Frame Bracket Knockout Replacement

NOTE: As originally installed, the upper control arm cannot be adjusted for caster or camber. However, if the caster or camber is measured and found to be out of tolerance, the caster and camber can be set to the proper specifications.


^ Tool Required:
- J 38794 Knockout Removal Tool, Or Equivalent

REMOVAL

NOTE: The jack or stand must remain under the lower control arm during the removal and installation procedure in order to retain the lower control arm position.
- Raise and support the vehicle.
- Support the lower control arms with jack or jack stands.





Remove or disconnect the following:
1. Tire and wheel assembly.
2. Nuts (50), cams (49), and bolts (48) from the upper control arm bracket (44).
3. Lift upper control arm (45) up and to the side to gain access to the inner portion of the frame bracket.





4. Frame bracket knockout using tool J 38794.
a. Do not distort frame bracket when removing knockout.
b. Apply extreme pressure lubricant to the threads of the T-bolt and insert the bolt through the knockout hole in the bracket support.
c. Install bridge onto T-bolt. The forward bracket requires the bridge to be installed between the legs of the bracket due to access problems.
d. Assemble the bridge, bearing (chamfered side out), washer, and nut in order.
e. The T-bolt head and bridge must line up horizontally with the knockout; the bridge should span the knockout without interfering with the knockout procedure.
f. Tighten the T-bolt head against the knockout by turning the nut at the opposite end using a socket and torque wrench.
g. An open end or adjustable wrench may be needed to prevent the T-bolt from losing horizontal alignment with the knockout.

CAUTION: Do not subject the tool to more than 100 Nm (75 ft. lbs.) torque. Exceeding the recommended torque may damage the tool and/or the bracket.

h. If the torque limit on the T-bolt is met and the knockout does not break free, use a die grinder of appropriate size. Using the stamped outline as a guide, remove the knockout. (Remove the wax coating in the knockout area to make the perforation lines more visible).
i. If the outline is not visible, use the T-bolt head installed horizontally, as a template, and scribe the frame bracket.
j. Repeat the procedure on the other upper control arm frame bracket.

INSTALLATION

CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion Inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.

Install or connect the following:
1. Upper control arm (45) into frame brackets (44).
2. Bolts (48) and cams (49) through frame brackets (44), and control arm (45).
3. Cams (49) and nuts (50). Install cams with radius toward frame brackets.
4. Partially tighten nut (50).
5. Front wheel assemblies.
6. Alignment machine heads.





NOTE: Check image for special requirements and alignment adjustments. Check vehicle ride height. Verify alignment specifications before proceeding.

7. Adjust caster and camber to the correct specifications by rotating the bolt head installed through adjuster cam.
- Tighten
a. Front upper control arm nuts (50) to 190 Nm (140 ft. lbs.).
b. Rear upper control arm nuts (50) to 190 Nm (140 ft. lbs.).
8. Set steering wheel on center, with wheels straight, and loosen adjuster sleeve nuts.
9. Adjust toe-in.
10. Tighten the tie rod adjuster sleeve nuts to 19 Nm (14 ft. lbs.).
11. Refer to steering linkage for proper position of clamps.
12. Recheck alignment specifications.
13. Lower the vehicle.