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204-01-1 Front Suspension 204-01-1 SECTION 204-01 Front Suspension VEHICLE APPLICATION: 2011.50 Ranger CONTENTS PAGE DESCRIPTION AND OPERATION Front Suspension 204-01-2 REMOVAL AND INSTALLATION Front Wheel Bearing (14 411 0; 14 411 4; 14 412 0; 14 414 4; 14 416 4) Wheel Knuckle — 2WD (14 343 0) Wheel Knuckle — 4WD (14 343 0) Front Strut and Spring Assembly (14 781 0; 14 782 0) Lower Arm (14 706 0; 14 707 0; 14 709 0) Upper Arm 204-01-4 204-01-8 204-01-12 204-01-16 204-01-18 204-01-20 DISASSEMBLY AND ASSEMBLY Front Strut and Spring Assembly (14 783 4) 204-01-22 Front Suspension 204-01-2 204-01-2 DESCRIPTION AND OPERATION Front Suspension 4X2 Item Description Item Description Stabilizer bar link Knuckle Upper arm Lower arm Stabilizer bar Shock absorber unit Suspension unit 4X2 Vehicles with increased ride height Item Description Item Description Stabilizer bar link Stabilizer bar Upper arm Knuckle 2011.50 Ranger G1268940en Front Suspension 204-01-3 204-01-3 DESCRIPTION AND OPERATION Item Description Lower arm Item Description Shock absorber unit Suspension unit 4X4 Item Description Stabilizer bar link Upper arm Stabilizer bar Knuckle Lower arm Half Shafts Shock absorber unit Suspension unit 2011.50 Ranger G1268940en Front Suspension 204-01-4 204-01-4 REMOVAL AND INSTALLATION Front Wheel Bearing(14 411 0; 14 411 4; 14 412 0; 14 414 4; 14 416 4) Special Tool(s) / General Equipment 204-348/3 Remover/Installer, Wheel Hub/Wheel Bearing 205-307 Installer, Wheel Speed Sensor Ring 308-095 Installer, Input Shaft Bearing 308-604 Installer, Output Drive Flange Seal Hydraulic Press Removal NOTE: Removal steps in this procedure may contain installation details 2011.50 Ranger G1269089en 204-01-5 Front Suspension 204-01-5 REMOVAL AND INSTALLATION Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation) 4x2 Refer to: Wheel Knuckle - 2WD (204-01 Front Suspension, Removal and Installation) 4x4 Refer to: Wheel Knuckle - 4WD (204-01 Front Suspension, Removal and Installation) All vehicles Special Tool(s): 204-348/3 General Equipment: Hydraulic Press General Equipment: Hydraulic Press 2011.50 Ranger G1269089en 204-01-6 Front Suspension 204-01-6 REMOVAL AND INSTALLATION Special Tool(s): 204-348/3, 205-307 2011.50 Ranger G1269089en 204-01-7 Front Suspension 204-01-7 REMOVAL AND INSTALLATION General Equipment: Hydraulic Press Special Tool(s): 205-307 General Equipment: Hydraulic Press Installation NOTE: Make sure that the sensor ring is correctly located • Old Front wheel bearing New Front wheel bearing • Press and install the new wheel bearing Special Tool(s): 308-095, 308-604 General Equipment: Hydraulic Press 2011.50 Ranger G1269089en Front Suspension 204-01-8 204-01-8 REMOVAL AND INSTALLATION Wheel Knuckle — 2WD(14 343 0) Special Tool(s) 211-020 Separator, Ball Joint 49-T028-3A0 Remover, Ball Joint Puller Set Removal Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation) NOTE: Removal steps in this procedure may contain installation details Torque: Nm CAUTIONS: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense A new part with the same part number or an equivalent part must be installed, if installation is necessary Do not use a part of lesser quality or substitute design Torque values must be used as specified during reassembly to make sure of correct retention of these parts Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake Before performing the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while the vehicle is being serviced Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation) WARNING: Make sure that no load is placed on the brake hose Refer to: Brake Disc (206-03 Front Disc Brake, Removal and Installation) 2011.50 Ranger G1269091en 204-01-9 Front Suspension 204-01-9 REMOVAL AND INSTALLATION WARNING: Make sure that a new nut is installed Special Tool(s): 211-020 CAUTION: Make sure that ball joint does not rotate Torque: 125 Nm WARNING: Make sure that a new nut is installed CAUTIONS: CAUTIONS: Do not use a hammer to separate the tie rod from the wheel knuckle or damage to the wheel knuckle can result Do not damage the tie-rod boot while installing the special tool Leave the tie-rod end retaining nut in place to protect the ball joint stud Use suitable packing material to prevent damage to the component Make sure that the ball joint ball does not rotate Torque: 14 Nm Torque: 80 Nm Torque: 65 Nm Protect the ball joint seal using a soft cloth to prevent damage CAUTIONS: Protect the ball joint seal using a soft cloth to prevent damage Do not damage the ball joint boot while installing the special tool Protect the ball joint seal using a soft cloth to prevent damage 2011.50 Ranger G1269091en 204-01-10 Front Suspension 204-01-10 REMOVAL AND INSTALLATION Special Tool(s): 49-T028-3A0 WARNING: Make sure that a new nut is installed NOTE: Make sure that the wheel knuckle is correctly secured Special Tool(s): 49-T028-3A0 11 NOTE: This step is only necessary when installing a new component Refer to: Front Wheel Bearing (204-01 Front Suspension, Removal and Installation) Torque: 175 Nm 10 CAUTIONS: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the wheel knuckle can result Do not damage the ball joint boot while installing the special tool Installation To install, reverse the removal procedure 2011.50 Ranger G1269091en 204-01-11 Front Suspension 204-01-11 REMOVAL AND INSTALLATION Refer to: Front Toe Adjustment (204-00 Suspension System - General Information, General Procedures) 2011.50 Ranger G1269091en Front Suspension 204-01-12 204-01-12 REMOVAL AND INSTALLATION Wheel Knuckle — 4WD(14 343 0) Special Tool(s) / General Equipment 211-020 Separator, Ball Joint 49-T028-3A0 Remover, Ball Joint Puller Set Puller Removal CAUTION: Make sure that hub nut is un-coined before removal NOTE: Removal steps in this procedure may contain installation details CAUTIONS: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense A new part with the same part number or an equivalent part must be installed, if installation is necessary Do not use a part of lesser quality or substitute design Torque values must be used as specified during reassembly to make sure of correct retention of these parts Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake Before performing the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while the vehicle is being serviced Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation) 2011.50 Ranger G1269098en 204-01-13 Front Suspension 204-01-13 REMOVAL AND INSTALLATION Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation) Torque: 125 Nm CAUTION: If the outer constant velocity (CV) joint boot is damaged a new halfshaft must be installed CAUTIONS: Do not use a hammer to separate the tie rod from the wheel knuckle or damage to the wheel knuckle can result Do not damage the tie-rod boot while installing the special tool Torque: Nm Leave the tie-rod end retaining nut in place to protect the ball joint stud Protect the ball joint seal using a soft cloth to prevent damage Special Tool(s): 211-020 WARNING: Make sure that no load is placed on the brake hose Refer to: Brake Disc (206-03 Front Disc Brake, Removal and Installation) CAUTION: Make sure that the ball joint ball does not rotate 2011.50 Ranger WARNING: Make sure that a new nut is installed CAUTIONS: Use suitable packing material to prevent damage to the component G1269098en 204-01-14 Front Suspension 204-01-14 REMOVAL AND INSTALLATION Make sure that the ball joint ball does not rotate Torque: 14 Nm Torque: 80 Nm Torque: 65 Nm 11 NOTE: Make sure that the wheel knuckle and halfshaft are correctly secured Torque: 175 Nm 12 CAUTIONS: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the wheel knuckle can result Do not damage the ball joint boot while installing the special tool Special Tool(s): 49-T028-3A0 10 CAUTIONS: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the wheel knuckle can result Do not damage the ball joint boot while installing the special tool Protect the ball joint seal using a soft cloth to prevent damage Special Tool(s): 49-T028-3A0 13 2011.50 Ranger CAUTION: Do not use a hammer to separate the outboard CV joint from the hub Damage to the threads and internal CV joint components can result Using the special tool, press the outboard CV joint until it is loose in the hub G1269098en 204-01-15 Front Suspension 204-01-15 REMOVAL AND INSTALLATION General Equipment: Puller dust cover and steering knuckle for proper installation Refer to: Front Toe Adjustment (204-00 Suspension System - General Information, General Procedures) To install, reverse the removal procedure CAUTION: If the outer constant velocity (CV) joint boot is damaged a new halfshaft must be installed NOTE: Only tighten the hub nut finger tight at this stage 14 CAUTION: Do not damage the axle shaft oil seal or the machined sealing surface on the outboard CV joint housing Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation) CAUTION: Make sure that hub nut is coined after installation Torque: 275 Nm Installation WARNINGS: Install a new lower arm ball joint retaining nut Failure to follow this instruction may result in personal injury Install a new tie-rod end retaining nut Failure to follow this instruction may result in personal injury CAUTION: Make sure that the ball joint ball does not rotate NOTE: The dust cover does not need to be removed unless it is being replaced Mark the 2011.50 Ranger G1269098en Front Suspension 204-01-16 204-01-16 REMOVAL AND INSTALLATION Front Strut and Spring Assembly(14 781 0; 14 782 0) Special Tool(s) 49-T028-3A0 Remover, Ball Joint Puller Set Removal WARNING: All vehicles are equipped with gas-pressurized shock absorbers which will extend unassisted Do not apply heat or flame to the shock absorbers during removal or component servicing Failure to follow these instructions may result in personal injury Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation) Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation) Torque: 55 Nm Torque: 235 Nm CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense A new part with the same part number or an equivalent part must be installed, if installation is necessary Do not use a part of lesser quality or substitute design Torque values must be used as specified during reassembly to make sure of correct retention of these parts NOTE: Removal steps in this procedure may contain installation details 2011.50 Ranger G1465140en 204-01-17 Front Suspension 204-01-17 REMOVAL AND INSTALLATION Torque: 65 Nm CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the wheel knuckle can result • Do not damage the ball joint boot while installing the special tool • Make sure that the knuckle assembly is secured with suitable retaining straps NOTE: Note the position of the components before removal Installation CAUTION: Before tightening any suspension bushing fasteners, use a suitable jack to raise the suspension To install, reverse the removal procedure Special Tool(s): 49-T028-3A0 Using a suitable jack support the lower control arm near the lower ball joint Lower the jack support to lower the control arm 2011.50 Ranger G1465140en Front Suspension 204-01-18 204-01-18 REMOVAL AND INSTALLATION Lower Arm(14 706 0; 14 707 0; 14 709 0) Special Tool(s) 49-T028-3A0 Remover, Ball Joint Puller Set Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense A new part with the same part number or an equivalent part must be installed, if installation is necessary Do not use a part of lesser quality or substitute design Torque values must be used as specified during reassembly to make sure of correct retention of these parts Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation) Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation) Torque: 175 Nm Torque: 250 Nm Torque: 260 Nm NOTE: Removal steps in this procedure may contain installation details CAUTIONS: Do not damage the ball joint boot while installing the special tool Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the wheel knuckle can result Make sure that the wheel knuckle is correctly secured 2011.50 Ranger G1269447en 204-01-19 Front Suspension 204-01-19 REMOVAL AND INSTALLATION Remove the Special Tool(s): 49-T028-3A0 Installation CAUTION: Before tightening any suspension bushing fasteners, use a suitable jack to raise the suspension To install, reverse the removal procedure 2011.50 Ranger G1269447en Front Suspension 204-01-20 204-01-20 REMOVAL AND INSTALLATION Upper Arm Special Tool(s) 49-T028-3A0 Remover, Ball Joint Puller Set Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense A new part with the same part number or an equivalent part must be installed, if installation is necessary Do not use a part of lesser quality or substitute design Torque values must be used as specified during reassembly to make sure of correct retention of these parts Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation) Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation) Refer to: Front Wheel Speed Sensor (206-09 Anti-Lock Control, Removal and Installation) Torque: 70 Nm NOTE: Removal steps in this procedure may contain installation details CAUTIONS: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the wheel knuckle can result Do not damage the ball joint boot while installing the special tool Make sure that the knuckle assembly is secured with suitable retaining straps 2011.50 Ranger G1269448en