Dodge Durango

 Service Manual

Suspension » Front suspension - 4x4
Removal and installation

Shock absorber

REMOVAL

(1) Raise and support vehicle.

(2) Remove the upper shock absorber nut, retainer and grommet (Fig. 4).

(3) Remove the lower bolt and remove the shock absorber.

INSTALLATION

NOTE: Upper shock nut must be replaced or use Mopar Lock 'N Seal or LoctiteT 242 on existing nut.

(1) Install the lower retainer (lower retainer is stamped with a L) and grommet on the shock absorber stud. Insert the shock absorber through the frame bracket hole.

(2) Install the lower bolt and tighten the bolt to 108 N*m (80 ft. lbs.).

(3) Install the upper grommet, retainer (upper retainer is stamped with a U) and new nut or use Mopar Lock 'N Seal or Loctitet 242 on existing nut, on the shock absorber stud. Tighten nut to 26 N*m (19 ft. lbs.).

Fig. 4 Shock Absorber

1 - NUT

2 - RETAINER

3 - GROMMET

4 - SHOCK

Torsion bar

CAUTION: The left and right side torsion bars are NOT interchangeable. The bars are identified and stamped R or L, for right or left. The bars do not have a front or rear end and can be installed with either end facing forward.

REMOVAL

(1) Raise and support the vehicle with the front suspension hanging.

(2) Turn the adjustment bolt counterclockwise to release spring load (Fig. 5).

NOTE: Count and record the number of turns for installation reference.

3) Remove the adjustment bolt from swivel.

(4) Remove torsion bar and anchor. Remove anchor from torsion bar.

(5) Remove all foreign material from torsion bar mounting in anchor and suspension arm.

(6) Inspect adjustment bolt, bearing and swivel for damage.

INSTALLATION

(1) Insert torsion bar ends into anchor and suspension arm.

(2) Position anchor and bearing in frame crossmember.

Install adjustment bolt through bearing, anchor and into the swivel.

(3) Turn adjustment bolt clockwise the recorded amount of turns.

(4) Lower vehicle and adjust the front suspension height. Refer to Suspension Height service procedure.

Steering knuckle

REMOVAL

(1) Raise and support vehicle.

(2) Remove wheel and tire assembly.

(3) Remove brake caliper, rotor, shield and ABS wheel speed sensor if equipped. Refer to Group 5 Brakes.

(4) Remove front driveshaft, refer to Group 3 Differential and Driveline.

(5) Remove tie rod end cotter pin and nut. Separate the tie rod from the knuckle with Remover MB-991113 (Fig. 6).

(6) Support the lower suspension arm with a hydraulic jack and raise the jack to unload the rebound bumper.

(7) Remove the upper ball joint cotter pin and nut.

Separate the ball joint from the knuckle with Remover MB-991113 (Fig. 7).

CAUTION: When installing Remover MB-991113 to separate the ball joint, be careful not to damage the ball joint seal.

(8) Remove the lower ball joint cotter pin and nut.

Separate the ball joint from the knuckle with Remover C-4150A (Fig. 8) and remove the knuckle.

(9) Remove the hub/bearing from the steering knuckle.

Fig. 6 Tie Rod End

1 - STEERING KNUCKLE

2 - REMOVER

3 - TIE ROD END

Fig. 7 Upper Ball Joint

1 - UPPER BALL STUD

2 - REMOVER

INSTALLATION

(1) Install the hub/bearing to the steering knuckle and tighten the bolts to 166 N*m (123 ft. lbs.).

NOTE: When installing hub/bearing with ABS brakes, position the speed sensor opening towards the front of the vehicle.

(2) Install the knuckle onto the upper and lower ball joint.

Fig. 8 Lower Ball Joint

1 - REMOVER

2 - LOWER BALL STUD

CAUTION: The ball joint stud tapers must be CLEAN and DRY before installing the knuckle.

Clean the stud tapers with mineral spirits to remove dirt and grease.

(3) Install the upper and lower ball joint nuts.

Tighten the upper ball joint nut to 81 N*m (60 ft.

lbs.) and the lower ball joint nut to 183 N*m (135 ft.

lbs.) then install cotter pins. Grease the lower ball joint.

(4) Remove the hydraulic jack from the lower suspension arm.

(5) Install the tie rod end and tighten the nut to 88 N*m (65 ft. lbs.). Install the cotter pin.

(6) Install the front driveshaft, refer to Group 3 Differential and Driveline.

(7) Install the ABS wheel speed sensor if equipped and brake shield, rotor and caliper. Refer to Group 5 Brakes.

(8) Install the wheel and tire assembly.

(9) Remove support and lower the vehicle.

Lower suspension arm

REMOVAL

(1) Raise and support the vehicle.

(2) Remove the wheel and tire assembly.

(3) Remove front driveshaft, refer to Group 3 Differential & Driveline.

(4) Remove torsion bar.

(5) Remove shock absorber lower bolt.

(6) Remove stabilizer bar.

(7) Remove the cotter pin and nut from lower ball joint. Separate ball joint from the steering knuckle with Remover C-4150A (Fig. 9).

(8) Remove suspension arm pivot bolts and suspension arm from frame rail brackets (Fig. 10).

(9) Inspect lower ball joint seal and replace if damaged.

Pry off old seal with screw driver if necessary.

Fig. 9 Lower Ball Joint

1 - REMOVER

2 - LOWER BALL STUD

Fig. 10 Lower Suspension Arm

1 - PIVOT BOLTS

2 - LOWER SUSPENSION ARM

INSTALLATION

(1) Install new lower ball joint seal by tapping on around the seal flange lightly with a hammer.

(2) Position the lower suspension arm at the frame rail brackets. Install the pivot bolts and nuts.

Tighten the nuts finger-tight.

(3) Insert the ball joint into steering knuckle.

Install and tighten the retaining nut to 183 N*m (135 ft. lbs.) and install a new cotter pin.

CAUTION: The ball joint stud taper must be CLEAN and DRY before installing the knuckle. Clean the stud taper with mineral spirits to remove dirt and grease.

(4) Install the torsion bar.

(5) Install shock absorber lower bolt and tighten to 108 N*m (80 ft. lbs.).

(6) Install the front driveshaft. Refer to Group 3 Differential & Driveline.

(7) Install the wheel and tire assembly.

(8) Remove support and lower the vehicle.

(9) Install the stabilizer bar.

(10) Tighten the lower suspension front pivot nut to 108 N*m (80 ft. lbs.). Tighten rear pivot bolt to 190 N*m (140 ft. lbs.).

(11) Adjust the front suspension height.

Upper suspension arm

REMOVAL

(1) Raise and support vehicle.

(2) Remove wheel and tire assembly.

(3) Remove brake hose brackets from suspension arm, refer to Group 5 Brakes.

(4) Position hydraulic jack under lower suspension arm and raise jack to unload rebound bumper.

(5) Remove shock absorber.

(6) Remove the cotter pin and nut from upper ball joint.

(7) Separate upper ball joint from the steering knuckle with Remover MB-991113 (Fig. 11).

CAUTION: When installing Remover MB-991113 to separate the ball joint, be careful not to damage the ball joint seal.

(8) Remove suspension arm pivot bar bolts and remove suspension arm (Fig. 12).

Fig. 11 Separate Upper Ball Joint

1 - UPPER BALL STUD

2 - REMOVER

Fig. 12 Upper Suspension Arm

1 - PIVOT BAR BOLT

2 - UPPER SUSPENSION ARM

INSTALLATION

(1) Position suspension arm pivot bar on mounting bracket. Install bolts and tighten (temporarily) to 136 N*m (100 ft. lbs.).

(2) Insert ball joint in steering knuckle and tighten ball joint nut to 81 N*m (60 ft. lbs.) then install a new cotter pin.

(3) Install shock absorber.

NOTE: Upper shock nut must be replaced or use Mopar Lock 'N Seal or LoctiteT 242 on existing nut.

(4) Remove hydraulic jack.

(5) Attach brake hose brackets to suspension arm, refer to Group 5 Brakes.

(6) Tighten upper suspension arm pivot bolts to 204 N*m (150 ft. lbs.).

(7) Install the wheel and tire assembly.

(8) Remove support and lower vehicle.

(9) Align front suspension.

Stabilizer bar

NOTE: To service the stabilizer bar the vehicle must be on a drive on hoist. The vehicle suspension must be at curb height for stabilizer bar installation.

REMOVAL

(1) Remove the stabilizer bar retainer bolts from the lower suspension arms (Fig. 13) and remove the retainers.

(2) Remove the stabilizer bar retainer nuts, bolts and retainers from the frame crossmember (Fig. 13) and remove the bar.

(3) If necessary, remove the bushings from the stabilizer bar.

Fig. 13 Stabilizer Bar

1 - LOWER SUSPENSION ARM

2 - FLAG NUT

3 - STABILIZER BAR

4 - RETAINER

INSTALLATION

(1) If removed, install the bushings on the stabilizer bar.

(2) Position the stabilizer bar on the frame crossmember brackets and install the retainers and nuts and bolts finger-tight (Fig. 13).

NOTE: Check the alignment of the bar to ensure there is no interference with the either frame rail or chassis component. Spacing should be equal on both sides.

(3) Install the stabilizer bar to the lower suspension arm.

(4) Install the retainers and bolts to the lower suspension arm and tighten to 34 N*m (25 ft. lbs.).

(5) Tighten the frame retainer nuts to 190 N*m (140 ft. lbs.).

(6) Tighten the frame retainer bolts to 108 N*m (80 ft. lbs.).

Hub/bearing

REMOVAL

(1) Raise and support vehicle.

(2) Remove wheel and tire assembly.

(3) Remove axle nut.

(4) Remove ABS wheel speed sensor if equipped, refer to Group 5 Brakes.

(5) Remove the brake caliper and rotor, refer to Group 5 Brakes.

(6) Remove hub/bearing mounting bolts from the steering knuckle (Fig. 14).

(7) Slid hub/bearing out of the steering knuckle and off the axle.

Fig. 14 Hub/Bearing

1 - HUB BEARING

2 - STEERING KNUCKLE

INSTALLATION

(1) Install the hub/bearing into the steering knuckle and tighten the bolts to 166 N*m (123 ft.

lbs.).

(2) Install the brake rotor and caliper.

(3) Install ABS wheel speed sensor if equipped.

(4) Install axle nut and tighten to 235 N*m (173 ft.

lbs.) and install cotter pin.

(5) Install wheel and tire assembly.

(6) Remove support and lower vehicle.

Wheel mounting studs

REMOVAL

(1) Raise and support vehicle.

(2) Remove wheel and tire assembly.

(3) Remove brake caliper and rotor, refer to Group 5 Brakes for procedure.

(4) Remove stud from hub with Remover C-4150A (Fig. 15).

INSTALLATION

(1) Install new stud into hub flange.

(2) Install three washers onto stud, then install lug nut with the flat side of the nut against the washers.

(3) Tighten lug nut until the stud is pulled into the hub flange. Verify that the stud is properly seated into the flange.

(4) Remove lug nut and washers.

(5) Install the brake rotor and caliper, refer to Group 5 Brakes for procedure.

(6) Install wheel and tire assembly, use new lug nut on stud or studs that were replaced.

(7) Remove support and lower vehicle.

Fig. 15 Wheel Stud Removal

1 - REMOVER

2 - WHEEL STUD