Steering/Suspension - Alignment Procedure Revision
TSB 04-24-1912/13/04
REVISED PROCEDURE FOR ADJUSTING ALIGNMENT
ON ALL SUSPENSIONS - NEW RIGHT HAND UPPER
CONTROL ARM DESIGN FOR TORSION BAR FRONT
SUSPENSIONS
FORD:
1998-2001 Explorer
1998-2003 Ranger
2000-2003 Explorer Sport
2001-2003 Explorer Sport Trac
ISSUE
The cam bolt and nut kit that was used for adjusting caster and camber on all torsion bar and coil spring front suspensions has been discontinued. If the caster and camber settings need to be adjusted, a washer must now be installed.
The right hand upper control arm design changed from a two piece design to a single piece design during the 2003 model year. The single piece design is now the only version of the upper control arm available for service of prior model year Rangers.
ACTION
Use the following Camber And Caster Adjustment procedure when either camber or caster need to be adjusted on any suspension, or if only a caster split adjustment is needed on a vehicle equipped with single piece upper control arm.
Use the following Caster Split Adjustment - Two Piece Right Hand Upper Control Arm procedure if only a caster split adjustment is needed on a vehicle equipped with a two piece upper control arm.
SERVICE PROCEDURE
CAMBER AND CASTER ADJUSTMENT
NOTE
THE UPPER CONTROL ARM-TO-FRAME MOUNTING BOLTS HAVE SET SHIMS THAT MUST BE REPLACED WITH WASHERS TO ALLOW FOR ADJUSTMENT OF THE ARM IN THE FRAME SLOT. THE VEHICLE SHOULD BE SUPPORTED BY THE LOWER CONTROL ARM TO EASE MOVEMENT OF THE UPPER ARM IN THE SLOT.
1. Remove and discard the upper control arm-to-frame nuts and shims (Figure 1).
2. Install new washers (W705040-5900) and nuts (N805480-5427). Tighten the nuts so there is tension, but the upper control arm can be moved for the alignment adjustment.
3. To adjust caster and camber refer to the chart. Adjustments that require moving the front and rear of the upper control arm should be made equally.
4. Torque the upper control arm-to-frame nuts to 98 lb.ft (133 N.m).
5. Check and if necessary adjust the front toe. Refer to the appropriate Workshop Manual for information.
CASTER SPLIT ADJUSTMENT - TWO PIECE RIGHT HAND UPPER CONTROL ARM
1. To decrease the right hand caster, loosen the ball joint adjustment nuts (Figure 2) and move the ball joint forward.
2. To increase the right hand caster, loosen the ball joint adjustment nuts and move the ball joint rearward.
3. Torque the ball joint adjustment nuts to 129 lb.ft (175 N.m).
4. Check and if necessary adjust the front toe. Refer to the appropriate Workshop Manual for information.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
3084 07
Disclaimer