Make a mark on the tire at the valve stem in order
to record the orientation of the tire to the wheel.
Wheel Removal (Single Wheels)
6. Remove the tire from the wheel. Refer to Tire
Mounting an d Dismounting Caution: If penetrating oil gets on the vertical
7. Use number 80 grit sandpaper to scuff the inside surfaces between the wheel a n d the rotor o r drum
of the rim surface at the leak area. it could cause the wheel to w ork loose as the
vehicle is driven, resulting in loss o f control and
8. Use general purpose cleaner such as 3M®
an In ju ry a c c id e n t
P/N 08984 or equivalent, to clean the leak area.
Notice: Never use heat to loosen a tight wheel. It can
9. Apply 3 mm (0.12 in) thick layer of
adhesive/sealant, GM P/N 1052366 or equivalent, shorten the life of the wheel, studs, or hub and
to the leak area. bearing assemblies. Wheel nuts must be tightened in
sequence and to the specified torque to avoid
10. Allow 1 hour for the adhesive/sealant to dry. bending the wheel or rotor.
11. Install the tire to the wheel. Refer to Tire Mounting Penetrating oil effectively removes tight wheels. Apply
and Dismounting
the oil sparingly to the hub surface, if oil is used.
12. Align the mark on the tire with the tire valve stem. Removing wheels can be difficult, because of foreign
13. Inflate the tire to 275 kPa (40 psi). material or a tight fit between the wheel center
14. Inspect the tire/wheel for leaks. hole and the hub or the rotor. Excessive force, such
15. Adjust the tire pressure to meet the specifications as hammering on the wheel or the tire, can cause
on the tire placard. damage. Slightly tapping the tire side wall with
a rubber mallet is acceptable. Wheel removal should
16. Balance the tire and wheel. Refer to Balancing
be done in the following way:
Tires and W heels in Vibration Diagnosis.
17. Install the tire and wheel. 1. Tighten all wheel nuts on the affected wheel.
Do not torque the wheel nuts.
• For vehicles with single wheels, front or rear,
refer to W heel Installation (Single W heels-Front 2. Loosen each wheel nut two turns.
or Rear)
9 For vehicles with dual rear wheels, refer to
W heel Installation (D u al R e a r Wheels)
3. Rock the vehicle from side to side in order to Removing wheels can be difficult, because of foreign
loosen the wheel. material or a tight fit between the wheel center
You also can rock the vehicle from front to back, hole and the hub or the rotor. Excessive force, such
allowing the vehicle several feet of movement as hammering on the wheel or the tire, can cause
in each direction. damage. Slightly tapping the tire side wall with
4. Apply quick, hard jabs to the brake pedal in order a rubber mallet is acceptable. Wheel removal should
to loosen the wheel. If this does not loosen the be done in the following way:
wheel, rock the vehicle from side to side, using the 1. Tighten all wheel nuts on the affected wheel.
body weight of one or more persons. Do not torque the wheel nuts.
5. Repeat this procedure if the wheel is still tight. 2. Loosen each wheel nut two turns.
Removal Procedure 3. Rock the vehicle from side to side in order to
loosen the wheel.
Tools Required
Torque Wrench or J 39544-K IT Wheel Nut Torque You also can rock the vehicle from front to back,
Adapters (use with pneumatic impact) allowing the vehicle several feet of movement
in each direction.
safety stands. 4. Apply quick, hard jabs to the brake pedal in order
2. Remove the hub cap, if required. to loosen the wheel. If this does not loosen the
wheel, rock the vehicle from side to side, using the
3. Remove the wheel nuts. Mark the location of the
body weight of one or more persons.
tire and wheel assembly to the hub assembly.
4. Remove the tire and wheel assembly. 5. Repeat this procedure if the wheel is still tight.
5. Clean the wheel nuts, the bolts, and the wheel Removal Procedure
and rotor mounting surfaces.
Tools Required
Wheel Removal (Dual Rear Wheels) Torque Wrench or J 39544-K IT Wheel Nut Torque
Adapters (use with pneumatic impact)
Caution: If penetrating o il gets on the vertical
surfaces betw een the w heel and the ro tor o r drum 1. Raise the vehicle. Support the vehicle with
it could cause the wheel to w ork loose as the safety stands.
vehicle is driven, resulting in loss o f control and
2. Remove the hub cap, if required.
an in ju ry accident.
3. Remove the wheel nuts. Mark the location of the
Notice: Never use heat to loosen a tight wheel. It can
tire and wheel assembly to the hub assembly.
shorten the life of the wheel, studs, or hub and bearing
assemblies. Wheel nuts must be tightened in sequence 4. Remove the clamp ring and the outer and
and to the specified torque to avoid bending the wheel inner wheel.
or rotor.
Penetrating oil effectively removes tight wheels. Apply
the oil sparingly to the hub surface, if oil is used.
Wheel Installation
(Single Wheeis-Front or Rear)
Caution: Before installing the wheels, rem ove a ny
buildup o f corrosion on the wheel m ounting surface
and brake drum o r disc m ounting surface b y
scraping a n d wire brushing. Installing wheels with
p o o r metal-to~metal contact a t the m ounting
surfaces can cause wheel nuts to loosen. This can
cause a wheel to com e o ff when the vehicle is
m oving, causing loss o f control and possibly
perso n al injury.
1. Install the tire and wheel assembly. Align the
locating mark of the tire and wheel to the hub
assembly.
Notice: A torque wrench or J 39544 must be used to
ensure that wheel nuts are tightened to specification.
Never use lubricants or penetrating fluids on wheel
stud, nuts, or mounting surfaces, as this can raise the
actual torque on the nut without a corresponding
torque reading on the torque wrench. Wheel nuts,
studs, and mounting surfaces must be clean and dry.
Failure to fo llow these instructions could result in
wheel, nut, and/or stud damage.
2 . Install the wheel nuts.
Tighten
• Tighten the wheel nuts to specifications. Refer
to Fastener Tightening Specifications.
• Tighten the wheel nuts evenly and alternately
in order to avoid excessive runout.
Notices.
3. Install the hub cap, if required.
Wheel Installation (Dual Rear Wheels)

1. Install the inner and outer wheel and the clamp
ring. Make sure the pins on the clamp ring face
outward.
N o tic e : A torque wrench or J 39544 must be used to
ensure that wheel nuts are tightened to specification.
Never use lubricants or penetrating fluids on wheel
stud, nuts, or mounting surfaces, as this can raise the
actual torque on the nut without a corresponding
torque reading on the torque wrench. Wheel nuts,
studs, and mounting surfaces must be clean and dry.
Failure to follow these instructions could result in
wheel, nut, and/or stud damage.
2 . Install the wheel nuts.
Tighten
• Tighten the wheel nuts to specifications. Refer
to F astener Tightening Specifications.
• Tighten the wheel nuts evenly and alternately
in order to avoid excessive runout.
Notices.
3. Install the hub cap, if required.
Tire Repair
Many different materials and techniques are on the
market to repair tires. Tire manufacturers publish
detailed instructions on how and when to repair tires.
Read these instructions.
Never plug a tire from the outside. Always dismount
the tire from the wheel. Inspect the inner liner for
damage. Plug and patch from the inside of the tire.
Tire Mounting and Dismounting

N o tic e : It is important to note that damage to either
the tire mounting surface or the wheel mounting holes
can result from the use of improper wheel attachment
or tire mounting techniques. It takes 70 seconds
for all the air to completely exhaust from a large tire.
Failure to follow proper procedures could cause the tire
changer to put enough force on the tire to bend the
wheel at the mounting surface. Such damage
may result in vibration and/or shimmy and under
severe usage lead to cracking.
Use a tire changing machine to mount or dismount the
tires. Follow the manufacturer’s instructions. Do not
use hand tools or tire irons to change a tire. These
may damage the tire beads or the wheel rim flanges.
N o tic e : Do not scratch the clear coating on
aluminum wheels with the tire changer attachments,
wheel mounting techniques, or tire changing tools.
Failure to follow proper procedures could cause
the aluminum wheel to corrode and the clear coating
to peel from the wheel.
1. Clean the rim bead seats with a wire brush or
coarse steel wool in order to remove old rubber
and light rust or corrosion. Before you mount
or dismount a tire, clean the bead area. Lubricate
the bead area well.
2. Install the valve core.
C au tio n : To a v o id s e rio u s p e rs o n a l in jury, d o n o t
s ta n d o v e r tire w h en in fla tin g . The h e a d m a y b re a k
w hen th e b e a d s n a p s o v e r th e s a fe ty h u m p . D o n o t
e x c e e d 2 7 5 kPa (4 0 p s i) p re s s u re w hen in fla tin g a n y
tire if b e a d s a re n o t seated . I f 2 7 5 k P a (4 0 p s i)
p re s s u re w ill n o t s e a t the b e a d s , d eflate, re lu b ric a te
the b e a d s a n d re in fla te . O v e rin fla tio n m a y c a u s e th e
b e a d to b re a k a n d ca u s e s e rio u s p e rs o n a l injury.
3. Inflate the tire to the proper air pressure.
4. Check the locating rings to ensure these rings
show around the rim flanges on both sides of
the wheel.
Tire Rotation
In order to equalize wear, rotate the tires at the
specified intervals. Refer to Maintenance Schedule
(Gasoline) or M aintenance Schedule (Diesel) in
Maintenance and Lubrication. In addition to scheduled
rotation, rotate the tire and wheel assembly whenever
you notice uneven tire wear.
Radial tires tend to wear faster in the shoulder area,
particularly in front positions, due to design. Radial
tires in non-drive locations may develop an irregular
wear pattern that can generate tire noise. This
especially makes regular tire rotation necessary.
• For vehicles with single rear wheels (four tires),
rotate the tires as shown.
1014
• For vehicles with single rear wheels (five tires),

rotate the tires as shown.
156806
For vehicles with dual rear wheels (same tire sizes

and load ranges), rotate the tires as shown.
• For vehicles with dual rear wheels (different tire
sizes and load ranges), rotate the tires as shown.
Spare Tire Carrier Replacement

(Suburban Models)
Removal Procedure
The spare tire mounting for the Suburban is at the left
rear wheel well. The Suburban uses a mount that
is part of the body.
1 . Remove the spare tire cover.
2. Remove the nut.
3. Remove the adapter.
4. Remove the spare tire.
156782
5. Remove the bolts from the support.

6 . Remove the support from the vehicle.
156780
1. Install the support.
N otice: Refer to F asten er Notice in Cautions and
Notices.
2 . install the bolts.
Tighten
Tighten the bolts to 5 N-m (44 ib in).
3. Install the spare tire.

3.1. Install the spare tire.
3.2. Install the adapter.
3.3. Install the nut.
3.4. Install the spare tire cover.
156782
Spare Tire Carrier Replacement

(2 Door Utility Models)
Removal Procedure
The spare tire mounting for the 2 Door Utility models
is at the left rear wheel well. A bracket retains the
spare tire.
1. Remove the spare tire cover.
3. Remove the nut from the bolt.
4. Remove the adapter from the bolt.
156785
5. Remove the bolts from the carrier.
6 . Remove the carrier.
156787
installation Procedure
1. Install the carrier.
Notices.
2. Install the bolts.
Tighten

4. Install the adapter.
5. Install the nut.
6 . Install the spare tire cover.
(All Pickup Models)
Removal Procedure
The pickup models use a winch/cable hoist system for
tire stowage. The hoist is behind the rear axle and
forward of the rear bumper.
1 . Remove the spare tire.
1.1. Attach a ratchet to the wheel with the
DOWN mark facing you.
1 .2 . Put the end of the wheel wrench through
the rear bumper access hole until the
wrench connects into the hoist shaft.
1.3. Turn the ratchet counterclockwise in order
to lower the tire.
1.4. Turn the ratchet until the spare tire can be
pulled out from under the vehicle.
1.5. Once the tire has been lowered, tilt the
retainer at the end of the cable and pull
the retainer through the wheel opening.
2. Remove the pin and the retainer from the shaft.
3 . Remove the bolts and the nuts.
4. Remove the hoist from the crossmember.
1. Install the hoist to the crossmember.
N o tic e : Refer to F astener Notice in Cautions and
Notices.
2. Install the bolts and the nuts.
Tighten
3. Install the pin and the retainer to the shaft.

4.1. Place the tire on the ground, with the valve
stem pointed down, at the rear of the vehicle.
4.2. Pull the wheel retainer through the wheel
opening.
4.3. Attach the ratchet to the wheel with the
UP mark facing you.
4.4. Place the end of the wheel wrench through
4.5. Turn the ratchet clockwise in order to raise
the tire.
4.6. When two clicks are heard, stop turning the
wrench.

(4 Door Utility)
Removal Procedure
The 4 Door Utility models use a winch/cable hoist
system for tire stowage. The hoist is behind the rear
axle and forward of the rear bumper.
1.1. Attach a ratchet to the wheel with the
DOWN mark facing you.
1.3. Turn the ratchet counterclockwise in order
to lower the tire.
156774
1.4. Turn the ratchet until the spare tire can be
pulled out from under the vehicle.
1 .5. Once the tire has been lowered, tilt the
retainer at the end of the cable and pull
the retainer through the wheel opening.
2. Remove the pin and the retainer that attaches the
shaft to the hoist assembly.
3. Remove the shaft from the hoist assembly.
4. Remove the two bolts that attach the hoist
assemb ly to the wheel carrier.
5. Remove the hoist assembly from the
wheel carrier.
1 . Install the hoist assembly to the wheel carrier.
N o tice : Refer to Fasten er Notice in Cautions
and Notices.
2. Install the bolts and the nuts that attach the hoist
assembly to the wheel carrier.
Tighten
3. Install the shaft to the hoist assembly.
4. Install the pin and the retainer that attaches the
shaft to the hoist assembly,
5.1. Place the tire on the ground, with the valve
stem pointed down, at the rear of the vehicle.
5.2. Pull the wheel retainer through the wheel
opening.
5.3. Attach the ratchet to the wheel with the
UP mark facing you.
5.5. Turn the ratchet clockwise in order to raise
the tire.
5.6. When two clicks are heard, stop turning
the wrench.
General Description Tires with a lower than recommended pressure can
cause the following conditions:
The factory installed tires are designed to operate
satisfactorily with loads up to and including the • A tire squeal on turns
full rated load capacity when these tires are inflated to • Hard steering
the recommended pressures. • Rapid wear and uneven wear on the edge of
Correct tire pressures, wheel alignment, and driving the tread
techniques have an important influence on tire life. • Tire rim bruises and tire rim rupture
Heavy cornering, excessive rapid acceleration, • Tire cord breakage
and heavy braking increase tire wear.
• High tire temperatures
Metric Wheel Nuts and Bolts Description • Reduced vehicle handling

• High fuel consumption
Metric wheel nuts and bolts are identified in
the following way: • Soft riding
• The wheel nut has the word Metric stamped on Unequal pressure on the same axle can cause the
the face. following conditions:
• The letter M is stamped on the end of the • Uneven braking
wheel bolt. • Steering lead
The thread sizes of metric wheel nuts and bolts are • Reduced vehicle handling
indicated by the following example: M12 x 1.5.
• M = Metric Tire Chain Usage Description
• 12 = Diameter in millimeters When you use tire chains, most current vehicles
• 1.5 = Millimeters per thread (gap between) require the following chain types:
Tire Inflation Description

When you inflate the tires to the recommended
inflation pressures, the factory-installed wheels and
tires are designed to handle loads to the tire’s
rated load capacity. Incorrect tire pressures, or
under-inflated tires, can cause the following conditions:
• Vehicle handling problems
• Poor fuel economy
• Shortened tire life
• Tire overloading
Check the tire pressure when the following apply:
• The tires are cool.
3
• The vehicle has not been driven for more
than 3 hours.
• The vehicle has been driven less
than 1.6 km (1 mi).
Check the tires monthly or before any extended trip. 1012
Adjust the tire pressure to the specifications on the tire • SAE Class S or 1100 eries, Type PL tire
label. Install the valve caps or extensions on the chains ( 1 ).
valves. These keep out dust and water.
• SAE Class U or 1200 eries, Type P tire chains (2 ).
The kilopascal (kPa) is the metric term for pressure.
The tire pressure may be printed in both • 1800 eries Lug Reinforced tire chains (3).
kilopascal (kPa) and psi. One psi equals 6.9 kPa. These chains are specially designed to limit the
Tires with a higher than recommended pressure can “fly off” effect that occurs when the wheel rotates.
cause the following conditions: Manufacturers of tire chains have a specific chain size
• A hard ride for each tire size. These ensure a proper fit when the
chains are installed. For this reason, purchase the
• Tire bruising correct chains for the tires on which the chains will be
• Rapid tread wear at the center of the tire used. Do not use rubber adjusters to take up slack in
chains that are loose due to incorrect size. Always
follow the chain manufacturer’s installation instructions.
Use of chains may adversely affect handling. When Use of any other tire size or type may seriously affect
using chains, remember the following information: the following items:
• Ensure that the vehicle is designed for chain • Vehicle ride
clearance. • Vehicle handling
• Adjust vehicle speed to road conditions. • Speedometer/odometer calibration
• Avoid sharp turns. • Vehicle ground clearance
• Avoid locked-wheel braking in order to help • Tire clearance to the body and chassis
prevent chain damage to the vehicle.
Inspect the tires. Replace tires when you find the
• Install the chains as tightly as possible on the following conditions:
drive tires. Tighten the chains again after
• The tires are worn to a point where
driving 0.4-0.8 km ( 1A - V& mi). Use of chains on
1 . 6 mm (1/16 in) or less tread remains, or, the
the non-drive tires is not recommended. These
cord or fabric shows. The tires may have built-in
chains may contact and damage the vehicle. If you
tread wear indicators that appear between the
must use chains on the non-drive tires, make
tread grooves when the tread is 1 . 6 mm (1/16 in)
sure that there is enough clearance.
or less. When the indicators appear in two or
• Do not exceed 70 km/h (45 mph) or the chain more adjacent grooves at three spots around the
manufacturer’s speed limit, if lower. tire, replace the tjre.
• Drive in a restrained manner. Avoid large bumps, • The tread or sidewall is cracked, cut, or snagged
potholes, severe turns, and other maneuvers deep enough to expose the cord or the fabric.
that could cause the tires to bounce up and down.
• The tire has a bump, bulge, or a split. Slight
• Follow any other instructions from the chain sidewall indentations are normal and this should
manufacturer that do not disagree with the above. not affect ride.
• The tire has a puncture, a cut, or other damage
Tire Description that cannot be repaired correctly because of
C au tio n : D o n o t m ix d iffe re n t ty p e s o f tires o n th e the size or location of the damage.
s a m e vehicle s u c h as rad ial, b ias, a n d b ia s -b e lte d
tires e x c e p t in e m e rg e n c ie s b e c a u s e veh icle All Seasons Tires Description
h a n d lin g m a y b e s e rio u s ly a ffe c te d a n d m a y re s u lt
Some vehicles are equipped with all-season radial
in lo s s o f c o n tro l a n d p o s s ib le s e rio u s in jury.
tires as standard equipment.
Important: Install new tires in pairs on the same axle. These tires have a 37 percent higher average rating
If you need to replace only one tire, this should be for snow traction than non all-season radial tires
paired with the tire that has the most tread. previously used. For this reason, these qualify as snow
A Tire Performance Criteria (TPC) specification tires. You can identify these tires by an M+S molded
number is molded in the sidewall near the tire size of in the tire sidewall after the size.
all original equipment tires. This number ensures
that the tire meets GM’s performance standards for P-Metric Sized Tires Description
traction, endurance, dimension, noise, handling, rolling
Most P-metric and LT-metric tires do not have exactly
resistance, and others. A specific TPC number
corresponding alpha/numeric tire sizes. For example,
usually is assigned to each tire size.
a P205/75R15 is not equal in size and load carrying
C3500HD models do not use TPC tires. Refer to the capacity to an FR78-15. Because of this, replacement
tire manufacturer for assistance. tires should be of the same TPC specification
Replacement tires should be the same size, load number (size, load range, and construction) as those
range, and construction as the original tires. originally on the vehicle. If you must replace
Replace the original tires with tires that have the P-metric or LT-metric tires with other sizes, consult a
same TPC specification number. tire dealer. Tire companies can best recommend
the closest match.
Use the following table for tire code designations: Steel Wheel Repair Description
Do not use heating, welding, or peening to repair
wheels. These methods are not approved. Do not use
inner tubes to repair leaky wheels or tires. If leaks
are found in a steel wheel, replace the wheel with a
wheel of original equipment quality.
Aluminum Wheels Description

Clean aluminum wheels and wax aluminum wheels
regularly. Do not use abrasive cleaners. These could
damage the protective coating of the wheel.
Special Tools and Equipment

Illustration Tool No. and Description
J 39544-GM
Wheel Nut Torque Adapters
(Use with pneumatic
156797
impact wrench that does
not exceed 250 Ib ft).
Tire Placard Description Includes: J 39544-12,
J 39544-13, J 39544-14,
The tire information label is on the rear face of the . J 39544-CSE
driver’s door. Refer to this label for tire information.
The label lists the following items: 1015
• Maximum vehicle load
• Tire size
• Cold inflation pressure
Wheels Description
Replace any wheel when the following
conditions apply:
• A bent wheel
• A dented wheel
• Wheels with excessive lateral or radial runout
• The welds leak air
• Elongated bolt holes
• The wheel nuts will not stay tight
Wheels with runout greater than specified may cause
objectionable vibrations.

1998 Sec 3-Suspension

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1998 Sec 3-Suspension

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Section 3

S u s p e n s io n G e n e ra l D ia g n o s is ....... ..............3 -3 W h e e l A lig n m e n t ............ .....................................3-18

Diagnostic Information and Procedures

Ve hicle Leads/Pulls (Leads to Either Side)

Vehicle Leads/Pulls (Pulls to One Side-No Braking)

Abnormal or Excessive Tire Wear (Heel and Toe Wear)

Abnormal or Excessive Tire Wear (Tire Edges Wear)

Abnormal or Excessive Tire Wear (Uneven)

Abnormal or Excessive Tire Wear (Scuffed Tires)

Abnormal or Excessive Tire Wear (Cupped Tires)

Abnormal or Excessive Tire Wear (Center of Tread)

On S4W D and F4W D vehicles, measure Z height from

For S4W D and F4W D vehicles, use the following

4. For 2WD vehicles, measure from the pivot bolt

1. Lift the rear bumper of the vehicle 38 mm (1.5 in).

Noisy Front Suspension

Poor Directional Stability

Tire Hop or Poor Handling (Radial Tire Waddle)

Noise Diagnosis - Front Suspension

Struts or Shock Absorbers Weak (Front)

Struts or Shock Absorbers Noisy (Front)

Struts or Shock Absorbers Leak (Front)

The pattern on the roller ends is caused by fine

The pattern on the races and the rollers is caused by

The metal smears on the roller ends are due to

The smearing of the metal is due to slippage. Slippage

The surface is flaked with metal due to bearing

The surface indentations in the race way are caused

The race is cracked due to improper fit, cocking, or

Wheel Alignm ent Specifications (K Model)

Fastener Tightening Specifications

GM SPO Group Numbers

6. The correct specification is 95.0 ± 6.0 mm. If not

Preliminary Alignment Inspection

Important: The jack or the jack stand must remain

The linear sum toe-in results when the distance

(1) Cam (14) Lower Ball Joint Cotter Pin

(1) Front Spring Spacer Cushion (17) Anchor Plate

Diagnostic Information and Procedures

4. Check the ball joints for vertical looseness. With the

Notice: Do not pry between the lower arm and the

Important: Do not hammer on a wheel bolt.

Upper Ball Joint Replacement (S4WD)

8. Remove the cotter pin.

Low er Bail J o in t Replacement (RWD)

8. Remove the lower ball joint from the lower control

Lower Ball Joint Replacement (S4WD)

Steering Knuckle Replacement

7. Remove the lower ball joint stud from the knuckle

8. Remove the upper ball joint stud from the knuckle

4. Install the splash shield to the knuckle.

5. Install the upper ball joint stud to the knuckle.

14. Remove the lower control arm nuts and the

8. Connect the ball joint to the knuckle.

Front Coil Springs .Replacement

2. Support the control arm using the J 23028-01.

Notice: Refer to Fastener Notice in Cautions and

Leaf Springs Replacement

5. Remove the nut and the washer.

8. Install the stabilizer link to the stabilizer shaft.

10. Install the shock absorber to the axle.

Wheel Hub, Bearing, and Seal

Wheel Hub, Bearing, and Seal

Torsion Bar and Support Assembly