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) 204-01-4
Wheel Knuckle — 2WD.................................................................................. (14 343 0) 204-01-8
Wheel Knuckle — 4WD.................................................................................. (14 343 0) 204-01-12
Front Strut and Spring Assembly.................................................................... (14 781 0;
14 782 0) 204-01-16
Lower Arm...................................................................................................... (14 706 0;
14 707 0;
14 709 0) 204-01-18
Upper Arm.......................................................................................................................... 204-01-20
DISASSEMBLY AND ASSEMBLY
Front Strut and Spring Assembly.................................................................... (14 783 4) 204-01-22
204-01-2 Front Suspension 204-01-2
DESCRIPTION AND OPERATION
Front Suspension
4X2
Item Description Item Description
1 Stabilizer bar link 4 Knuckle
2 Upper arm 5 Lower arm
3 Stabilizer bar 6 Shock absorber unit
7 Suspension unit
4X2 Vehicles with increased ride height
Item Description Item Description
1 Stabilizer bar link 3 Stabilizer bar
2 Upper arm 4 Knuckle
2011.50 Ranger G1268940en
204-01-3 Front Suspension 204-01-3
DESCRIPTION AND OPERATION
Item Description Item Description
5 Lower arm 6 Shock absorber unit
7 Suspension unit
4X4
Item Description
1 Stabilizer bar link
2 Upper arm
3 Stabilizer bar
4 Knuckle
5 Lower arm
6 Half Shafts
7 Shock absorber unit
8 Suspension unit
2011.50 Ranger G1268940en
204-01-4 Front Suspension 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
1. Refer to: Health and Safety Precautions (100-00 4x4
General Information, Description and
Operation). 4. Refer to: Wheel Knuckle - 4WD (204-01 Front
Suspension, Removal and Installation).
4x2
All vehicles
2. Refer to: Wheel Knuckle - 2WD (204-01 Front
Suspension, Removal and Installation). 5. Special Tool(s): 204-348/3
General Equipment: Hydraulic Press
3.
6. General Equipment: Hydraulic Press
2011.50 Ranger G1269089en
204-01-6 Front Suspension 204-01-6
REMOVAL AND INSTALLATION
8.
7.
9. 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 2.
3. Special Tool(s): 205-307
General Equipment: Hydraulic Press
Installation
1. NOTE: Make sure that the sensor ring is
correctly located.
• 1. Old Front wheel bearing. 2. 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
204-01-8 Front Suspension 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
2. Refer to: Wheel and Tire (204-04 Wheels and
Removal Tires, Removal and Installation).
NOTE: Removal steps in this procedure may 3. Torque: 7 Nm
contain installation details.
1. 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 4. WARNING: Make sure that no load is
Operation). 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
5. WARNING: Make sure that a new nut is Special Tool(s): 211-020
installed.
CAUTION: Make sure that ball joint does
not rotate.
Torque: 125 Nm
7. WARNING: Make sure that a new nut is
installed.
CAUTIONS:
6. CAUTIONS: Use suitable packing material to prevent
damage to the component.
Do not use a hammer to separate the tie
rod from the wheel knuckle or damage Make sure that the ball joint ball does
to the wheel knuckle can result. not rotate.
1. Torque: 14 Nm
Do not damage the tie-rod boot while
2. Torque: 80 Nm
installing the special tool.
3. Torque: 65 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.
8. 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 Special Tool(s): 49-T028-3A0
9. WARNING: Make sure that a new nut is 11. NOTE: This step is only necessary when
installed. installing a new component.
NOTE: Make sure that the wheel knuckle is Refer to: Front Wheel Bearing (204-01 Front
correctly secured. 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
1. To install, reverse the removal procedure.
2011.50 Ranger G1269091en
204-01-11 Front Suspension 204-01-11
REMOVAL AND INSTALLATION
2. Refer to: Front Toe Adjustment (204-00
Suspension System - General Information,
General Procedures).
2011.50 Ranger G1269091en
204-01-12 Front Suspension 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
2. CAUTION: Make sure that hub nut is
Removal un-coined before removal.
NOTE: Removal steps in this procedure may
contain installation details.
1. 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
3. Refer to: Wheel and Tire (204-04 Wheels and Torque: 125 Nm
Tires, Removal and Installation).
4. CAUTION: If the outer constant velocity
(CV) joint boot is damaged a new
halfshaft must be installed.
8. CAUTIONS:
Do not use a hammer to separate the tie
rod from the wheel knuckle or damage
to the wheel knuckle can result.
5. Torque: 7 Nm 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.
Protect the ball joint seal using a soft
cloth to prevent damage.
Special Tool(s): 211-020
6. WARNING: Make sure that no load is
placed on the brake hose.
9. WARNING: Make sure that a new nut is
Refer to: Brake Disc (206-03 Front Disc Brake, installed.
Removal and Installation).
CAUTIONS:
7. CAUTION: Make sure that the ball joint
ball does not rotate. Use suitable packing material to prevent
damage to the component.
2011.50 Ranger G1269098en
204-01-14 Front Suspension 204-01-14
REMOVAL AND INSTALLATION
Make sure that the ball joint ball does 11. NOTE: Make sure that the wheel knuckle and
not rotate. halfshaft are correctly secured.
1. Torque: 14 Nm Torque: 175 Nm
2. Torque: 80 Nm
3. Torque: 65 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. 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.
2011.50 Ranger 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).
2. To install, reverse the removal procedure.
3. 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.
4. Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
5. CAUTION: Make sure that hub nut is
coined after installation.
Torque: 275 Nm
Installation
1. 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
204-01-16 Front Suspension 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
1. Refer to: Health and Safety Precautions (100-00
Removal General Information, Description and
Operation).
WARNING: All vehicles are equipped with
gas-pressurized shock absorbers which 2. Refer to: Wheel and Tire (204-04 Wheels and
will extend unassisted. Do not apply heat Tires, Removal and Installation).
or flame to the shock absorbers during 3. 1. Torque: 55 Nm
removal or component servicing. Failure 2. Torque: 235 Nm
to follow these instructions may result in
personal injury.
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
4. Torque: 65 Nm 8. NOTE: Note the position of the components
before removal.
5. CAUTION: Do not use a hammer to
separate the ball joint from the wheel
knuckle or damage to the wheel knuckle Installation
can result.
CAUTION: Before tightening any
• Do not damage the ball joint boot while suspension bushing fasteners, use a
installing the special tool. suitable jack to raise the suspension.
• Make sure that the knuckle assembly is
secured with suitable retaining straps. 1. To install, reverse the removal procedure.
Special Tool(s): 49-T028-3A0
6. Using a suitable jack support the lower control
arm near the lower ball joint.
7. Lower the jack support to lower the control arm.
2011.50 Ranger G1465140en
204-01-18 Front Suspension 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
1. Refer to: Health and Safety Precautions (100-00
Removal General Information, Description and
Operation).
CAUTION: Suspension fasteners are Refer to: Wheel and Tire (204-04 Wheels and
critical parts because they affect Tires, Removal and Installation).
performance of vital components and 2. 1. Torque: 175 Nm
systems and their failure can result in 2. Torque: 250 Nm
major service expense. A new part with the 3. Torque: 260 Nm
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.
3. 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.
1. To install, reverse the removal procedure.
2011.50 Ranger G1269447en
204-01-20 Front Suspension 204-01-20
REMOVAL AND INSTALLATION
Upper Arm
Special Tool(s)
49-T028-3A0
Remover, Ball Joint Puller Set
Removal
CAUTION: Suspension fasteners are 1. Refer to: Health and Safety Precautions (100-00
critical parts because they affect General Information, Description and
performance of vital components and Operation).
systems and their failure can result in
2. Refer to: Wheel and Tire (204-04 Wheels and
major service expense. A new part with the
Tires, Removal and Installation).
same part number or an equivalent part
must be installed, if installation is 3. Refer to: Front Wheel Speed Sensor (206-09
necessary. Do not use a part of lesser Anti-Lock Control, Removal and Installation).
quality or substitute design. Torque values
must be used as specified during 4. Torque: 70 Nm
reassembly to make sure of correct
retention of these parts.
NOTE: Removal steps in this procedure may
contain installation details.
5. 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
204-01-21 Front Suspension 204-01-21
REMOVAL AND INSTALLATION
Special Tool(s): 49-T028-3A0
6. Torque: 80 Nm
Installation
CAUTION: Before tightening any
suspension bushing fasteners, use a
suitable jack to raise the suspension.
1. To install, reverse the removal procedure.
2011.50 Ranger G1269448en
204-01-22 Front Suspension 204-01-22
DISASSEMBLY AND ASSEMBLY
Front Strut and Spring Assembly(14 783 4)
Special Tool(s)
204-167
Compressor, Coil Spring
204-215
Adapter for 204-167
2. 1. Install the Special Tool(s): 204-167, 204-215
Disassembly
NOTE: Removal steps in this procedure may
contain installation details.
1. WARNING: Take extra care when
handling the compressed spring.
Refer to: Front Strut and Spring Assembly
(204-01 Front Suspension, Removal and
Installation).
3. NOTE: Note the position of each component
before removal.
2011.50 Ranger G1465143en
204-01-23 Front Suspension 204-01-23
DISASSEMBLY AND ASSEMBLY
Assembly 6. NOTE: Make sure that the lower end of the coil
spring is correctly seated on the step of the
4. WARNING: Take extra care when lower spring seat while the front shock absorber
handling the compressed spring. is installed.
To assemble, reverse the disassembly NOTE: Make sure that these components are
procedure. installed to the noted removal position.
5. NOTE: Only tighten the nut finger tight at this NOTE: Make sure that the installation marks
stage. are aligned.
Special Tool(s): 204-167, 204-215 Special Tool(s): 204-167, 204-215
2011.50 Ranger G1465143en
204-01-24 Front Suspension 204-01-24
DISASSEMBLY AND ASSEMBLY
7. 1. Damper bush bottom axis .
Special Tool(s): 204-167, 204-215
2. NOTE: Make sure that the angle between
the rear upper mounting stud and the damper
bottom bush as axis is as specified.
37° ± 3°
2011.50 Ranger G1465143en
204-01-25 Front Suspension 204-01-25
DISASSEMBLY AND ASSEMBLY
8. CAUTION: Use a suitable spanner to
prevent the piston rod from rotating.
Special Tool(s): 204-167, 204-215
Torque: 65 Nm
9. Remove the Special Tool(s): 204-167, 204-215
10. Refer to: Front Strut and Spring Assembly
(204-01 Front Suspension, Removal and
Installation).
2011.50 Ranger G1465143en
