4-Wheel Drive Torsion Bar Front Suspension

Introduction

Click to enlarge

Torsion Bars

REMOVAL & INSTALLATION

F-150, F-250, Expedition and Navigator

The torsion bar adjusting bolt location

1. Raise and safely support the vehicle.
2. Match mark and measure the length of the torsion bar being removed.

Torsion bars are marked for left-hand or right-hand installation. If removing both torsion bars, make sure to reinstall in the correct position. If replacing a torsion bar, make sure that it is the correct torsion bar for the side being replaced.

3. Install Torsion Bar Adjuster T95T-5310-A and Adapter Plates T96T-5310-A, or equivalents.
4. Tighten the adjuster tool until it touches the torsion bar adjuster.
5. Remove the torsion bar adjuster bolt and nut.
6. Remove 6 torsion bar crossmember retaining bolts.
7. Remove the crossmember support.
8. Remove the torsion bar from the vehicle.

To install:

9. Place the torsion bar in position ensuring that it is the correct torsion bar for the side being installed.
10. Install the crossmember support and 6 retaining bolts. Tighten the retaining bolts to 40-50 ft. lbs. (53-72 Nm).
11. Install the torsion bar adjuster bolt and nut, then remove the torsion bar adjuster tool and adapters.
12. Tighten the adjusting bolt until the match marks are in alignment.
13. Lower the vehicle.
14. Measure the ride height and adjust if necessary.
15. Check the alignment and adjust if not within specification.
16. Road test the vehicle and check for proper operation.

ADJUSTMENT

F-150, F-250, Expedition and Navigator

1. Place the vehicle on a level surface.
2. Bounce the front end to normalize the ride height.
3. Measure the ride height on both sides of the vehicle from the frame to the ground.
4. Loosen the lock nut and add or delete turns until the vehicle is level and at the correct curb height.
5. Tighten the lock nut.
6. Road test the vehicle and recheck the measurements.

Shock Absorbers

TESTING

Refer to shock testing under 2 wheel drive coil spring suspension.

REMOVAL & INSTALLATION

F-150, F-250, Expedition and Navigator

Hold the shock absorber stem and remove the nut, washer and bushing from the top of the shock absorber stud

Remove the lower shock retaining nut and bolt

1. Hold the shock absorber stem and remove the nut, washer and bushing from the top of the shock absorber stud.
2. Raise and support the vehicle.
3. Remove the lower retaining nut and bolt.
4. Remove the shock absorber from the vehicle.

To install:

5. Install 1 washer and bushing to the top stem of the shock absorber.
6. Place the shock absorber up through the coil spring.
7. Install the lower retaining nut and bolt. Tighten to 57-77 ft. lbs. (77-104 Nm).
8. Lower the vehicle.
9. Install the shock absorber upper bushing, washer and retaining nut. Tighten the nut to 22-29 ft. lbs. (30-40 Nm).
10. Lower the vehicle.
11. Road test the vehicle and check for proper operation.

Upper Ball Joint

INSPECTION

Refer to upper ball joint inspection under 2-wheel drive coil spring suspension in this section.

REMOVAL & INSTALLATION

F-150, F-250, Expedition and Navigator

The upper ball joint is an integral part of the upper control arm and is not a serviceable component. Replacement of the ball joint requires replacing the upper control arm assembly.

Lower Ball Joint

INSPECTION

Refer to upper ball joint inspection under 2-wheel drive coil spring suspension in this section.

REMOVAL & INSTALLATION

F-150, F-250, Expedition and Navigator

The lower ball joint is an integral part of the lower control arm and is not a serviceable component. Replacement of the ball joint requires replacing the lower control arm.

Stabilizer Bar

REMOVAL & INSTALLATION

F-150, F-250, Expedition and Navigator

Remove both stabilizer bar-to-stabilizer bar link retaining nuts, washers and bushings and ...

... separate the stabilizer bar ends from the stabilizer bar links

Remove the stabilizer bar links from the lower control arms

Remove the stabilizer bar brackets

1. Raise and safely support the vehicle.
2. Remove the right front wheel and tire assembly.
3. Remove 6 retaining bolts and remove the skid plate.
4. Remove both stabilizer bar-to-stabilizer bar link retaining nuts, washers and bushings and separate the stabilizer bar ends from the stabilizer bar links.
5. Remove the stabilizer bar links from the lower control arms, if needed.
6. Remove 4 bolts securing 2 stabilizer bar insulator brackets.
7. Remove the stabilizer bar brackets and the stabilizer bar.
8. Remove the stabilizer bar by rotating the bar as it is removed through the right-hand side of the vehicle.

To install:

9. Place the stabilizer bar in position, rotating the bar as required for installation.
10. Install 2 stabilizer bar insulator brackets. Install 4 retaining bolts and tighten to 19-25 ft. lbs. (26-34 Nm).
11. Install the stabilizer bar links to the lower control arms, if removed.
12. Connect the stabilizer bar to the stabilizer bar links. Install the bushings, washers and retaining nuts. Tighten the stabilizer bar link retaining nuts to 16-21 ft. lbs. (22-28 Nm).
13. Install the skid plate and 6 retaining bolts. Tighten the bolts to 10-13 ft. lbs. (14-17 Nm).
14. Install the wheel and tire assembly. Torque the lug nuts to 83-112 ft. lbs. (113-153 Nm).
15. Lower the vehicle.
16. Road test the vehicle and check for proper operation.

Upper Control Arm

REMOVAL & INSTALLATION

F-150, F-250, Expedition and Navigator

The upper control arm-to-body mounts

1. Raise and safely support the vehicle.
2. Remove the wheel and tire assembly.
3. Support the lower control arm with a transmission jack or equivalent adjustable jack.
4. Match mark the upper control arm adjusting cams.
5. If equipped with 4-wheel ABS, remove the speed sensor harness bracket bolt and position the harness aside.
6. Remove the cotter pin and castellated nut from the upper ball joint. Discard the cotter pin.
7. Using Pitman Arm Puller T64P-3590-F or equivalent, separate the ball joint from the wheel spindle.
8. Remove 2 nuts and bolts securing the upper control arm to the body brackets.
9. Remove the upper control arm and ball joint assembly from the vehicle.

To install:

10. Align the match marks on the upper control arm adjusting cams.
11. Place the upper control arm in position to the body brackets and install 2 retaining bolts and nuts. Do not tighten at this time.
12. Install the ball joint stud to the wheel spindle and install the castellated nut. Tighten the nut to 56-77 ft. lbs. (76-104 Nm). Install a new cotter pin.
13. Raise the lower control arm to position the control arms at normal curb height and tighten the front upper control arm retaining nut first, to 84-112 ft. lbs. (113-153 Nm).
14. With the vehicle still at curb height, tighten the rear upper control arm retaining nut to 84-112 ft. lbs. (113-153 Nm).
15. Remove the transmission jack or equivalent from under the lower control arm.
16. If equipped with 4-wheel ABS brake system, position the speed sensor harness and install the bracket bolt. Tighten the speed sensor bracket bolt to 62-80 inch lbs. (7-9 Nm).
17. Install the wheel and tire assembly. Torque the lug nuts to 83-112 ft. lbs. (113-153 Nm).
18. Lower the vehicle.
19. Check the alignment and adjust if not within specification.
20. Road test the vehicle and check for proper operation.

Lower Control Arm

REMOVAL & INSTALLATION

F-150, F-250, Expedition and Navigator

The lower control arm-to-body mounts

These vehicles require that the torsion bar tension be relieved before removing the lower control arm. If either the lower control arm or lower ball joint require replacement, the lower control arm and ball joint must be replaced as a unit.

1. Raise and safely support the vehicle.
2. Match mark and measure the length of the torsion bar being removed.

Torsion bars are marked for left-hand or right-hand installation. If removing both torsion bars, make sure to reinstall in the correct position. If replacing a torsion bar, make sure that it is the correct torsion bar for the side being replaced.

3. Install Torsion Bar Adjuster T95T-5310-A and Adapter Plates T96T-5310-A, or equivalents.
4. Tighten the adjuster tool until it touches the torsion bar adjuster.
5. Remove the torsion bar adjuster bolt and nut.
6. Remove 6 torsion bar crossmember retaining bolts.
7. Remove the crossmember support.
8. Remove the torsion bar from the vehicle.
9. If equipped with 4 wheel ABS disconnect the sensor wire bracket bolt.
10. Remove the lower shock absorber retaining nut and bolt.
11. Disconnect the lower control arm castle nut and cotter pin and separate the ball joint from the steering knuckle.
12. Disconnect the stabilizer bar link from the lower control arm.
13. Remove the 2 lower control arm nuts and bolts.
14. Remove the lower arm and torsion bar.

To install:

15. Install the lower control arm and torsion bar. Tighten the bolts to 150 ft. lbs. (200 Nm).
16. Connect the lower ball joint and tighten the castle nut to 80-110 ft. lbs. (113-153 Nm).
17. Connect the stabilizer bar link to the lower control arm. tighten the nut to 16-21 ft. lbs. (22-28 Nm).
18. Place the torsion bar in position ensuring that it is the correct torsion bar for the side being installed.
19. Install the lower shock absorber retaining nut and bolt. Tighten to 55-74 ft. lbs. (76-103 Nm).
20. Secure the ABS sensor bracket, if equipped.
21. Install the crossmember support and 6 retaining bolts. Tighten the retaining bolts to 40-50 ft. lbs. (53-72 Nm).
22. Install the torsion bar adjuster bolt and nut, then remove the torsion bar adjuster tool and adapters.
23. Tighten the adjusting bolt until the match marks are in alignment.
24. Lower the vehicle.
25. Measure the ride height and adjust if necessary.
26. Check the alignment and adjust if not within specification.
27. Road test the vehicle and check for proper operation.

Front Hub and Bearing

REMOVAL & INSTALLATION

F-150, F-250, Expedition and Navigator

The 3 hub-to-knuckle retaining bolts

The wheel bearings are of the cartridge design and are an integral part of the hub assembly. The bearing are permanently lubricated and require no maintenance or adjustments. If required, a new hub assembly must be installed.

1. Raise and safely support the vehicle.
2. Remove the wheel and tire assembly.
3. Remove the disc brake caliper.
4. Remove the disc brake pads and anti-rattle clips.
5. Remove 2 anchor plate retaining bolts and remove the anchor plate.
6. Remove the disc brake rotor.
7. Remove 3 disc brake rotor shield retaining bolts and the shield.
8. If equipped with 4-wheel ABS, remove the speed sensor retaining bolt and move the speed sensor and harness aside.
9. Remove the hub nut cotter pin, retainer and the hub nut. Discard the cotter pin.
10. Remove 3 hub assembly retaining bolts from the inside of the steering knuckle.
11. Push the CV-joint inward and remove the hub assembly.

If necessary, use a suitable puller to separate the hub assembly from the CV-joint. Use care not to over extend the CV-joint and boot when removing the hub assembly.

12. If required, remove the grease seal from the steering knuckle.

To install:

13. If removed, install a new grease seal with Seal Installer T96T-1175-A, Drawbar T77F-1176-A and Cup Replacer T80T-4000-P, or equivalents.
14. Install the hub assembly to the steering knuckle and secure with 3 retaining bolts. Tighten the bolts to 110-145 ft. lbs. (149-201 Nm).
15. Align the splines, then push the CV-joint into the hub assembly.
16. If equipped with 4-wheel ABS, install the speed sensor and secure with 1 retaining bolt. Tighten the bolt to 60-84 inch lbs. (7-9 Nm).
17. Install the disc brake rotor shield and 3 retaining bolts. Tighten the bolts to 80-107 inch lbs. (9-12 Nm).
18. Install the hub nut and tighten to 188-254 ft. lbs. 255-345 Nm).
19. Install the hub nut retainer and a new cotter pin.
20. Install the disc brake rotor.
21. Place the anchor plate in position and install 2 retaining bolts. Tighten the bolts to 125-168 ft. lbs. (170-230 Nm).
22. Install the brake pad anti-rattle clips and install the disc brake pads.
23. Install the disc brake caliper.
24. Install the wheel and tire assembly. Torque the lug nuts to 83-112 ft. lbs. (113-153 Nm).
25. Lower the vehicle.
26. Pump the brake pedal several times to position the brake pads prior to moving the vehicle.
27. Road test the vehicle and check for proper operation.

Wheel Alignment

Refer to wheel alignment under 2 wheel drive coil spring suspension.

Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning.