Suspension Geometry Evaluation
Perform an alignment on the vehicle. If necessary, refer to the manufacture of your dealerships equipment for proper operation ot your alignment equipment. For information regarding alignment procedures and specifications, refer to the appropriate Dodge Ram Service Manual, Group 2. Please document all alignment angles before changing any angle, after adjustments have been made, and after performing a road test.
NOTE:
ANY NON-FACTORY INSTALLED EQUIPMENT SHOULD BE REMOVED IF AT ALL POSSIBLE (E.G SNOW PLOW, TOOL BOXES THAT CAN BE EASILY REMOVED, ETC.), COSMETIC ACCESSORIES CAN REMAIN ON VEHICLE (E.G. BUG DEFLECTORS, RUNNING BOARDS, ETC.). AFTERMARKET WHEEL AND TIRE ASSEMBLIES, LIFT KITS, AND OTHER NON-AUTHORIZED SUSPENSION ALTERING COMPONENTS MUST BE REMOVED. FACTORY AUTHORIZED SUSPENSION COMPONENTS, WHEELS, AND TIRES SHOULD BE INSTALLED PRIOR TO PREFORMING ANY ALIGNMENT CHECKS.
1. If the alignment angles are within specifications, continue to step 7, if not, continue to the next step (step 2).
2. CORRECTING THRUST ANGLE
a) If thrust angle is incorrect, raise the vehicle on an appropriate frame support style lift (rear axle must be allowed to extend fully).
b) Support the axle to remove all weight from springs and yet not support any weight of the vehicle.
c) Inspect the part number of both leaf springs. If both springs have the same part number, proceed to the next step. If the part numbers are different from side to side, then having springs of different lengths could cause incorrect thrust angle. Verify that the springs are of the same length by measuring the springs from the front spring eye to the rear spring eye (service part numbers may have different part numbers then production part numbers). If springs are of different lengths, install the correct springs and recheck thrust angle. Refer to the appropriate Service Manual for information regarding rear spring service.
d) Loosen the nuts from the spring clamp bolts that attach the spring to the axle (Figure 3).
e) Using a prybar, reposition the rear axle to obtain a 0.0° +/- 0.2° of thrust angle.
NOTE:
MAKE SURE THE LEAF SPRING CENTERBOLT IS BEING LOCATED EN THE ALIGNMENT HOLE IN THE SPRING SPACER SEAT, NOT EN THE VOID OF THE SPRING SEAT.
f) Tighten the spring clamp nuts until they force the plate flush against the axle tube.
g) Remove axle supports and lower the vehicle so that the tires support the weight of the vehicle.
h) Tighten the spring clamp retaining nuts.
CAUTION:
DO NOT OVER TORQUE THE SPRING CLAMP RETAINING NUTS. EXCEEDING THE TORQUE SPECIFICATION WILL CAUSE DAMAGE TO THE SPRING CLAMP BOLTS
i) Verify rear thrust angle. Repeat steps a through i until rear thrust angle is within specifications.
3. CORRECTING FOR REAR CAMBER OR TOE
a) If rear toe and/or camber are out of specifications, but thrust angle is within specifications, replace the rear axle assembly. Refer to the appropriate Service Manual for information regarding rear differential service.
4. CORRECTING FOR FRONT CASTER/CAMBER
Independent Front Suspension
a) If caster or camber require adjustment, move the pivot bar located on the top of the upper suspension arm (Figure 4). Refer to the appropriate Dodge Ram Truck Service Manual, Group 02 for proper alignment procedures.
Link/Coil Suspension
NOTE:
IF THE VEHICLE IS EQUIPPED WITH A DANA 44 FRONT AXLE (ALL 1500 SERIES 4X4), CASTER AND TOE ARE THE ONLY FRONT ALIGNMENT ANGLES THAT CAN BE ALTERED. VEHICLES EQUIPPED WITH A DANA 60 FRONT AXLE (8800 LB. GVW 2500 SERIES 4X4 AND 3500 SERIES 4X4) OR VEHICLES THAT HAVE A SOLID FRONT AXLE (3500 4X2 CAB CHASSIS) ARE CAPABLE OF HAVING CASTER, CAMBER, AND TOE ALTERED. REFER TO THE APPROPRIATE DODGE RAM SERVICE MANUAL, GROUP 02 FOR PROPER ALIGNMENT PROCEDURES.
Caster Adjustments
i) To adjust caster, loosen both right and left cam adjusters, located on the front section of the lower suspension arm (Figure 5).
NOTE:
BOTH CAM ADJUSTERS SHOULD BE ALLOWED TO MOVE FREELY.
ii) Rock the cam adjuster bolt back and forth until the cam adjuster finds its neutral or unloaded position. This will allow both right and left lower suspension arm bushings to be equally loaded.
iii) Adjust both cams evenly until the correct caster angle has been achieved. Refer to the appropriate Dodge Ram Service Manual, Group 02 for proper alignment procedures.
iv) The tires must support the vehicle weight before the cam bolts are tightened. Tighten the nuts of the cam bolts to 129 N.m (95 ft. lbs.) of torque.
Camber And Cross Caster Adjustments (Dana 60 Front Axle And Solid Front Axle Only)
i) Loosen both right and left cam adjusters, located on the front section of the lower suspension arm (Figure 5).
NOTE:
BOTH CAM ADJUSTERS SHOULD BE ALLOWED TO MOVE FREELY.
ii) Rock the cam adjuster bolt back and forth until the cam adjuster finds its neutral or unloaded position. This will allow both right and left lower suspension arm bushings to be equally loaded.
iii) Tighten the nuts to the cam bolt only tight enough so that the cam bolts do not move.
iv) Lower the vehicle so that the tires support the weight of the vehicle. Tighten the nuts of the cam bolts to 129 N.m (95 ft. lbs.) of torque.
v) Now, front camber and/or cross caster/cross camber can be altered by installing offset upper ball joint sleeves. The tollowing sleeves are available from Mopar.
04886060AA 0.25° Offset Ball joint Sleeve
04886061AA 0.50° Offset Ball joint Sleeve
04886062AA 0.75° Offset Ball joint Sleeve
04886063AA 1.00° Offset Ball joint Sleeve
The sleeve can be rotated a total of eight different positions to be able to increase or decrease caster and/or camber.
NOTE:
THE OFFSET BALL JOINT SLEEVES SHOULD ONLY BE USED TO CORRECT FOR A CAMBER OR CROSS CASTER ADJUSTMENT. ONCE CAMBER AND CROSS CASTER ARE CORRECT, CONTINUE BY USING THE LOWER SUSPENSION ARM CAM ADJUSTERS TO ACHIEVE THE PREFERRED CASTER SETTINGS.
vi) Before the sleeve can be installed, an alignment check must be performed with the caster cam adjusters in the equally loaded position.
Record your readings.
Left Caster ___________ Right Caster ___________
Left Camber_________ Right Camber__________
vii) To remove the original upper ball joint sleeve, raise the vehicle on an appropriate lift that will allow the suspension to be unloaded.
viii) Remove the tire/wheel assembly.
ix) Remove the upper ball joint cotter pin.
x) Remove the upper ball joint nut.
xi) Use a hammer and chisel to drive the original ball joint sleeve from the axle tube yoke.
CAUTION:
TO PREVENT DAMAGE TO THE AXLE TUBE YOKE OR BALL JOINT, PLACE THE CHISEL ON THE UPPER LIP OF THE SLEEVE ONLY DURING REMOVAL.
WARNING:
ALWAYS WEAR APPROPRIATE EYE PROTECTION WHEN PERFORMING THE BALL JOINT SLEEVE REMOVAL PROCEDURE.
xii) Choose the appropriate offset upper ball joint sleeve based upon the camber and caster values recorded in step vi.
xiii) After positioning the sleeve into the axle tube yoke, install the ball joint nut and tighten the upper ball joint nut to 95 N.m (70 ft. lbs.) of torque. Then, advance the nut to the next slot to line up with the hole in the ball joint stud. Install the cotter pin.
xiv) Verify that the ball joint does not bind during a turn. Remove the steering linkage from the steering knuckle arms. Using a spring scale at the steering knuckle arm tie rod attachment hole, check the amount of force required to turn the steering knuckle. Ball joints are considered binding if the force required to turn the steering knuckle exceeds 25 pounds. If the force is below 25 pounds, proceed to step xxviii. If ball joint binding is noticed, the upper and lower ball joints will have to be aligned properly. Remove the caliper assembly and the ABS Wheel Speed Sensor (WSS) (if equipped).
xv) Remove the hub and rotor assembly.
xvi) Remove the axle shaft.
CAUTION:
CAREFULLY REMOVE THE AXLE SHAFT. DAMAGE TO THE AXLE SHAFT SEAL COULD RESULT IF THE SPLINES ARE ALLOWED TO TOUCH THE SEAL.
xvii) Remove the upper ball joint nut.
xviii) Remove the lower ball joint nut.
xix) Remove the knuckle assembly from the axle yoke and move the ball joint stud to ensure that the ball joint is free in the socket. If the ball is not free, work the stud around in the socket to lubricate and free the ball.
xx) Install the knuckle assembly into the axle yoke.
xxi) Lubricate the threads with a penetrating oil such as Mopar General Purpose Lube, p/n 04544926, and install the lower ball joint nut finger tight.
xxii) Tighten the lower ball joint nut to 47.5 N.m (35 ft. lbs.) of torque.
xxiii) Tighten the upper ball joint nut to 94 N.m (70 ft. lbs.) of torque, then advance the nut to the next slot to line up with the hole in the ball joint stud. Install the cotter pin.
xxiv) Re-tighten the lower ball joint nut to 190-217 N.m (140-160 ft. lbs.) of torque.
xxv) Install the axle shaft and verify that the lubricant in the front differential is at the proper level.
xxvi) Install the hub and rotor assembly. Tighten the bolts to 170 N.m (125 ft. lbs.) of torque.
xxvii) Install the brake caliper and the WSS.
xxviii) Connect the steering linkage at the steering knuckle arms. Tighten the tie rod nut to 88 N.m (65 ft. lbs.) of torque.
xxix) Install the tire/wheel assembly. Tighten the lug nuts to the sequence and torque specified in the appropriate Dodge Ram Service Manual, Group 22.
xxx) Verify that camber and caster is now within specifications, it not within specification, repeat steps vi through xxx until camber and caster are within specifications.
5. CORRECTING FOR TOE
To set toe, use the procedures outlined in the appropriate Dodge Ram Service Manual Group 02.
CAUTION:
ON 4X4 VEHICLES, IT IS CRITICAL TO POSITION TIE ROD ADJUSTING SLEEVE SO THAT THE TIE ROD CLAMP DOES NOT COME IN CONTACT WITH THE STEERING DAMPENER DURING JOUNCE AND REBOUND. POSITION THE CLAMP BOLTS IN LINE WITH THE CLAMP LOCKING ARM.
6. Record the alignment angles after all adjustments have been corrected.
7. Road Test the vehicle tor the condition described by the customer. The initial test should be performed on a smooth highway, free of road crown, ruts, speed bumps, or pot holes.
^ Drive the vehicle at highway speeds, preferably without cross wind conditions.
^ If cross wind conditions are prevalent, drive the vehicle in both directions to the cross wind.
Decel the vehicle from highway speeds without applying the brakes.
Record any drift condition noticed.
^ Identify whether the vehicle drifts while holding the steering wheel or does it drift only after the steering wheel is allowed to move freely.
B. If the vehicle drifts with the steering wheel remaining stationary, re-perform the Alignment Evaluation, record your readings, and proceed to the next step. If the vehicle did not drift, proceed to step 11.
9. If the alignment angles were changed (after performing road test) from the previously recorded readings (after correcting alignment angles), re-inspect suspension and steering components for wear or damage. Also, verify that all suspension and steering components are secured and their fasteners are tightened properly.
10, If alignment values have not changed, verify that the tires are not causing the drift condition. This can be accomplished by cross switching the front tires and performing the road test again. If the drift changes direction, rotate the tires front to rear then, continue to step 11.
11. (Road Test Evaluation cont.) Next, perform several brake applications from speeds greater then 50 mph to a complete stop. This portion of the road test should be performed on several different types of road surfaces.
^ First series of brake applications should be a normal type of brake application (similar to the way you would come to a stop at a stop sign).
^ Second series of brake applications should be a hard braking application but, try not to activate ABS.
Record what happens to the vehicle during each series of brake applications.
12. If the vehicle did drift but the steering wheel DID NOT remain stationary, re-perform the Brake Evaluation. It the vehicle did drift with the steering wheel remaining stationary, and the vehicle is a 4X4, perform the following Repair Procedure. If the drift condition has been resolved, return the vehicle to the customer.