Front Shock Absorber - Installation

INSTALLATION

CAUTION: When installing an ACR adjustable shock assembly, make sure the remote canister fixed to the damper body is positioned inboard on the vehicle. If a shock assembly is installed incorrectly, contact with the suspension will occur.

NOTE: When installing a front ACR adjustable shock assembly it is important to note that the street (factory) settings for rebound (1) and compression (2) damping are; Compression = Position 13, Rebound = Position 18. To achieve these settings, turn the adjustment knobs clockwise (+) to the stop ("Full Hard" or "0" Position), then turn the knobs back (counterclockwise (-)) the requested amount of clicks. For further information, refer to the Owners Manual Addendum for ACR.

1. Install shock assembly (6) down through center of upper control arm (1).
2. Install shock assembly in mounting bracket on lower control arm (5). Install bolt and nut as shown. Do not tighten mounting bolt at this time.
3. Using a pry bar, carefully push down on upper control arm far enough to install top of shock assembly into frame bracket.
4. Install shock assembly into frame bracket and install bolt and nut. Do not tighten mounting bolt at this time.
5. Install stabilizer bar link (4) into mounting hole on lower control arm. Install stabilizer bar link nut and tighten to 23 Nm (17 ft. lbs.).

6. Install wheel and tire assembly Tires and Wheels - Installation. Progressively tighten wheel mounting nuts in proper sequence to 135 Nm (100 ft. lbs.).
7. Lower vehicle.
8. Verify vehicle fuel tank is full of fuel. If tank is not full of fuel, reduction in weight will affect height of vehicle and design height measurement.
9. Remove any load within passenger and luggage compartments that is not factory equipment.
10. Position vehicle on alignment rack/drive-on lift equipped with front turntables and rear slip plates.
11. Check all tires for proper inflation pressure and adjust as necessary.
12. Proceed with STANDARD SHOCK ASSEMBLY (NON-ACR) or ACR ADJUSTABLE SHOCK ASSEMBLY below to complete this procedure.

STANDARD SHOCK ASSEMBLY (NON-ACR)

1. Raise front of vehicle.
2. Remove both front tire and wheel assemblies.

3. Install Suspension Height Stands (1), Special Tool 9096, in place of removed wheels as shown. Install all wheel mounting nuts and progressively tighten in proper sequence to 135 Nm (100 ft. lbs.).
4. Lower vehicle positioning Height Stand legs squarely onto alignment rack turntables (3), not allowing tool to come into contact with stationary parts of alignment rack. Make sure locking pins are removed from turntables before Height Stands make contact.

NOTE: When setting vehicle to design height while using Suspension Height Stands it is critically important to perform the following:
- Make sure locating pins are inserted in correct wheel diameter holes in Heights Stands or measurement will be incorrect. Front wheels use 18 in. position hole. Rear wheels use 19 in. position hole.
- Place ends of Suspension Height Gages, Special Tool 6914, right-side-up (same direction as if mounted against wheels) with notches against locating pins in ends of Suspension Height Stands as shown, otherwise measurements will be incorrect.

5. Place Suspension Height Gage (1), Special Tool 6914, between Suspension Height Stands (2) against locating pins. Make sure ends of Gage are correctly attached to Locating pins in Stands. Refer to above note.

CAUTION: Only apply weight to seat cushions as described in 5. Do not over-ballast the vehicle. If vehicle is over-ballasted, design height will be incorrect.

6. Add 150 pounds ballast weight (2, 3) to each seat cushion (1, 4) (300 pounds total) to lower vehicle to specified design height.

7. Jounce vehicle several times, each time paying special attention to release vehicle at very bottom of jounce cycle. This is very important in allowing suspension to settle to correct height.

8. Measure and record vehicle's front design height. Measure distance (2) between top of Suspension Height Gage (4) and each frame rail at forward edge of Gage. This is the nearest point to the Principle Locating Point (PLP) hole (1).

9. Compare recorded measurements to specifications. Wheel Alignment
10. If recorded height is higher than specifications, jounce vehicle and remeasure. Before remeasuring design height, be sure to jounce the vehicle as described in 7. If still above specifications, one or more rubber bushing mounted suspension components may not be properly positioned and tightened. Loosen component fasteners as necessary to allow suspension to enter specified design height, then retighten each to specified torque Front Suspension Specifications. For further information, Service and Repair. NOTE: If loosening the lower control arm mounting bolts is necessary, be sure the alignment adjustment cams do not turn. The cams must stay in their original position so the alignment of the vehicle is not affected.

11. Tighten shock assembly upper mounting bolt to 136 Nm (100 ft. lbs.).
12. Tighten shock assembly lower mounting bolt to 136 Nm (100 ft. lbs.).
13. Return vehicle to curb height.
14. Raise vehicle and remove special tools.
15. Install tire and wheel assemblies. Tires and Wheels - Installation. Progressively tighten wheel mounting nuts in proper sequence to 135 Nm (100 ft. lbs.).
16. Lower vehicle.

ACR ADJUSTABLE SHOCK ASSEMBLY

1. Raise front of vehicle.
2. Remove both front tire and wheel assemblies.

CAUTION: Only apply weight to seat cushions as described in 5. Do not over-ballast the vehicle. If vehicle is over-ballasted, design height will be incorrect.

5. Add 150 pounds ballast weight (2, 3) to each seat cushion (1, 4) (300 pounds total) to lower vehicle to specified design height.

CAUTION: Only apply weight to seat cushions as described in 6. Do not over-ballast the vehicle. If vehicle is over-ballasted, the design height will be incorrect.

6. Add 150 pounds ballast weight (2, 3) to each seat cushion (1, 4) of vehicle (300 pounds total) to lower vehicle to specified design height.

7. Place a straightedge from lift runway to runway directly below the wheel center line for the rear axle. If a straightedge cannot be located, Height Gages, Special Tool 6914, can be used. Do not attempt to place Height Gages on wheel flanges, only across lift runways as indicated here.
8. Jounce vehicle several times, each time paying special attention to release vehicle at very bottom of jounce cycle. This is very important in allowing suspension to settle to correct height.

9. Measure and record vehicle's front design height. Measure distance (1) straight up from bottom of straightedge (4) to each frame rail at the nearest point to the Principle Locating Point (PLP) hole (2).
10. Compare recorded measurements to specifications. Wheel Alignment

11. If recorded height is outside of specifications, jounce vehicle and remeasure. Before remeasuring design height, be sure to jounce the vehicle as described in 8. If still outside specifications, the spring height on the shock assembly may need to be adjusted or one or more rubber bushing mounted suspension components may not be properly positioned and tightened. To adjust spring height, refer to the Owners Manual Addendum for ACR. To adjust rubber bushing mounted suspension components, loosen component fasteners as necessary to allow suspension to enter specified design height, then retighten each to specified torque Front Suspension Specifications. For further information, Service and Repair. NOTE: If loosening the lower control arm mounting bolts is necessary, be sure the alignment adjustment cams do not turn. The cams must stay in their original position so the alignment of the vehicle is not affected.

12. Tighten shock assembly upper mounting bolt to 136 Nm (100 ft. lbs.).
13. Tighten shock assembly lower mounting bolt to 136 Nm (100 ft. lbs.).
14. Return vehicle to curb height.
15. Raise vehicle and remove special tools.
16. Install tire and wheel assemblies. Tires and Wheels - Installation. Progressively tighten wheel mounting nuts in proper sequence to 135 Nm (100 ft. lbs.).
17. Lower vehicle.