Suspension: Service and Repair

Suspension Assembly

Removal

1. CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used.

Raise rear of vehicle and support on stands.
2. Remove rear wheels.





3. CAUTION: Do not suspend caliper from brake hose as this will damage the hose.

Remove brake caliper from carrier.
1. Remove caliper spring clip.
2. Remove guide pin dust caps.
3. Slacken and withdraw guide pins.
4. Remove caliper from carrier and tie to suspension bump stop bracket.





4. Disconnect wheel speed sensor connector.





5. Remove and discard tie strap securing wheel speed sensor harness to brake hose clip.





6. Adaptive damping system only:
^ Remove top cover from shock absorber.
^ Disconnect shock absorber harness connector by pressing lugs down and pulling connector up.





7. Remove shock absorber upper mounting plate to body nuts.
8. Repeat steps 3 to 7 on opposite side of vehicle.





9. Fully slacken but do not remove parking brake cable adjuster nut.





10. Release appropriate side parking brake cable from connecting clip.





11. Withdraw parking brake cable through equalizer (LH side cable only).





12. Mark position of driveshaft coupling to flexible coupling with paint.





13. Remove drive shaft from differential drive coupling.
^ Remove drive shaft to differential drive coupling bolts.
^ Carefully withdraw and lower drive shaft from differential coupling.





14. Raise differential assembly.
^ Position trolley jack under differential assembly.
^ Position a suitable piece of wood between jack and differential.
^ Raise jack to just take the weight of the rear suspension.





15. Remove exhaust mounting to suspension bracket bolts.





16. Remove subframe front mounting bracket to body bolts.





17. Remove subframe front mounting bracket.
^ Remove mounting bracket to subframe bolt.
^ Remove front mounting bracket.





18. Remove differential strut upper mounting to body bracket securing bolt.
19. Repeat steps 15 to 18 on opposite side of vehicle.
20. Raise rear of vehicle to provide clearance for assembly removal.





21. Remove differential/suspension assembly.
^ Ensure that hydraulic pipes, harnesses and drive shaft will not obstruct suspension removal.
^ Carefully lower differential/suspension assembly and traverse clear of vehicle.





22. Retrieve subframe mounting bush shims.
23. With assistance, position differential/suspension assembly on bench.
24. Clean subframe mounting bushes and corresponding body locations.

Installation





1. Apply a thin coat of grease to subframe bushes and place shims in position.
2. With protective wood under, position differential/suspension assembly on trolley jack.
3. Traverse trolley jack into position under vehicle.





4. Raise trolley jack to position differential/suspension assembly to vehicle.





5. Install mounting bracket.
^ Position mounting bracket to subframe.
^ Install but do not tighten new mounting bracket to subframe/body bolt.





6. Install new mounting bracket to body outer bolt and tighten to 41 - 54 Nm.





7. Install new mounting bracket to body inner bolts and tighten to 88 -118 Nm.





8. Tighten mounting bracket to subframe/body bolt to 88 -118 Nm.





9. Install new differential strut to body bracket bolt and tighten to 68 - 92 Nm.
10. Repeat steps 6 to 9 on opposite side of vehicle.
11. Lower and remove trolley jack.
12. Lower rear of vehicle to working height.





13. Align marks previously painted on drive shaft and flexible coupling.





14. Install new drive shaft coupling bolts and nuts and tighten to 76 - 88 Nm.





15. Install exhaust brackets.
^ Position exhaust mounting bracket on subframe.
^ Install bolts and nuts and tighten to 22 - 28 Nm.
^ Repeat operation on opposite side exhaust mounting.





16. Route parking brake cable through equalizer (LH side cable only).





17. Install parking brake cable in connecting clip.
18. Adjust parking brake cable.





19. If adaptive damping is fitted:
^ Connect shock absorber harness connector, ensuring connector key locates in socket keyway.





20. Install shock absorber upper mounting plate to body nuts.
21. Release brake caliper from bump stop tie.





22. Install brake caliper on carrier.
1. Position caliper assembly on carrier.
2. Install guide pins and tighten to 25 - 30 Nm.
3. Install dust caps.
4. Install brake caliper spring clip.





23. Install wheel speed sensor on hub carrier.
^ Position sensor on hub carrier and install and tighten bolt to 7 - 10 Nm.
^ Connect wheel speed sensor harness to sensor.





24. Using new tie strap, secure wheel speed sensor harness to hub carrier.
25. Repeat steps 20 to 25 on opposite side of vehicle.
26. Install rear wheels.
27. Remove stands and lower vehicle onto wheels.
28. Raise vehicle on four-post lift.
29. Lower four-post lift
30. Apply parking brake.

Remove suspension subframe from vehicle.