E. Wheel Alignment

NOTE:
The following alignment procedure is only required on vehicles that have had the steering gear crossmember replaced.

1. Before beginning the wheel alignment on the vehicle, the following pre-alignment inspection must be completed.

a. Check and adjust the tire pressure. Refer to the placard on the vehicle for pressure specification.

b. Verify correct tire size and equal treadwear.

c. Inspect each tire/wheel assembly for evidence of an unbalance condition.

d. Inspect the wheels for excessive radial and/or lateral runout.

e. Inspect the front and rear wheel hub and bearing assemblies for looseness.

f. Inspect ball studs and linkage pivot points and the steering gear for looseness, roughness, binding or a sticking condition.

g. Inspect all suspension components for wear.

h. Inspect the front and rear shock absorber assemblies for leaks or signs of damage.

i Inspect the front and rear coil springs on the shock absorbers for signs of damage.





j. Verify that the front suspension upper control arm sport shims have not been removed (Figure 12). Correct camber angles can not be set if the sport shims have been removed.

CAUTION:
The vehicle's suspension geometry and alignment settings change rapidly as the vehicle changes height. For this reason, it is extremely important that all suspension specifications be checked and adjusted with the vehicle at the correct curb height. Alignment specifications must be checked with the vehicle at curb height, the fuel tank full, fluids at the correct fill level, and all factory supplied equipment (top, removable windows, spare tire etc.) must be in the vehicle.

NOTE:
Any additional repairs discovered during the pre-alignment inspection are the vehicle owner's responsibility.

2. Place the vehicle on an alignment machine.

NOTE:
The alignment machine being used must have the capability of performing a four-wheel alignment.

3. Check and set the curb height of the vehicle using the procedure below.

NOTE:
Curb height is the height that the vehicle is at when it has a full tank of fuel, all fluids are filled to their proper levels, and no passengers or additional weight is added to the vehicle. All factory supplied equipment (top, removable windows, spare tire etc.) must be in the vehicle.





a. Install front and rear Vehicle Height Checking Fixture (Special Tool # 6914) at the base of both inner flanges of the front and rear wheels as shown in Figure 13.

NOTE:
Vehicles equipped with the ACR package and/or BBS racing wheels must have Special Tool # 8396-1 adapters installed onto Special Tool # 6914 checking fixture before installing on the front and rear wheels.





b. Check the distance from the bottom of each of the front frame rails to the top surface of the Vehicle Height Checking Fixture (Special Tool # 6914) (Figure 14). The distance should be:

^ 1996 and 1997 model year:
1-1/2 inches +/- 1/4 inch
(38 mm +/- 6 mm).

^ 1998 and 1999 model year:
2 inches +/- 1/4 inch
(50 mm +/- 6 mm).





c. Check the distance from the bottom of each of the rear frame rails to the top surface of the Vehicle Height Checking Fixture (Special Tool # 6914) (Figure 15). The distance should be:

^ 1996 and 1997 model year:
2 inches +/- 1/4 inch
(50 mm +/- 6 mm).

^ 1998 and 1999 model year:
2-1/2 inches +/- 1/4 inch
(64 mm +/- 6 mm).

d. If the vehicle does not meet curb height specifications, continue with Section "F - Setting the Vehicle Design Height" before continuing with this procedure. If the curb height is within specifications, continue with Step 4 of this procedure.

NOTE:
Vehicle curb height can be affected if the rubber bushings used in the vehicle's suspension are not tightened with the~ vehicle at Design Height. This is due to the extreme stiffness of the rubber used in the suspension component bushings.

4. Install the wheel alignment equipment onto the vehicle per alignment equipment manufacturer's instructions.

NOTE:
The vehicle is equipped with flangeless style wheels, thus any alignment equipment used must be capable of attaching to the outside edge of the wheel rim lip.

CAUTION:
Both front and rear caster angle on the vehicle must be read directly off the front and rear knuckle through the use of inclinometer sensors attached to the DRB III scan tool. Do not use the alignment machine's sweep method to measure caster angle.

NOTE:
All necessary adapters, cables, switch box and inclinometers are available in Viper Essential Tool Kit # 6990.

5. Use the following procedure to connect and calibrate the DRB III and inclinometers.

NOTE:
The DRB III must have a Super Card 2 installed to perform caster measurements.





a. Plug the cable from the switch box (Special Tool # 6996) into the PEP module connector on the DRB III marked "INCL" (Figure 16).

b. Plug the power cable (supplied with the DRB III kit) into the DRB III power connector marked "VEHICLE" (Figure 16).





c. Attach the two inclinometers (Special Tool # 6989) to the switch box (Special Tool # 6996) (Figure 17).

NOTE:
Only two inclinometers are supplied and should be used as a pair to measure either rear caster or front caster, one at a time.

d. Attach the power cable from the DRB III to the vehicle data connector.

e. Select the PEP Module Tools (# 4) option from the main menu screen.

f. Select the Inclinometer/Viper Alignment (# 4) option from the Stand Alone Main Menu.

g. Select the Read/Display Angle (# 1) option from Inclinometer Main Menu. This option is used to calibrate the inclinometers before being used on the vehicle.

CAUTION:
The inclinometer (Special Tool # 6989) must be calibrated prior to each time it will be used to read the caster angle on the vehicle.

h. Press F2 on the DRB III key pad to show both inclinometers.





i. Place both inclinometers together on a known flat level surface such as the alignment rack, with the knurled ends of the fastening screws facing upward (Figure 18).

j. Press enter to continue.

k. Rotate the inclinometers 180 degrees in place, then press enter again to calibrate both inclinometers in the other direction. The inclinometers are now ready to be installed on the vehicle (Figure 18).





6. Mount the inclinometers to the rear Caster Angle Fixtures (Special Tool # 6916) (Figure 19).





7. Once the inclinometers are attached to the rear Caster Angle Fixtures, they can be mounted on the rear knuckle caster angle pads as shown in Figures 20.

CAUTION:
The caster pads are located on the rear edge of the rear knuckle. Be sure that the caster pads are thoroughly cleaned before mounting the caster inclinometers on the knuckles. The caster inclinometers must sit flat on the caster pads to obtain accurate caster readings.





8. Adjust the rear caster angle using the measurements viewed on the DRB III screen, and the camber angle using the measurements viewed on the alignment equipment. Camber and caster angles are adjusted by turning the cam bolts on the lower control arm bushings (Figure 21). Refer to the Alignment Specifications Chart in this document.





9. Transfer the inclinometers to the front Caster Angle Fixtures (Special Tool # 6915) (Figure 22).





10. Once the inclinometers are attached to the front Caster Angle Fixtures, the fixtures can be mounted on the front knuckle caster pads as shown in Figures 23.

CAUTION:
The caster pads are located on the front edge of the front steering knuckle. Be sure that the caster pads are thoroughly cleaned before mounting the caster inclinometers on the front steering knuckles. The caster inclinometers must sit flat on the caster pads to obtain accurate caster readings.





11. Adjust the front caster angle using the measurements viewed on the DRB III screen, and the camber angle using the measurements viewed on the alignment equipment. Camber and caster angles are adjusted by turning the cam bolts on the lower control arm bushings (Figure 24). Refer to the Alignment. Specifications Chart in this document.

12. Set the front and rear static wheel toe using the following procedure.

NOTE:
The engine should be running during the front wheel toe setting procedure.

a. Start the engine and turn the wheels both ways before straightening and centering the steering wheel. Center the steering wheel and retain the steering wheel position with a steering wheel clamp.





b. Loosen the front outer tie rod end jam nut (Figure 25).

c. Remove the clamp from the front inner tie rod boot (Figure 25).





d. Remove the clamp from the rear flex joint boot and loosen the tie rod jam nut (Figure 26).

e. To adjust the rear wheel toe, rotate the right and/or left toe link in the direction required to obtain the specified individual wheel toe position. Refer to the Alignment Specifications Chart in this document.

f. To adjust the front wheel toe, grasp and rotate the right and/or left inner tie rod at the adjustment serration in the direction required to obtain the specified individual wheel toe position. Refer to the Alignment Specifications Chart in this document.

g. Once the individual wheel toe is set to specifications, tighten all of the jam nuts to 55 ft. lbs. (75 N.m).

h. Straighten both front tie rod boots at the inner tie rod so that the boots are not twisted. Then install both inner tie rod boot clamps.

i. Straighten both rear flex joint boots so that the boots are not twisted (Figure 26). Then install both boot clamps.

j. Remove the steering wheel clamp.

13. Remove the alignment equipment from the vehicle.

14. Remove the caster angle inclinometers from the front knuckles.

15. Remove the vehicle from the alignment rack and return it to the customer.