204-01-4 2046-01-41 SECTION : 204-01 Front Suspen: VEHICLE APPLICATION : 2004.0 Territory CONTENTS PAGE SPECIFICATIONS Specifications. - nage tec ---204-01-2 DESCRIPTION AND OPERATION Front Suspension (AWD)....... cts ie aaa ---204-01-3 Front Suspension Assembly (RWD) wnc.s.cossonesvsnneesnnncrnnnsec Z 204-01-3 Wheel Knuckle Assembly ...... nanarensonneamnennnneennnesngee Nd Rear Lower Control Arm (RLCA) . Front Lower Control Arm (FLCA).. Upper Control Arm (UCA).. Stabiliser Bar... DIAGNOSIS AND TESTING Front Suspension ......-. ---204-01-8 REMOVAL AND INSTALLATION Rear Lower Control Arm (RLCA) SOND in icsnsin 5 ---204-01-9 Front Lower Control Arm (FLCA) BN a ecenernentn - ~.204-01-9 Upper Control Arm pe De vesnnenesennn ~.204-01-10 Upper Control Arm Ball Joint .. z eS ~-204-01-11 Stabiliser Bar Droplinks. cose ais BS ence ~-204-01-11 Stabiliser Bar BUSHING... .ovennntnntneensneenn pearance .204-01-12 Stabiliser Bar....... 204-014-412 Front Knuckle and Hut 204-01-14 Knuckle Lower Ball Joint. Front Hub Bearing (AWD Only)... Spring and Shock Absorber. Assembly 204-01-18 Pencil Brace oe... a essa / sone 204-01-21 Front Suspension Module . esscsssee sora 204-01-22 204-01-16 204-01-16 (01/2004 2004.0 Terntory204-01-2 204-01-2 SPECIFICATIONS General Specifications ‘Specification fAngie between upper [76.22 2° control arm and bracket iStabiiser bar diameter | 20= 0.2mm 27 2 0.2mm Torque Specifications (BS sensor to knuckle wxle pac nut aliper to KAUCKIS Tavis 10 RLCA bolls (AWD only) levis 10 shock absorber (AWD only) Differential to subframe bolt RH (1) [Engine mount to subframe FLCA to knuckle FLCA to subframe [Heat shield to knuckle [Link to stabiliser bar INVH brace to subframe. Pencil brace to sublrame LER rece RICA mabame [Steecng gear to svbiame Jao" 1] [Subicame to body pots) fro. | [Subframe to body nuts (5) t say Upper conve amo vee [Upper control arm to mounting bracket *SC - Significant Component # - Denotes torqued at ride height ‘00001 en (0172004 2004.0 Territory204-01-3 204-01-3 DESCRIPTION AND OPERATION Front Suspension (AWD) ‘The front suspension module has two variations, RWD and AWD. The AWD transmits torque to the front wheels via a differential (located on the LHS of the subframe) and two independent halfshafts. ‘The independent front suspension design is based on the wheel knuckle being supported by two lower control arms and an upper control arm. The Rear Lower Control Arm (RLCA) Supports the spring and shock absorber assembly via a clevis. The upper and lower control arms, steering gear and stabiliser bar droplinks attach 10 the knuckle through flexible ball joints allowing the knuckle to rotate. The design allows for servicing on either side of the module. Alternatively, the entire module may be removed from the vehicle. Vehicle body roll is controlled by a spring steel stabilizer bar that is mounted in rubber bushings held to the subframe by brackets. The stabilizer bar is connected to the knuckle via a link. Ball joints at these connections provide flexibility and ride features. ‘600003 en (01/2004 2004.0 Territory204-01-4 204-01-4 DESCRIPTION AND OPERATION (Continued) Wheel Knuckle Assembly ‘AUsO3290 AWD illustrated ee a [2 ____| Steering gear tie rod ends [5 [oper convorarm (uca) | [5 [Frontiowerconvotarm (FLGA)_—____| Rear lower control arm (RLCA) Bal jot“ FLCA [> __[knuckte assembiy 00004 en (0172004 2004.0 Territory204.01-5 204-01-5 DESCRIPTION AND OPERATION (Continued) Rear Lower Control Arm (RLCA) The RCLA assembly consists of a forged arm with a rubber bush on the subframe end and an integral ball joint on the knuckle end. A mounting bush for the front shock absorber is also pressed into the arm. if ee “f oS Ausosted Description RLCA with ‘Shock absorber bush RLCA to subframe bush Bolt (M14~2x101 Hex Flange PLT) Nut - RLGA to subframe (M142 Hex Flange Nylock PC 10) Nut - RLGA to knuckle (Mt4x2 Hex Flange Nylock PC 10) 00006 en’ (01/2004 2004.0 Terntory204-01-6 204-01-6 DESCRIPTION AND OPERATION (Continued) Front Lower Control Arm (FLCA) ‘The FCLA assembly consists of a forged arm with a rubber bush on the subframe end. f usostes (Description: FLCA to subframe bush FLCA [Bolt (M142x120 Hex Flange PLT) [Nut & captive washer - knuckle to FLCA (MIax2 Hex Flange Nylock PG10) Nut: FLCA to sublrame (M14x2 Hex Flange Nylock PC10) ‘00006 en (0172004 2004.0 Territory204.01-7 204-01-7 DESCRIPTION AND OPERATION (Continued) Upper Control Arm (UGA) The UCA assembly consists of a cast iron arm with two rubber, mounting bushes that connect it to the: mounting bracket that is bolted to the body. A balljoint ‘connects the UCA to the front suspension knuckle auso2269 em [Description 1 ‘Arm assembly, front suspension upper ‘Knuckle assembly F4 Knuckle bot Stabler ber (6) ~ ausoates Stabiliser Bar tem Description The stabiliser bar assembly consists of the stabiliser [; Siebieer bar bar and two droplinks. The assembly is attached to the subframe by two brackets and two rubber 2 Stabiliser bar bush D-blocks. The droplink serves as alinkage between [3 ‘Screw - stabliser bar bush bracket to the knuckle and the stabiliser bar. The droplink has subframe (M8x1.25%20 Hex Flange) ball joints at both ends connecting the link to the stablliser bar and the knuckle. The stabiliser bar Gropiinks should be replaced as a pair to ensure Suspension side roll is evenly controlled. ‘Stabiliser bar bush bracket 'Nut- droplink to knuckle (MI2c1'5 Hex Nylock) Nut - droplink to stabiliser bar (M1215 Hex Nylock) 00008 en’ (01/2004 2004.0 Terntory204-01-8 204-01-8 DIAGNOSIS AND TESTING Front Suspension Refer to Section 204-00. 00009 en! (01/2004 2004.0 Territory204.01-9 204-01-9 REMOVAL AND INSTALLATION Rear Lower Control Arm (RLCA) Removal 1. Hoist the vehicle and remove the front wheel. 2. Remove RLCA to shock absorber bolt. 3. Loosen (crack) RLCA to knuckle nut and remove the nut, Ne mh ie e AL en ( usoster 4, Loosen and remove RLCA to subirame nut 5. Remove RLCA to subframe bolt. ausostes 6. Slide RLCA free from the front suspension module, Installation 1. Locate RLCA balljoint stud to knuckle and slide RLCA into subframe Loosely attach a new RLCA to knuckle nut. 3. Install RLCA to subframe bolt and loosely attach a new RLCA to subframe nut. 4. Install RLCA to shock absorber bolt. 5. Ensure vehicle is at ride height. Refer to Section 204-00, 6. Torque RLCA to subframe bolt and nut to specification. ausoste9. 7. Torque the RLCA to knuckle nut to specification. NOTE: When tightening a balljoint nut, hold the stud end with a spanner to avoid twisting and ‘damaging the boot. usos190 Front Lower Control Arm (FLCA) Removal 1. Hoist the vehicle and remove the front wheel 2. Loosen (crack) FLCA to knuckle nut and remove the nut, 3. Loosen and remove FLCA to subframe nut. 4. Remove FLCA to subframe bolt. ausoai91 GO00TT en (01/2004 2004.0 Terntory2204-01-10 204-01-40 REMOVAL AND INSTALLATION (Continued) 5. Slide FLCA free from the front suspension module. Installation 1. Locate the knuckle balljoint stud to FLCA and slide FLCA into subframe. 2. Loosely attach a new FLCA to knuckle nut 3. Attach FLCA to subframe bolt and loosely attach @ new FLCA to subframe nut, 4, Torque FLCA to subframe bolt and nut to specification, with vehicle at ride height. Refer to Section 204.00, WW ‘nusos162 5. Torque FLCA to knuckle nut to specification. NOTE: When tightening a balljoint nut, hold the stud end with a spanner to avoid twisting and damaging the boot. Upper Control Arm Removal 1. Raise the vehicle and support it under the body fe Remove the wheel. Disconnect the stabiliser bar link at the lower connection. NOTE: It is important to disconnect the stabiliser bar drop link from the knuckle before disconnecting the upper control arm from the knuckle, to prevent any risk of damage to the drop link. Separate the upper ball joint from the knuckle. Tie the knuckle to prevent the half shaft from disconnecting and causing ball joint damage. Remove the spring and shock assembly. Refer ‘Spring & Shock Absorber - Removal, this section. Remove the four nuts securing the upper arm bracket to the suspension tower and remove the assembly from the vehicle. 7. Remove the two bolts and the bracket from the control arm. NOTE: As this bush is a double bonded bush it is important to reinstall the arm in the same angular position relative to the bracket to ensure ‘maximum life of the bush. Therefore it is recommended to mark the angular position of the control arm relative to the bracket to allow installation to be in the same orientation (Angle between arm and bracket is 76.2 + 2° as per illustration). NOTE: This angular position is important to ensure maximum life of the bush, Installation 1. Position the upper arm on the bracket at the correct angular position of 76.2 + 2° as illustrated and install and tighten new prevailing torque nuts to specification, 1 Upper control arm Bracket } 2. Position the control arm assembly on the suspension tower and install and torque the attaching nuts to specification. 47 Nm 3. Install spring and shock assembly. Refer Spring & ‘Shock Absorber - Installation, this section GO00TT en (0172004 2004.0 Territory204.01-44 2204-01-11 REMOVAL AND INSTALLATION (Continued) 4, Attach the ball joint to the knuckle and tighten the Removal ‘clamp bolt to specification. Remove the knuckle 4. Place receiver 888-100-7 or 888-500-5 under tie upper arm casting, 2. Using a hydraulic press and a suitable mandrel push out ball joint. = Installation FF 1. Remove rubber boot from the new ball joint, ensuring not to damage the boot or retainer ring - lip. 2. Position ball joint over control arm. 3. Place receiver 204-229-4 under upper arm casting, 4. Using a hydraulic press, push ball joint home with tool 204-230-8 uso3291 5. Reinstall protective rubber boot and retainer ring a ______________ op, 5. Re-connect the stab bar link at the bottom and torque to specification. Refer this Section. Stabiliser Bar Droplinks 6. Install the wheel and torque ta specification. 7. Lower the vehicle. pemeeal 1. Raise vehicle on hoist. Upper Control Arm Ball Joint 2. Remove the front wheels. 3. Loosen (crack) link to knuckle nut and remove the [Special Tool(s) nut. 204-299 4. Loosen (crack) link to stabiliser bar nut and remove the nut 204-230 AUso“s37 . 700 pee: 5. Remove drop link. Installation 1. Locate upper ball joint into knuckle. NOTE: When installing the upper balljoint into the knuckle, ensure the anti-rotation washer supplied as part of the assembly is correctly seated on fe} both the ball stud flats, and within the cast 866-500 features on the rear of the knuckle. 2. Locate lower ball joint into stabiliser bar. 000074 en (01/2004 2004.0 Terntory2204-01-12 2046-01-42 REMOVAL AND INSTALLATION (Continued) 3. Install a new link to stat to specification, NOTE: When tightening a balljoint nut, hold the stud end with a spanner to avoid twisting and damaging the boot. iser bar nut and torque SNM} / A ‘AUSOES3E ai ara 4. Install a new link to knuckle nut and torque to specification. Stabiliser Bar Bushing NOTE: Damage to suspension andior steering components may occur if care is not taken when positioning hoist adaptors or jacks when lifting the vehicle, Do not allow contact with the steering linkage. Removal 1. Raise the vehicle on a hoist. 2. Remove the stabiliser bar bush bracket to subframe screws and ramove the bracket from the stabiliser bar. 3. Push the bushes free of the bar, the bushes will flex around the stabiliser bar. NOTE: A screwdriver may be required to assist in pressing the stabiliser bar bush free. AU800280 Installation 1. Fit new bushes over the stabiliser bar in the correct operating position 2. Place the bushing bracket over the bush so that ‘mounting holes line up. AX caution: when installing the stabiliser bar bush bracket screws, make sure the screws are properly locaied in the weld nuts. DO NOT FORCE the screws into cross threading the weld nuts or the entire subframe will need to be replaced. 3. Torque the stabiliser bar bush bracket to subframe screws to specification, usosi94 AUSO86S - Stabiliser Bar Removal 1. Remove stabiliser bar éroplinks, refer to this section 2. Remove the LHS and RHS stabiliser bar bush bracket and bush, refer to this section. 3. Remove the clevis to RLGA bolt (AWD only). ‘G000074 en (0972004 2004.0 Territory2046-01-13 204-01-43 REMOVAL AND INSTALLATION (Continued) 4, Remove the LHS and RHS clevis to spring / shocker assembly bolts and remove the clevis from shock absorber (AWD only}. Rotate / Jiggle the stabiliser bar out of the RHS of the subframe. Installation 1. Rotate / Jiggle the stabiliser bar into its correct ‘operating position through the RHS of the front suspension module. Install the LHS and RHS stabiliser bar bush and bush bracket. Refer to this section. Install the LHS and RHS clevis to shock absorber bolts and torque to specification (AWD only). 4. Install the LHS and RHS clevis to RLCA bolts and torque to specification ausosi76. Install the LHS and RHS stabiliser bar droplinks. Refer to this section. ‘GO00T6 en (01/2004 2004.0 Terntory2204-01-14 2046-01-44 REMOVAL AND INSTALLATION (Continued) Front Knuckle and Hub item [Description [Axle pac nut (M24) [Bolt - ABS sensor ta knuckle (M6x1_0x25 HEX FLNG HD) [Nut droplink to knuckle (M12x1.5 HEX FLNG NYLOG) [Nut upper control arm to knuckle [Nut & captive washer - FLOA to knuckle (M1ax2 HEX FLNG NYLOG PC 10) [Nut RLCA to Knuckle (Mia@ HEX FLNG NYLOG PC 10) [Nut tie rod end to knuckle (M12x1,75 HEX FLNG NYLOC PCA) Removal 1, Raise Vehicle on hoist and remove front wheels. 2, Loosen the axle pac nut, NOTE: Pac nuts are substantially torqued. Loosen and remove ABS sensor to knuckle bolt. Remove ABS sensor from knuckle. Remove the front brake caliper and rotor. Refer to Section 206-03 Loosen and remove drop link to knuckle nut. NOTE: Itis important to disconnect the stabiliser bar drop link from the knuckle before disconnecting the upper control arm from the knuckle, to prevent any risk of damage to the drop link 7. Remove upper control arm to knuckle nut and bolt. 8. Loosen (crack) RLCA to knuckle nut and remove the nut. 9. Loosen (crack) FLCA to knuckle nut and remove the nut, 10. Loosen (crack) tie rod end to knuckle nut and remove the nut ‘GO00017 en (0172004 2004.0 Territory2046-01-15 2204-01-45 REMOVAL AND INSTALLATION (Continued) 11, Remove axle pac nut. 12, Remove knuckle free from halfshaft (AWD only). 13. Remove knuckle assembly from halfshaft (AWD. only) in a horizontal direction NOTE: Knuckles must be removed ina direction parallel to the halfshafts (AWD only) to avoid damage to the ABS tone wheel teeth on the halfshaft (AWD only) and hub splines. NOTE: To remove the knuckle, attach a hub puller to the hub and centre the puller screw on the halfshatt See sion OE Installation 1. Position knuckle assembly over halfshaft spline {AWD only), with halfshaft supported horizontally. Replace axle pac nut and loosely tighten. ‘90 Nm auso3223. 2. Locate knuckle ball joint stud to FLCA and install ‘a new nut, torque nut to specification. NOTE: When tightening any balljoint nut, hold the stud end with a spanner to avoid twisting and damaging the boot. 3. Locate RLCA ball joint stud to knuckle and install a new nut, torque nut to specification. 4. Locate Upper Control arm bail joint stud to knuckle and torque bolt to specification. 5. Locate tie rod end ball joint stud to knuckle and install a new nut, torque to specification. 6. Locate drop link ball joint stud to knuckle and install a new nut, torque to specification. 7. Use an appropriate method to restrain the hub to Prevent rotation when tightening the axle pac nut. 8. Torque axle pac nut to specification. G00017 en (01/2004 2004.0 Terntory2204-01-16 2046-01-46 REMOVAL AND INSTALLATION (Continued) Knuckle Lower Ball Joint 3. Support knuckle in a press with hub facing down and using a suitable mandrel, press the hub out of [Special Tools) meres i AX caution: Ensure that the knuckle is adequately supported, as the loads required to push out the hub are Substantial (2,000 to 3,000Kg). NOTE: The bearing will be destroyed during this process. The outside inner cup will remain on the hub and cannot be removed. ssra0s240 204-537 ssTaness7 1. Remove knuckle and hub assembly. Refer this Section. 2, Remove ball joint retaining circlip 3. Position 204-537-2 under the knuckle, 4. Using a press and 204-240-4, press the ball joint out of the knuckle, Installation 1. Position 204-637-2 under the knuckle. 2. Using a press and 205-537-1, press the ball jaint into the knuckle. 3. Fit ball joint retaining circip. 4, Re-install the knuckle and hub assembly. Refer this Section, Front Hub Bearing (AWD Only) Description 1 Knuckle 2 Mandrel 3 Press plates 4 Hub 3 6 Bearing Outside inner race (remains on hub). Removal 4, Remove knuckle and hub assembly. Refer this Section. 2. Remove front brake disc splash shield. ‘GO00017 en (0172004 2004.0 Territory204.01-47 2204-01-17 REMOVAL AND INSTALLATION (Continued) 4, Remove the bearing retaining circlip from the 6. Support the inner side of the knuckle in a press kauckle, using Special Too! 205-466 and using a suitable mandrel, press the bearing out of the knuckle. AX caution: Ensure that the knuckle is adequately supported, as the loads required to push out the bearing are substantial (2,000 to 3,000Kg).. YQ ausoss25 3° 5. Remove the inside inner cup from the bearing and insert it into the outside of the bearing to replace the cup left om the hub. 6 HOG ww = O @ ausos372 ty Press siem SST 205-466 Bearing [| wanaret Installation 1. Lightly lubricate the bearing bore in the knuckle to aide pressing in the new bearing, as the press loads are relatively high (2,000-3,000 Kg). 00079 en (01/2004 2004.0 Terntory2204-01-18 2046-01-48 REMOVAL AND INSTALLATION (Continued) 2. Support the knuckle in a press and using a Suitable mandrel that bears. on the outer race of the bearing, press the bearing into the knuckle. AX caution: Ensure that the knuckle Is adequately supported, as the loads required to push in the bearing are substantial (2,000 to 3,000Kg). ‘Ays04361 3. Fit a new bearing retaining circlip. 4, Tur the knuckle over and support it, using Special Service Tool 205-466. 5. Lightly lubricate the hub journal with grease to assist pressing the hub into the bearing. 6. Align the hub journal with the bearing and press the hub into the bearing. A\ caution: ensure that the knuckle is adequately supported, a8 the loads required to ush in the hub are substantial (2,000 to SlovoKg). NOTE: Apply only sufficient press force to seat the hub, as excessive installation force at this time could damage either the bearing or the bearing retaining circlip. ‘Auso4360 7. Fitthe front brake disc splash shield. 8. Reinstall the knuckle. Refer this Section Spring and Shock Absorber Assembly RWD front spring & shock absorber assembly @O@m—"L.__@© RORORC) Hn} nnn OOD SHO d © ‘ausoos49 Tem [Description 1 Nyloc nut 2 Washer 3 Insulator 4 Bracket assembly a [| Soro, ron suspension con] 7 ‘Shock absorber assembly, front (RWD illustrated) 6 Nut e Bumpstop 00019 en (0172004 2004.0 Territory204-01-19 2204-01-19 REMOVAL AND INSTALLATION (Continued) AWD front spring & shock absorber assembly Description’ ‘Shook absorber, Front Lower control arm, rear RWD front shock absorber mounting. ~ 7 Ww 2 2. Remove two of the three nuts securing the shock ‘absorber/spring assembly to the suspension tower and loosen the third nut, but do not remove. Us03282 3. Raise the vehicle - supporting it under the body rails, 4. Remove the wheel and separate the upper ball joint stud from the knuckle, NOTE: Tie the knuckle to prevent the hatf shaft from disconnecting and causing ball joint damage. Le nus03515 ausoazes Tam [Description rt ‘Shock absorber, front 5. RWO - Remove the shock absorber ower 2. ok Hex BeSa Ms AWD - Remove the 4 bolts mounting the shock 3 Nut Mra absorber to the clevis. Note the position of the a ‘Aim assembly, front suspension low brake hose bracket Removal * 1. Remove the coolant bottle or the air cleaner box depending upon which side is to be removed, 00079 en (01/2004 2004.0 Terntory2204-01-20 2046-01-20 REMOVAL AND INSTALLATION (Continued) ‘Auso22es 6. Remove the third nut supporting the shock absorber!spring assembly to the suspension tower, gently ease down the lower arm and remove the assembly, taking care to ensure that the shock absorber lower brackets do not damage the dust boot of the lower ball joint. Also take care not to damage the ABS sensor wire (where fitted. Ausosze2 7, Install the shock absorber/spring assembly onto the spring compressor and compress the spring to relieve the tension from the shock absorber piston rod AX warninc: do not attempt to separate the spring from the shock absorber until the spring is restrained by the use of a spring compressor, Remove the nut, upper insulator assembly and spring seat insulator from the shock absorber piston rod and withdraw the shock absorber. Release the tension from the spring if the spring is to be changed. lation Ensure that the bumpstop is correct fitted onto the shock absorber, compress the spring in the spring compressor and assemble the shock absorber into it 2. Set the stop of the shock absorber spring seat, against the spring lower end, fit the upper spring seat insulator and rotate it's stop against the upper end of the spring. Fit the spring cap with any of the three studs at the specified angle relative to the centre line of the shock absorber assembly to lower control arm mounting bolt (lower spring seat stop end) BOLT AXIS (SHOCK | ‘ASSY TOLOWER. | LoweR END ‘OF SPRING LOCATION ANGLE RHSASSY. 40" LHS ASSY.20" Aus00350 Assemble the upper insulator assembly and nut ‘onto the shock absorber piston rod, Partly release the spring compressor and torque the nut to specification whilst preventing the spring cap from rotating by use of a soft lever (eg piece of wood) against two of the three studs. Fully release the spring compressor. Install the shock absorber/spring assembly into the vehicle, The lower spring tall is to be to the front on LHS and to the rear on RHS. Take care not to damage boot of the lower ball joint. or the ABS wire (where fitted) and loosely fit one of the ‘nuts supporting the assembly to suspension tower RWO - Fit the shock absorber lower mounting bolt and loosely fit the nut. AWD - Install 4 bolts mounting shock absorber to levis including installation of brake hose bracket NOTE: Bolt thread must point towards the front of the vehicle Fit the upper ball joint stud to the knuckle; fit the clamp bolt and nut. Torque the nut to specification, 5. 90 Nm}———»\<> ausos291 00019 en (0172004 2004.0 Territory2204-01-24 2204-01-21 REMOVAL AND INSTALLATION (Continued) 9. Fitthe two remaining nuts securing the upper —3._Loosen and remove pencil brace to RLCA nut and spring seat cap to the tower. bolt, 10. Fit the wheel 4. Loosen and remove pencil brace to body nut. 11. With the vehicle weight on its" wheels, torque the shock absorber lower mounting hardware to specification. aus03200, ~ 5. Remove pencil brace from subframe. Installation 1. Install pencil brace and line up the mounting holes. Locate pencil brace to subframe, screw into subframe weld nut and torque to specification. AX caution: wnen instating the pencil brace to subframe screw, make sure the screw is properly located in the weld nuts. 00 NOT FORCE the screws into cross threading the weld nuts or the entire subframe will need to be replaced. AUS03290 Ni 12. Torque the three nuts on the suspension tower, to specification. 35.Nm Auso3199 - 2. Install a new pencil brace to RLCA nut and torque the nut and bolt to specification. 3. Install pencil brace to body nut and torque to specification. Aus00348, Pencil Brace Removal 1. Raise vehicle on hoist, 2. Loosen and remove pencil brace to subframe screw. ‘Go0021 en (01/2004 2004.0 Terntory204-01-22 2046-01-22 REMOVAL AND INSTALLATION (Continued) Front Suspension Module General Assembly (AWD) 00022 en 01/2004 2004.0 Territory204.01-23 2204-01-23 REMOVAL AND INSTALLATION (Continued) [Special Tools} ‘502-008 Ad warninc: 00 not use this too! to support the weight of the engine and transmission. The SST is designed to remove the subframe and suspensionisteering, it is NOT designed to remove the engine and transmission. sss7s02-008, Removal 1. Loosen front wheel nuts. 2, Disconnect battery earth cable. 3. Disconnect battery to starter motor and relay box cables. 4, Remove flex tube from airbox to intake manifold and remove LHS engine mount nut. NOTE: To remove LHS engine mount nut use a universal with a long extension accessing the nut behind the throttle body. 8. Disconnect the steering gear pressure line from the pump Ausoss65. [lem —[ Desorption [Teressure ine 9. Using the ignition steering lock, lock steering wheel with wheels in the straight ahead position 410. Disconnect the intermediate shaft / steering column upper connection and swing free of steering gear. Refer to Section 211-02. Ausos363: 5 ausoszo1 7 6. Siphon power steering fluid from reservoir. 7. Disconnect steering gear pressure switch electrical connector, 11. Mount the engine support bracket on the strut reinforcement panels and support the engine from engine hoisting points. Ausos2i8: 12 13, Remove the front wheels. Replace one wheel nut on each side to prevent brake disc dislodging e the vehicle on hoist. 00022 en’ (01/2004 2004.0 Terntory2204-01-24 204-01-24 REMOVAL AND INSTALLATION (Continued) 14, Remove LHS and RHS brake caliper to knuckle bolts and it caliper assembly free from rotor. Support the caliper assembly by hanging it from the spring / shocker assembly on a hook, being careful not to damage the brake hose. Refer to 17. Remove the lower air deflector. Ke i. 7 is AR J A ay Auso3123 - ausos203 18, Disconnect engine earth strap and starter motor cable, 19. Disconnect steering gear return line and bracket from steering gear. Refer to Section 211-02. 15. Remove LHS and RHS upper control arm to knuckle nuts and bolts. ‘Aus03208 16. Support the knuckle via a hook to: subframe. NOTE: Itis important to support the knuckle correctly when removing the front module to avoid over extending the inner GW plunge joint and risking damage to the halfshaft assembly. NOTE: Care must also be taken to avoid excessive angular movement of the lower balljoints that could result in damage to either the joint or dust boots. 00022 en AUSO3479 (0172004 2004.0 Territory204.01-25 2204-01-25 REMOVAL AND INSTALLATION (Continued) 21. Mark the position of the front drive shaft CV ‘mounting bracket (AWD Only) with the diff flange so that proper realignment is possible and drive shaft balance can be maintained. Refer to Section 205-01 NOTE: Record the position of any balance weights so that they can be reinstalled in the correct position(s) ‘Aus03205 22. Unbolt the front drive shaft from the diff lange (AWD Only) and secure out of way. Refer to Section 205-01, NOTE: Do not over-extend the front driveshaft CV jeint connected to the transfer case flange. ausoxos (3 item [Description 1 ‘Constant velocity joint 2 Differential flange 3 Bolt 23. Disconnect the differential breather hose (AWD. only) from engine mount. 24, Remove LHS and RHS spring/shocker (clevis) to rear lower control arm bolts. tel | an YY, \ | Ns f | : | avsoszor 25. Disconnect the transmission cooling line bracket, from the front left of subframe. 26. Remove 3 LHS and 3 RHS NVH brace bolts (torque box brace) and remove braces. BAW, o¢ 27, Fite font module removal fixture, Special Tool 502.008 tote ont moaue ensuring atts try aiaches veers roceedng Remove the 2 LHS conte subframe retaining bat (fro diagram Font Subtame tachment Locatone. fame 28 4) and hosing centre RES sorame retaning bok tem 8 Position an extended trolley jack below the front mode renova ture Spece! Toot S02 008 Cowor te vile un tho meu bout 100 mm above he axtonded jack abet jock fake te weight of the ont module: De na raise fhovencle 30, Remove the RHS and LHS subiame rear flaring bots (er © dagram Pont Subtame Atachmnt Locabon, toms 687) Remove both the RHS and LHS subframe front retaining bolts (refer to diagram Front Subframe Atochmont ocotone tems 182) Slow lower tho jack, ensuring hat nothing cotehes asin ont modu Gescende om the vehicle. Asos312: 28. 29. 3 32, ‘00022 en (01/2004 2004.0 Terntory2204-01-26 2046-01-26 REMOVAL AND INSTALLATION (Continued) 33, Raise the vehicle to fully release the front module. NOTE: It is recommended that the steering intermediate shaft is removed before re-installing the front module to make installation easier. Installation 1. With the front module mounted on Special Too! §02-008 and on a suitable trolley jack, position it underneath the engine bay so that the module is in its approximate installed position. is important that the trolley jack is correctly positioned underneath module so that there is even ribution, if not correctly positioned the module may be damaged. ‘0 simplify front module installation, it is recommended that the intermediate steering shaft be from the steering gear. 2. Lower the vehicle with the hoist until the subframe mounting points are approximately 100 mm from the boay. 3, Raise the front suspension module using the jack. Use the2 studs on the LHS of the subframe to position the subframe to the body side rail NOTE: Carefully guide engine mount studs into their correct locations while raising front module into position. At the same time, carefully feed the power steering hose and starter motor cable into position. 4, Loosely attach engine mount nuts (00 NOT FULLY TIGHTEN). 5. Install subframe front and rear bolts (refer to diagram Front Subframe Attachment Locations, items 1,2,6 & 7) (DO NOT FULLY TIGHTEN). AX CAUTION: The rear bolts have large captive washers. Non-genuine bolts without the captive washer must not be used. 6. Raise the vehicle Position a transmission jack under Special Too! 502-008 to support the subframe. 8. Install the centre RHS subframe retaining bolt and the 2 LHS centre subframe retaining bolts (refer to diagram Front Subframe Attachment Locations, items 3, 4 & 5) (D0 NOT FULLY TIGHTEN), Ausnsse 00022 en (0172004 2004.0 Territory204.01-27 2204-01-27 REMOVAL AND INSTALLATION (Continued) 9. Torque all bolts and nuts to specification. Refer diagram above, NOTE: All torques must be accurately applied 10. Install LHS and RHS NVH brace (torque box brace) and torque bolts to specification. 10, ZX. CAUTION: When installing the NVH brace bolts to subframe, make sure the bolts are properly located in the weld nuts. DO NOT FORCE the bolts into cross threading the weld nuts or the entire subframe will need to be replaced. Boe. ee 23 Nm] auso3s11 11. Reconnect the transmission cooling line bracket to the LHS subframe. 12. Allach the power steering line connector and torque to specification. Refer to Section 211-02 13, Reconnect differential breather hose to the engine ‘mount (AW/D only). 414. Install LHS and RHS spring/shocker assembly (clevis) to RLCA bolts and torque to specification. Refer Specifications, this Section. 15. Reconnect engine earth strap. 16. Install lower air deflector. 17. Reconnect front drive shaft to differential flange (AWD Only), lining up the previously marked positions and torque to specification. Refer to Section 205-01. NOTE: Ensure that any balance weights previously removed are reinstalled in their correct, position. 36.Nm Aus03238. 18. Lower jack and remove Special Too! 502-008. 19, Fit LHS and RHS UCA ball joint to knuckle and torque to specification. Refer Specifications, this Section, Remove the knuckle support hook Reconnect ABS sensor cables. Refer to Section 206-03. Install LHS and RHS brake calipers and torque the caliper to knuckle bolts to specification. Refer to Section 206-03. 20. 24, 22. ausosi24. 23, Reinstall front wheels. 24. Lower the vehicle. 25. Remove engine support bracket. ‘00022 en (01/2004 2004.0 Terntory2204-01-28 2046-01-28 REMOVAL AND INSTALLATION (Continued) 26. Revfit the intermediate shaft to steering gear and steering column. Torque bolts to specification. Refer to Section 211-04 AX warninc: on AWO vehicies, the Steering angle sensor is programmed to read the “straight ahead” position of the steering column. If the steering column is inadvertently rotated more than one turn from “straight ahead” when it is removed from the vehicle, then the Steering Angle Sensor (SAS) must be recalibrated. Refer to Section 206-098. ‘auso3367 ) 27. Reconnect the steering gear pressure line to the pump and torque to specification. Refer to Section 211-02, Ausoss6 28. Reconnect steering gear pressure switch connector. 29. Torque LHS and RHS engine mount nuts to specification. Refer to Section 303-014. NOTE: To install LHS engine mount nut use a Universal with a long extension accessing the nut behind the throttle body. 30. Reconnect airbox to manifold flex tube. 31. Reconnect the battery to starter motor and battery to relay box power cabies 32, Reconnect battery earth strap 33. Resfil power steering reservoir and bleed system. Refer to Section 211-00. 00022 en (0172004 2004.0 Territory