2000 DODGE DURANGO Service Repair Manual

SERVICE MANUAL
2000
DURANGO
To order the special service tools used and
illustrated, please refer to the instructions on
inside back cover.
NO PART OF THIS PUBLICATION MAY BE
REPRODUCED, STORED IN A RETRIEVAL
SYSTEM, OR TRANSMITTED, IN ANY FORM OR
BY ANY MEANS, ELECTRONIC, MECHANICAL,
PHOTOCOPYING, RECORDING, OR OTHERWISE,
WITHOUT THE PRIOR WRITTEN PERMISSION
OF DAIMLERCHRYSLER CORPORATION.
DaimlerChrysler Corporation reserves the right to make changes in design or
to make additions to or improvements in its products without imposing any
obligations upon itself to install them on its products previously manufac-
tured.
Litho in U.S.A. Copyright © 1999 DaimlerChrysler Corporation
15M0799
NEXT PAGE ᮣ

FOREWORD
The information contained in this service manual has been prepared for the professional automotive tech-
nician involved in daily repair operations. Information describing the operation and use of standard and
optional equipment is included in the Owner’s Manual provided with the vehicle.
Information in this manual is divided into groups. These groups contain general information, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and compo-
nents. To assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar
after the group title is aligned to a solid tab on the first page of each group. The first page of the group has
a contents section that lists major topics within the group. If you are not sure which Group contains the infor-
mation you need, look up the Component/System in the alphabetical index located in the rear of this manual.
A Service Manual Comment form is included at the rear of this manual. Use the form to provide
DaimlerChrysler Corporation with your comments and suggestions.
Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When
replacing fasteners, always use the same type (part number) fastener as removed.
DaimlerChrysler Corporation reserves the right to change testing procedures, specifications, diagnosis,
repair methods, or vehicle wiring at any time without prior notice or incurring obligation.
NEXT PAGE ᮣ

GROUP TAB LOCATOR
Introduction
0 Lubrication and Maintenance
2 Suspension
3 Differential and Driveline
5 Brakes
7 Cooling System
8A Battery
8B Starting Systems
8C Charging System
8D Ignition System
8E Instrument Panel Systems
8F Audio Systems
8G Horn Systems
8H Speed Control System
8J Turn Signal and Hazard Warning Systems
8K Wiper and Washer Systems
8L Lamps
8M Passive Restraint Systems
8N Electrically Heated Systems
8O Power Distribution System
8P Power Lock Systems
8Q Vehicle Theft/Security Systems
8R Power Seat System
8S Power Window Systems
8T Power Mirror Systems
8U Chime/Buzzer Warning Systems
8V Overhead Console Systems
8W Wiring Diagrams
9 Engine
11 Exhaust System
13 Frame and Bumpers
14 Fuel System
19 Steering
21 Transmission and Transfer Case
22 Tires and Wheels
23 Body
24 Heating and Air Conditioning
25 Emission Control Systems
Component and System Index
Service Manual Comment Forms (Rear of Manual)

INTRODUCTION
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
VEHICLE IDENTIFICATION NUMBER (VIN)
PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
VEHICLE SAFETY CERTIFICATION LABEL . . . . . . 2
INTERNATIONAL SYMBOLS. . . . . . . . . . . . . . . . . 2
FASTENER IDENTIFICATION. . . . . . . . . . . . . . . . . 3
FASTENER USAGE . . . . . . . . . . . . . . . . . . . . . . . . 6
THREADED HOLE REPAIR . . . . . . . . . . . . . . . . . . 6
METRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 6
TORQUE REFERENCES. . . . . . . . . . . . . . . . . . . . . 6
VEHICLE IDENTIFICATION NUMBER (VIN)
PLATE
The Vehicle Identification Number (VIN) plate is
attached to the top left side of the instrument panel
(Fig. 1). The VIN contains 17 characters that provide
data concerning the vehicle. Refer to the decoding
chart to determine the identification of a vehicle.
Fig. 1 Vehicle Identification Number (VIN)
1 – VIN
DN INTRODUCTION 1

VIN DECODING INFORMATION
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of Origin 1= USA
2 Make B = Dodge
3 Vehicle Type 4 = Multipurpose Passenger Vehicle
4 Gross Vehicle Weight Rating H = 6001-7000 lbs.
5 Vehicle Line
R = Durango 4x2
S = Durango 4x4
6 Series 2 = Durango
7 Body Style 8 = Sport Utility 4 Door
8 Engine
N=4.7L
Y=5.2L
Z=5.9L
9 Check Digit
10 Model Year Y=2000
11 Assembly Plant F = Newark Assembly
12 Thru 17 Vehicle Build Sequence Assembly Sequence
VEHICLE SAFETY CERTIFICATION LABEL
A vehicle safety certification label (Fig. 2) is
attached to every DaimlerChrysler Corporation vehi-
cle. The label certifies that the vehicle conforms to all
applicable Federal Motor Vehicle Safety Standards.
The label also lists:
• Month and year of vehicle manufacture.
• Gross Vehicle Weight Rating (GVWR). The gross
front and rear axle weight ratings (GAWR’s) are
based on a minimum rim size and maximum cold tire
inflation pressure.
• Vehicle Identification Number (VIN).
• Type of vehicle.
• Type of rear wheels.
• Bar code.
• Month, Day and Hour (MDH) of final assembly.
• Paint and Trim codes.
• Country of origin.
The label is located on the driver-side door shut-
face.
INTERNATIONAL SYMBOLS
DESCRIPTION
The graphic symbols illustrated in the following
International Control and Display Symbols Chart are
used to identify various instrument controls. The
symbols correspond to the controls and displays that
are located on the instrument panel.
Fig. 2 Vehicle Safety Certification Label—Typical
2 INTRODUCTION DN
DESCRIPTION AND OPERATION (Continued)

FASTENER IDENTIFICATION
DESCRIPTION
GRADE/CLASS IDENTIFICATION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 10.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts.
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
DN INTRODUCTION 3

FASTENER IDENTIFICATION
4 INTRODUCTION DN

FASTENER STRENGTH
DN INTRODUCTION 5

FASTENER USAGE
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
Figure art, specifications and torque references in
this Service Manual are identified in metric and SAE
format.
During any maintenance or repair procedures, it is
important to salvage all fasteners (nuts, bolts, etc.)
for reassembly. If the fastener is not salvageable, a
fastener of equivalent specification must be used.
THREADED HOLE REPAIR
Most stripped threaded holes can be repaired using
a Helicoil௡. Follow the manufactures recommenda-
tions for application and repair procedures.
METRIC SYSTEM
DESCRIPTION
The metric system is based on quantities of one,
ten, one hundred, one thousand and one million.
The following chart will assist in converting metric
units to equivalent English and SAE units, or vise
versa.
CONVERSION FORMULAS AND EQUIVALENT VALUES
MULTIPLY BY TO GET MULTIPLY BY TO GET
in-lbs x 0.11298 = Newton Meters (N·m) N·m x 8.851 = in-lbs
ft-lbs x 1.3558 = Newton Meters (N·m) N·m x 0.7376 = ft-lbs
Inches Hg
(60° F)
x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg
psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches
Feet x 0.3048 = Meters (M) M x 3.281 = Feet
Yards x 0.9144 = Meters M x 1.0936 = Yards
mph x 1.6093 = Kilometers/Hr. (Km/h) Km/h x 0.6214 = mph
Feet/Sec x 0.3048 = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec
mph x 0.4470 = Meters/Sec (M/S) M/S x 2.237 = mph
Kilometers/
Hr. (Km/h)
x 0.27778 = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr.
(Km/h)
COMMON METRIC EQUIVALENTS
1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters
1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter
1 Mile = 1.6 Kilometers
Refer to the Metric Conversion Chart to convert
torque values listed in metric Newton- meters (N·m).
Also, use the chart to convert between millimeters
(mm) and inches (in.)
TORQUE REFERENCES
DESCRIPTION
Individual Torque Charts appear at the end of
many Groups. Refer to the Standard Torque Specifi-
cations Chart for torque references not listed in the
individual torque charts.
6 INTRODUCTION DN

METRIC CONVERSION CHART
DN INTRODUCTION 7

TORQUE SPECIFICATIONS
8 INTRODUCTION DN

LUBRICATION AND MAINTENANCE
TABLE OF CONTENTS
page page
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . . . 3
JUMP STARTING, TOWING AND HOISTING . . . . . 8
LUBRICANTS
TABLE OF CONTENTS
page page
SERVICE PROCEDURES
PARTS AND LUBRICANT
RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . 1
INTERNATIONAL SYMBOLS . . . . . . . . . . . . . . . . . 1
CLASSIFICATION OF LUBRICANTS. . . . . . . . . . . . 1
FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . 2
SERVICE PROCEDURES
PARTS AND LUBRICANT RECOMMENDATIONS
When service is required, DaimlerChrysler Corpo-
ration recommends that only Mopar௡ brand parts,
lubricants and chemicals be used. Mopar provides
the best engineered products for servicing Daimler-
Chrysler Corporation vehicles.
INTERNATIONAL SYMBOLS
DaimlerChrysler Corporation uses international
symbols to identify engine compartment lubricant
and fluid inspection and fill locations (Fig. 1).
CLASSIFICATION OF LUBRICANTS
Only lubricants bearing designations defined by
the following organization should be used to service a
DaimlerChrysler Corporation vehicle.
• Society of Automotive Engineers (SAE)
• American Petroleum Institute (API) (Fig. 2)
• National Lubricating Grease Institute (NLGI)
(Fig. 3).
ENGINE OIL
SAE VISCOSITY RATING INDICATES ENGINE OIL VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. SAE 30 specifies a single viscos-
ity engine oil. Engine oils also have multiple
viscosities. These are specified with a dual SAE vis-
cosity grade which indicates the cold-to-hot tempera-
ture viscosity range.
• SAE 30 = single grade engine oil.
• SAE 10W-30 = multiple grade engine oil.
DaimlerChrysler Corporation only recommends
multiple grade engine oils.
API QUALITY CLASSIFICATION
This symbol (Fig. 2) on the front of an oil container
means that the oil has been certified by the Ameri-
can Petroleum Institute (API) to meet all the lubri-
cation requirements specified by DailmlerChrysler
Corporation.
Refer to Group 9, Engine for gasoline engine oil
specification.
Fig. 1 International Symbols
DN LUBRICATION AND MAINTENANCE 0 - 1

GEAR LUBRICANTS
SAE ratings also apply to multiple grade gear
lubricants. In addition, API classification defines the
lubricants usage.
LUBRICANTS AND GREASES
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 3) on the label. At the bottom NLGI
symbol is the usage and quality identification letters.
Wheel bearing lubricant is identified by the letter
“G”. Chassis lubricant is identified by the latter “L”.
The letter following the usage letter indicates the
quality of the lubricant. The following symbols indi-
cate the highest quality.
SPECIALIZED LUBRICANTS AND OILS
Some maintenance or repair procedures may
require the use of specialized lubricants or oils. Con-
sult the appropriate sections in this manual for the
correct application of these lubricants.
FLUID CAPACITIES
Fuel Tank
All . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 L (25 gal.)
Engine Oil W/Filter change
4.7 L . . . . . . . . . . . . . . . . . . . . . . . . . 5.7L (6.0 qts.)
5.2L . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 L (5.0 qts.)
5.9L . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 L (5.0 qts.)
Cooling System
4.7L . . . . . . . . . . . . . . . . . . . . . . . . . . . 16L (17qts.)
5.2L . . . . . . . . . . . . . . . . . . . . . . . 13.6 L (14.3 qts.)
5.9L . . . . . . . . . . . . . . . . . . . . . . . 13.6 L (14.3 qts.)
Automatic Transmission
Dry fill capacity. *
42RE, 44RE & 46RE . . . . . . . 9.1-9.5 L (19-20 pts.)
45RFE . . . . . . . . . . . . . . . . . . . . 13.33 L (28.0 pts.)
* Depending on type and size of internal cooler,
length and inside diameter of cooler lines, or use of
an auxiliary cooler, these figures may vary. Refer to
Group 21, Transmission for proper fluid fill proce-
dure.
Transfer Case
NV231 . . . . . . . . . . . . . . . . . . . . . . . 1.2 L (2.5 pts.)
NV231–HD . . . . . . . . . . . . . . . . . . . 1.2 L (2.5 pts.)
NV242 . . . . . . . . . . . . . . . . . . . . . . . 1.4 L (3.0 pts.)
Front Axle
Model 194–FIA . . . . . . . . . . . . . . . . 1.4 L (3.0 pts.)
Rear Axle
8-1/4 in. . . . . . . . . . . . . . . . . . . . . . 2.1 L (4.4 pts.)*
9-1/4 in. . . . . . . . . . . . . . . . . . . . . . 2.3 L (4.9 pts.)*
* Include 0.05 L (0.25 pts.) friction modifier for
limited slip axles.
Power Steering
Power steering fluid capacities are dependent on
engine/chassis options as well as steering gear/cooler
options. Depending on type and size of internal
cooler, length and inside diameter of cooler lines, or
use of an auxiliary cooler, these capacities may vary.
Refer to Section 19 of the service manual for proper
fill and bleed procedures.
Fig. 2 API Symbol
Fig. 3 NLGI Symbol
1 – WHEEL BEARINGS
2 – CHASSIS LUBRICATION
3 – CHASSIS AND WHEEL BEARINGS
0 - 2 LUBRICATION AND MAINTENANCE DN
SERVICE PROCEDURES (Continued)

MAINTENANCE SCHEDULES
TABLE OF CONTENTS
page
SERVICE PROCEDURES
MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . . 3
SERVICE PROCEDURES
MAINTENANCE SCHEDULES
There are two maintenance schedules that show
proper service for the vehicle.
First is Schedule “A”. It lists all the scheduled
maintenance to be performed under “normal” operat-
ing conditions.
Second is Schedule “B”. It is a schedule for vehi-
cles that are operated under the conditions listed at
the beginning of that schedule.
Use the schedule that best describes the driving
conditions.
Where time and mileage are listed, follow the
interval that occurs first.
At Each Stop For Gasoline
• Check engine oil level, add as required.
• Check windshield washer solvent and add if
required.
• Clean windshield and wiper blades as required.
Once A Month
• Check tire pressure and look for unusual wear
or damage.
• Inspect battery and clean and tighten terminals
as required.
• Check fluid levels of coolant reservoir, power
steering and transmission and add as needed.
• Check all lights and all other electrical items for
correct operation.
• Inspect and clean wiper blades. Replace if
required.
At Each Oil Change
• Inspect exhaust system.
• Inspect brake hoses.
• Rotate the tires at each oil change interval
shown on Schedule “A” (7,500 miles) or every other
interval shown on Schedule “B” (6,000 miles).
• Check engine coolant level, hoses, and clamps.
EMISSION CONTROL SYSTEM MAINTENANCE
The scheduled emission maintenance listed in bold
type on the Maintenance Schedules, must be done at
the mileage specified to assure the continued proper
functioning of the emission control system. These,
and all other maintenance services included in this
manual, should be done to provide the best vehicle
performance and reliability. More frequent mainte-
nance may be needed for vehicles in severe operating
conditions such as dusty areas and very short trip
driving.
FLUID FILL LOCATIONS AND LUBRICATION
POINTS
The fluid fill/check locations and lubrication points
are located in each applicable group.
SCHEDULE “A”
7,500 Miles (12 000 km) or at 6 months
• Change engine oil.
• Replace engine oil filter.
• Lubricate front suspension ball joints if
required.
• Inspect front wheel bearings.
• Inspect brake linings.
• Replace engine air cleaner element.
• Replace spark plugs.
• Drain and refill automatic transmission fluid
and change filter (4.7L).
• Drain and refill automatic transmission fluid.
Replace filter and adjust bands (5.2L & 5.9L).
• Drain and refill transfer case fluid.

required.
• Flush and replace engine coolant at 36 months,
regardless of mileage.
• Flush and replace engine coolant if not done at
36 months.
• Replace ignition cables (5.2L & 5.9L).
• Inspect PCV valve, replace as necessary.*
• Inspect auto tension drive belt and replace if
required (5.2L & 5.9L).
required.
• Drain and refill transfer case.
• Flush and replace engine coolant if it has been
30,000 miles (48 000 km) or 24 months since last
change.
required.
change.
required.
required.
change.
required.
required.
change.
required.
*This maintenance is recommended by Chrysler
Corporation to the owner but is not required to main-
tain the warranty on the PCV valve.

Important: Inspection and service should also be
performed any time a malfunction is observed or sus-
pected.
SCHEDULE “B”
Schedule “B” is for vehicles operated under the fol-
lowing conditions:
• Frequent short trip driving less than 5 miles (8
km)
• Frequent driving in dusty conditions
• Trailer towing
• Extensive idling
• More than 50% of driving is at sustained high
speeds during hot weather, above 90°F (32°C)
3,000 Miles (5 000 km)
6,000 Miles (10 000 km)
9,000 Miles (14 000 km)
12,000 Miles (19 000 km)
Replace filter and adjust bands (5.2L & 5.9L).‡
• Change rear axle fluid.
• Change front axle fluid (4x4).
15,000 Miles (24 000 km)
• Inspect engine air cleaner element, replace
as necessary.
18,000 Miles (29 000 km)
21,000 Miles (34 000 km)
required.
24,000 Miles (38 000 km)
27,000 miles (43 000 km)
30,000 Miles (48 000 km)
33,000 Miles (53,000 km)
36,000 Miles (58 000 km)
39,000 Miles (62 000 km)
42,000 Miles (67 000 km)
45,000 Miles (72 000 km)
required.
as necessary.

48,000 Miles (77 000 km)
51,000 Miles (82 000 km)
• Flush and replace engine coolant.
54,000 Miles (86 000 km)
57,000 Miles (91 000 km)
60,000 Miles (96 000 km)
required (5.2L & 5.9L).
63,000 Miles (101 000 km)
66,000 Miles (106,000 km)
required.
69,000 Miles (110 000 km)
72,000 Miles (115 000 km)
75,000 Miles (120 000 km)
as necessary.
required.
78,000 Miles (125 000 km)
81,000 Miles (130 000 km)
30,000 miles (48 000 km) since last change.
84,000 Miles (134 000 km)
87,000 Miles (139 000 km)
90,000 Miles (144 000 km)
required.
required.

93,000 Miles (149 000 km)
96,000 Miles (154 000 km)
99,000 Miles (158 000 km)
• Change engine oil
102,000 Miles (163 000 km)
105,000 Miles (168 000 km)
as necessary.
required.
108,000 Miles (173 000 km)
111,000 Miles (178 000 km)
required.
30,00 miles (48 000 km) since last change.
114,000 Miles (182 000 km)
117,000 Miles (187 000 km)
120,000 Miles (192 000 km)
• Replace ignition cables.
required.
*This maintenance is recommended by Chrysler
Corporation to the customer but is not required to
maintain warranty on the PCV valve.
‡Prolonged operation with heavy loading, espe-
cially in hot weather, use of vehicle for off-the-high-
way operation, and trailer towing require the more
frequent transmission service indicated with a ‡ in
Schedule “B”. Perform these services if the vehicle is
usually operated under these conditions.
Important: Inspection and service should also be
performed any time a malfunction is observed or sus-
pected.

JUMP STARTING, TOWING AND HOISTING
TABLE OF CONTENTS
page page
SERVICE PROCEDURES
JUMP STARTING PROCEDURE. . . . . . . . . . . . . . . 8
TOWING RECOMMENDATIONS. . . . . . . . . . . . . . . 9
TWO-WHEEL-DRIVE VEHICLE TOWING . . . . . . . . 9
FOUR-WHEEL-DRIVE VEHICLE TOWING . . . . . . 10
HOISTING RECOMMENDATIONS. . . . . . . . . . . . . 11
SERVICE PROCEDURES
JUMP STARTING PROCEDURE
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN GROUP 8A, BATTERY/START-
ING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT
JUMP START A FROZEN BATTERY, PERSONAL
INJURY CAN RESULT. DO NOT JUMP START WHEN
MAINTENANCE FREE BATTERY INDICATOR DOT IS
YELLOW OR BRIGHT COLOR. DO NOT JUMP
START A VEHICLE WHEN THE BATTERY FLUID IS
BELOW THE TOP OF LEAD PLATES. DO NOT
ALLOW JUMPER CABLE CLAMPS TO TOUCH
EACH OTHER WHEN CONNECTED TO A BOOSTER
SOURCE. DO NOT USE OPEN FLAME NEAR BAT-
TERY. REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCING OF BATTERY CURRENT. WHEN
USING A HIGH OUTPUT BOOSTING DEVICE, DO
NOT ALLOW BATTERY VOLTAGE TO EXCEED 16
VOLTS. REFER TO INSTRUCTIONS PROVIDED
WITH DEVICE BEING USED.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE:
(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
• Battery cable clamp condition, clean if necessary.
• Frozen battery.
• Yellow or bright color test indicator, if equipped.
• Low battery fluid level.
• Generator drive belt condition and tension.
• Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When using another vehicle as a booster
source, park the booster vehicle within cable reach.
Turn off all accessories, set the parking brake, place
the automatic transmission in PARK or the manual
transmission in NEUTRAL and turn the ignition
OFF.
(3) On disabled vehicle, place gear selector in park
or neutral and set park brake. Turn off all accesso-
ries.
(4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to neg-
ative terminal (-). DO NOT allow clamps at opposite
end of cables to touch, electrical arc will result.
Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the
ground cable attaching point as possible (Fig. 1).
(6) Start the engine in the vehicle which has the
booster battery, let the engine idle a few minutes,
then start the engine in the vehicle with the dis-
charged battery.
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(7) Allow battery in disabled vehicle to charge to
at least 12.4 volts (75% charge) before attempting to
start engine. If engine does not start within 15 sec-
onds, stop cranking engine and allow starter to cool
(15 min.), before cranking again.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
• Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
• When using a Booster vehicle, disconnect
BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive
terminal.
• Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle.

TOWING RECOMMENDATIONS
A vehicle equipped with SAE approved wheel lift-
type towing equipment can be used to tow all vehi-
cles. When towing a 4WD vehicle using a wheel-lift
towing device, use tow dollies under the opposite end
of the vehicle. A vehicle with flatbed device can also
be used to transport a disabled vehicle (Fig. 2).
SAFETY PRECAUTIONS
CAUTION: The following safety precautions must
be observed when towing a vehicle:
• Secure loose and protruding parts.
• Always use a safety chain system that is inde-
pendent of the lifting and towing equipment.
• Do not allow towing equipment to contact the
disabled vehicle’s fuel tank.
• Do not allow anyone under the disabled vehicle
while it is lifted by the towing device.
• Do not allow passengers to ride in a vehicle
being towed.
• Always observe state and local laws regarding
towing regulations.
• Do not tow a vehicle in a manner that could
jeopardize the safety of the operator, pedestrians or
other motorists.
• Do not attach tow chains, T-hooks, or J-hooks to
a bumper, steering linkage, drive shafts or a non-re-
inforced frame hole.
• Do not tow a heavily loaded vehicle. Use a flat-
bed device to transport a loaded vehicle.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels removed,
install lug nuts to retain brake drums or rotors.
A towed vehicle should be raised until lifted wheels
are a minimum 100 mm (4 in) from the ground. Be
sure there is adequate ground clearance at the oppo-
site end of the vehicle, especially when towing over
rough terrain or steep rises in the road.
RAMP ANGLE
If a vehicle with flatbed towing equipment is used,
the approach ramp angle should not exceed 15
degrees.
TOWING WHEN KEYS ARE NOT AVAILABLE
When the vehicle is locked and keys are not avail-
able, use a flat bed hauler. A wheel-lift device can be
used on 4WD vehicles provided all the wheels are
lifted off the ground using tow dollies.
TWO-WHEEL-DRIVE VEHICLE TOWING
Chrysler Corporation recommends that a vehicle be
towed with the rear end lifted, whenever possible.
WARNING: WHEN TOWING A DISABLED VEHICLE
AND THE DRIVE WHEELS ARE SECURED IN A
WHEEL LIFT OR TOW DOLLIES, ENSURE THE
TRANSMISSION IS IN THE PARK POSITION (AUTO-
MATIC TRANSMISSION) OR A FORWARD DRIVE
GEAR (MANUAL TRANSMISSION).
WARNING: ENSURE VEHICLE IS ON A LEVEL SUR-
FACE OR THE WHEELS ARE BLOCKED TO PRE-
VENT VEHICLE FROM ROLLING.
Fig. 1 Jumper Cable Clamp Connections
1 – ENGINE GROUND
2 – NEGATIVE JUMPER CABLE
3 – BATTERY NEGATIVE CABLE
4 – POSITIVE JUMPER CABLE
5 – BATTERY POSITIVE CABLE
6 – BATTERY
7 – TEST INDICATOR
Fig. 2 Tow Vehicles With Approved Equipment

TWO WHEEL DRIVE TOWING-REAR END LIFTED
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
2WD vehicles can be towed with the front wheels
on the surface for extended distances at speeds not
exceeding 48 km/h (30 mph).
(1) Attach wheel lift device to rear wheels.
(2) Place the transmission in neutral.
(3) Raise vehicle to towing position.
(4) Attach safety chains. Route chains so not to
interfere with tail pipe when vehicle is lifted.
(5) Turn the ignition switch to the OFF position to
unlock the steering wheel.
(6) Secure steering wheel in straight ahead posi-
tion with a clamp device designed for towing.
(7) Place transmission in park.
TWO WHEEL DRIVE TOWING-FRONT END LIFTED
CAUTION: Many vehicles are equipped with air
dams, spoilers, and/or ground effect panels. To
avoid component damage, a wheel-lift towing vehi-
cle or a flat-bed hauling vehicle is recommended.
(3) Raise the rear of the vehicle off the ground and
install tow dollies under rear wheels.
(4) Attach wheel lift device to front wheels and
raise vehicle to towing position.
(5) Attach the safety chains.
(8) Place transmission in park.
FOUR-WHEEL-DRIVE VEHICLE TOWING
Chrysler Corporation recommends that a vehicle be
transported on a flat-bed device. A Wheel-lift device
can be used provided all the wheels are lifted off
the ground using tow dollies.
WARNING: WHEN TOWING A DISABLED VEHICLE
AND THE DRIVE WHEELS ARE SECURED IN A
WHEEL LIFT OR TOW DOLLIES, ENSURE THE
TRANSMISSION IS IN THE PARK POSITION.
CAUTION: Many vehicles are equipped with air
dams, spoilers, and/or ground effect panels. To
avoid component damage, a wheel-lift towing vehi-
cle or a flat-bed hauling vehicle is recommended.
FOUR WHEEL DRIVE TOWING—REAR END LIFTED
(1) Attach wheel lift device to front wheels.
(3) Raise the front of the vehicle off the ground
and install tow dollies under front wheels.
(4) Attach wheel lift device to rear wheels and
(5) Attach safety chains to frame rails. Route
chains so not to interfere with tail pipe when vehicle
is lifted.
(8) Place the transmission in park.
FOUR WHEEL DRIVE TOWING—FRONT END
LIFTED
(3) Raise the rear of the vehicle off the ground and
install tow dollies under rear wheels.
(4) Attach wheel lift device to front wheels and
(5) Attach the safety chains.
(8) Place the transmission in park.

HOISTING RECOMMENDATIONS
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
NENT IS REMOVED FROM A VEHICLE, THE
CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY
SUPPORT OR SECURE VEHICLE TO HOISTING
DEVICE WHEN THESE CONDITIONS EXIST.
FLOOR JACK
CAUTION: Do not attempt to lift a vehicle with a
floor jack positioned under:
• An axle tube.
• Aluminum differential.
• A body side sill.
• A steering linkage component.
• A drive shaft.
• The engine or transmission oil pan.
• The fuel tank.
• A front suspension arm.
When properly positioned, a floor jack can be used
to lift a Durango vehicle (Fig. 3). Support the vehicle
in the raised position with jack stands at the front
and rear ends of the frame rails.
HOIST
A vehicle can be lifted with:
• A single-post, frame-contact hoist.
• A twin-post, chassis hoist.
• A ramp-type, drive-on hoist.
NOTE: When a frame-contact type hoist is used,
verify that the lifting pads are positioned properly
(Fig. 3).
Fig. 3 Correct Vehicle Lifting Locations—Typical

SUSPENSION
TABLE OF CONTENTS
page page
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FRONT SUSPENSION - 4x2 . . . . . . . . . . . . . . . . . . 6
FRONT SUSPENSION - 4x4 . . . . . . . . . . . . . . . . . 14
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . 23
ALIGNMENT
TABLE OF CONTENTS
page page
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING
PRE-ALIGNMENT INSPECTION. . . . . . . . . . . . . . . 2
SERVICE PROCEDURES
SUSPENSION HEIGHT - 4x4 . . . . . . . . . . . . . . . . . 3
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
WHEEL ALIGNMENT
DESCRIPTION
Wheel alignment involves the correct positioning of
the wheels in relation to the vehicle. The positioning
is accomplished through suspension and steering
linkage adjustments. An alignment is considered
essential for efficient steering, good directional stabil-
ity and to minimize tire wear. The most important
measurements of an alignment are caster, camber
and toe (Fig. 1).
CAUTION: Never attempt to modify suspension or
steering components by heating or bending.
NOTE: Periodic lubrication of the front suspension/
steering system components may be required. Rub-
ber bushings must never be lubricated. Refer to
Group 0, Lubrication And Maintenance for the rec-
ommended maintenance schedule.
OPERATION
• CASTER is the forward or rearward tilt of the
steering knuckle from vertical. Tilting the top of the
knuckle forward provides negative caster. Tilting the
top of the knuckle rearward provides positive caster.
Positive caster promotes directional stability. This
angle enables the front wheels to return to a straight
ahead position after turns.
• CAMBER is the inward or outward tilt of the
wheel relative to the center of the vehicle. Tilting the
top of the wheel inward provides negative camber.
Tilting the top of the wheel outward provides positive
camber. Incorrect camber will cause wear on the
inside or outside edge of the tire.
• TOE is the difference between the leading
inside edges and trailing inside edges of the front
tires. Wheel toe position out of specification cause’s
unstable steering, uneven tire wear and steering
wheel off- center. The wheel toe position is the final
front wheel alignment adjustment.
DN SUSPENSION 2 - 1

• THRUST ANGLE is the angle of the rear axle
relative to the centerline of the vehicle. Incorrect
thrust angle can cause off-center steering and exces-
sive tire wear. This angle is not adjustable, damaged
component(s) must be replaced to correct the thrust
angle.
PRE-ALIGNMENT INSPECTION
Before starting wheel alignment, the following
inspection and necessary corrections must be com-
pleted. Refer to Suspension and Steering System
Diagnosis Chart for additional information.
(1) Inspect tires for size, air pressure and tread
wear.
(2) Inspect front wheel bearings for wear.
(3) Inspect front wheels for excessive radial or lat-
eral runout and balance.
(4) Inspect ball studs, linkage pivot points and
steering gear for looseness, roughness or binding.
(5) Inspect suspension components for wear and
noise.
(6) On 4x4 vehicles check suspension height.
(7) Road test the vehicle.
SUSPENSION AND STEERING SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
FRONT END NOISE 1. Loose or worn wheel bearing. 1. Replace wheel bearing.
2. Loose or worn steering or
suspension components.
2. Tighten or replace components as
necessary.
3. Lower ball joint (4x4). 3. Gease joint and perform diagnosis and
testing.
EXCESSIVE PLAY IN
STEERING
1. Loose or worn wheel bearing. 1. Replace wheel bearing.
necessary.
3. Loose or worn steering gear. 3. Adjust or replace steering gear.
FRONT WHEELS SHIMMY 1. Loose or worn wheel bearing. 1. Replace wheel bearing.
necessary.
3. Tires worn or out of balance. 3. Replace or balance tires.
4. Alignment. 4. Align vehicle to specifications.
VEHICLE INSTABILITY 1. Loose or worn wheel bearing. 1. Replace wheel bearing.
necessary.
3. Tire pressure. 3. Adjust tire pressure.
Fig. 1 Wheel Alignment Measurements
1 – FRONT OF VEHICLE
2 – STEERING AXIS INCLINATION
3 – PIVOT POINT
4 – TOE-IN
2 - 2 SUSPENSION DN

EXCESSIVE STEERING
EFFORT
1. Loose or worn steering gear. 1. Adjust or replace steering gear.
2. Column coupler binding. 2. Replace coupler.
VEHICLE PULLS TO ONE
SIDE
necessary.
4. Radial tire lead. 4. Rotate or replace tire as necessary.
5. Brake pull. 5. Repair brake as necessary.
6. Weak or broken spring. 6. Replace spring.
7. Ride height 4WD only. 7. Measure and adjust ride height.
SERVICE PROCEDURES
SUSPENSION HEIGHT - 4x4
The vehicle suspension height should be measured
and adjusted if necessary before performing wheel
alignment procedure. Also when front suspension
components have been replaced. This measure must
be performed with the vehicle supporting it’s own
weight and taken on both sides of the vehicle.
HEIGHT MEASUREMENT
(1) Jounce the front of the vehicle.
(2) Measure and record the distance between the
ground and the center of the lower suspension arm
rear mounting bolt head (Fig. 2).
(3) Measure and record the distance between the
ground and the center of the front wheel (Fig. 2).
(4) Subtract the first measurement from the sec-
ond measurement. The difference between the two
measurement should be 73 mm (2.9 inches) Ϯ 3 mm
(0.12 inches).
HEIGHT ADJUSTMENT
To adjust the vehicle height turn the torsion bar
adjustment bolt CLOCKWISE to raise the vehicle
and COUNTER CLOCKWISE to lower the vehicle.
CAUTION: ALWAYS raise the vehicle to the correct
suspension height, NEVER lower the vehicle to
obtain the correct suspension height. If the vehicle
suspension height is too high, lower the vehicle
below the height specification. Then raise the vehi-
cle to the correct suspension height specification.
This will insure the vehicle maintains the proper
suspension height.
NOTE: If a height adjustment has been made, per-
form height measurement again on both sides of
the vehicle.
WHEEL ALIGNMENT
NOTE: 4x4 suspension height measurement must
be performed before alignment.
Fig. 2 Height Measurement
DN SUSPENSION 2 - 3
DIAGNOSIS AND TESTING (Continued)

CAMBER AND CASTER ADJUSTMENT
Camber and caster angle adjustments involve
changing the position of the upper suspension arm
pivot bar (Fig. 3).
NOTE: On 4x2 vehicles use Alignment Tool 8393 for
alignment. The tool attaches to the pivot bar on the
upper control arm.
CASTER
Moving the rear position of the pivot bar in or out,
will change the caster angle significantly and camber
angle only slightly. To maintain the camber angle
while adjusting caster, move the rear of the pivot bar
in or out. Then move the front of the pivot bar
slightly in the opposite direction.
To increase positive caster angle, move the rear
position of the pivot bar inward (toward the engine).
Move the front of pivot bar outward (away from the
engine) slightly until the original camber angle is
obtained.
CAMBER
Move the front of the pivot bar in or out. This will
change the camber angle significantly and caster
angle slightly.
After adjustment is made tighten the pivot bar
nuts to proper torque specification.
TOE ADJUSTMENT
The wheel toe position adjustment is the final
adjustment.
(1) Start the engine and turn wheels both ways
before straightening the wheels. Secure the steering
wheel with the front wheels in the straight-ahead
position.
(2) Loosen the tie rod jam nuts.
NOTE: Each front wheel should be adjusted for
one-half of the total toe position specification. This
will ensure the steering wheel will be centered
when the wheels are positioned straight-ahead.
(3) Adjust the wheel toe position by turning the tie
rod as necessary (Fig. 4).
(4) Tighten the tie rod jam nut to 75 N·m (55 ft.
lbs.).
(5) Verify the specifications
(6) Turn off engine.
Fig. 3 Caster & Camber Adjustment-Typical
1 – PIVOT BAR
2 – + CASTER
3 – + CAMBER
4 – UPPER ARM SUSPENSION
Fig. 4 Toe Adjustment
1 – JAM NUT
2 – TIE ROD
3 – TIE ROD END
2 - 4 SUSPENSION DN

SPECIFICATIONS
ALIGNMENT
VEHICLE CASTER (Ϯ 0.50°) CAMBER (Ϯ 0.50°) TOTAL TOE (Ϯ 0.06°)
4x2 3.10° −0.25° 0.10°
4x4 3.30° −0.25° 0.10°
MAX RT to LT
DIFFERENCE
0.50° 0.50° 0.06
THRUST ANGLE 0° Ϯ 0.4°
NOTE: All alignment specifications are in degrees.
DN SUSPENSION 2 - 5

FRONT SUSPENSION - 4x2
TABLE OF CONTENTS
page page
FRONT SUSPENSION - 4X2 . . . . . . . . . . . . . . . . . 6
SHOCK ABSORBERS . . . . . . . . . . . . . . . . . . . . . . 6
COIL SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . . . 7
SUSPENSION ARMS . . . . . . . . . . . . . . . . . . . . . . . 7
STABILIZER BAR. . . . . . . . . . . . . . . . . . . . . . . . . . 7
LOWER BALL JOINT . . . . . . . . . . . . . . . . . . . . . . . 7
UPPER BALL JOINT . . . . . . . . . . . . . . . . . . . . . . . 8
SHOCK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . 8
REMOVAL AND INSTALLATION
SHOCK ABSORBER. . . . . . . . . . . . . . . . . . . . . . . . 8
COIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . . . 9
LOWER SUSPENSION ARM . . . . . . . . . . . . . . . . 10
UPPER SUSPENSION ARM . . . . . . . . . . . . . . . . . 10
STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . 11
HUB/BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
WHEEL MOUNTING STUDS. . . . . . . . . . . . . . . . . 12
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 12
SPECIAL TOOLS
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . 13
FRONT SUSPENSION - 4X2
DESCRIPTION
The front suspension is designed to allow each
wheel to adapt to different road surfaces indepen-
dently. The wheels are mounted to hub bearings on
the cast iron steering knuckle spindles. The double-
row hub bearings are sealed and lubricated for life.
The steering knuckles turn (pivot) on ball joints riv-
eted to the outboard portion of the suspension arms.
The ball joints are lubricated for life.
The 4x2 front suspension is comprised of (Fig. 1) :
CAUTION: Components attached with a nut and
cotter pin must be torqued to specification. Then if
the slot in the nut does not line up with the cotter
pin hole, tighten nut until it is aligned. Never loosen
the nut to align the cotter pin hole.
CAUTION: Suspension components with rubber/
urethane bushings (except stabilizer bar) should be
tightened with the vehicle at normal ride height. It is
important to have the springs supporting the weight
of the vehicle when the fasteners are torqued. If
springs are not at their normal ride position, vehicle
ride comfort could be affected and premature bush-
ing wear may occur.
• Shock absorbers
• Coil springs
• Suspension arms
• Stabilizer bar
• Jounce/Rebound Bumpers
• Steering Knuckle
SHOCK ABSORBERS
DESCRIPTION
The top of the low-pressure gas charged shock are
bolted to the frame. The bottom of the shock are
bolted to the lower suspension arm.
OPERATION
The shock absorbers dampen jounce and rebound
of the vehicle over various road conditions.
Fig. 1 Front Suspension - 4X2
1 – UPPER SUSPENSION ARM
2 – STEERING KNUCKLE
3 – COIL SPRING
4 – LOWER SUSPENSION ARM
5 – STABILIZER BAR
2 - 6 SUSPENSION DN

COIL SPRINGS
DESCRIPTION
The springs mount between the lower suspension
arms and frame rail spring seats. A rubber isolator
seats on top off the spring to help prevent noise.
OPERATION
The coil springs control ride quality and maintain
proper ride height.
STEERING KNUCKLE
DESCRIPTION
The knuckle is a single casting with legs machined
for the upper and lower ball joints. The knuckle also
has machined mounting locations for the front brake
calipers and hub bearing.
OPERATION
The steering knuckle pivot between the upper and
lower ball joint. Steering linkage attached to the
knuckle allows the vehicle to be steered.
SUSPENSION ARMS
DESCRIPTION
The upper suspension arm bolts on frame brackets
through the arm pivot shaft. The frame brackets
have slotted holes which allow the arms to be
adjusted for caster and camber. Pivot shaft bushings
are not replaceable.
The lower suspension arms bolt to the lower frame
brackets and pivot through bushings, these bushings
The suspension arms have lube for life riveted ball
studs. The suspension arm travel (jounce) is limited
through the use of urethane bumpers. Rebound
travel is limited by the shock absorber.
STABILIZER BAR
DESCRIPTION
The bar extends across the front underside of the
chassis and mounts on the frame rails. Links con-
nected the bar to the lower suspension arms. Stabi-
lizer bar mounts are isolated by rubber bushings.
Links are isolated with rubber grommets.
OPERATION
The stabilizer bar is used to minimize vehicle front
sway during turns. The spring steel bar helps to con-
trol the vehicle body in relationship to the suspen-
sion.
LOWER BALL JOINT
(1) Raise the front of the vehicle. Place safety floor
stands under both lower suspension arms as far out-
board as possible. Lower the vehicle to allow the
stands to support some or all of the vehicle weight.
NOTE: The upper suspension arms must not con-
tact the rebound bumpers.
(2) Remove the tire and wheel assemblies.
(3) Mount a dial indicator solidly under the lower
suspension arm.
(4) Position indicator plunger against the bottom
of the steering knuckle lower ball joint boss.
NOTE: The dial indicator plunger must be perpen-
dicular to the machined surface of the steering
knuckle lower ball joint boss (Fig. 2).
(5) Position a pry bar over the top of the upper
suspension arm and under the pivot bar of the upper
suspension arm. Pry down on the upper suspension
arm and then zero the dial indicator.
(6) Reposition the pry bar under the upper suspen-
sion arm and on top of the frame rail. Pry up on the
upper suspension arm and record the dial indicator
reading.
(7) If the travel exceeds 1.52 mm (0.060 in.),
replace the lower suspension arm.
Fig. 2 Lower Ball Joint Boss
1 – BALL JOINT BOSS
3 – DIAL INDICATOR
DN SUSPENSION 2 - 7

UPPER BALL JOINT
(1) Position a floor jack under the lower suspen-
sion arm. Raise the wheel and allow the tire to
lightly contact the floor (vehicle weight relieved from
the tire).
(2) Mount a dial indicator solidly on the upper sus-
pension arm.
(3) Position the indicator plunger against the
upper ball joint boss of the steering knuckle.
(4) Grasp the top of the tire and apply force in and
out. Look for movement at the ball joint between the
upper suspension arm and steering knuckle.
(5) If lateral movement is greater than 1.52 mm
(0.060 in.), replace upper suspension arm.
SHOCK DIAGNOSIS
A knocking or rattling noise from a shock absorber
may be caused by movement between mounting
bushings and metal brackets or attaching compo-
nents. These noises can usually be stopped by tight-
ening the attaching nuts. If the noise persists,
inspect for damaged and worn bushings, and attach-
ing components. Repair as necessary if any of these
conditions exist.
A squeaking noise from the shock absorber may be
caused by the hydraulic valving and may be intermit-
tent. This condition is not repairable and the shock
absorber must be replaced.
The shock absorbers are not refillable or adjust-
able. If a malfunction occurs, the shock absorber
must be replaced. To test a shock absorber, hold it in
an upright position and force the piston in and out of
the cylinder four or five times. The action throughout
each stroke should be smooth and even.
The shock absorber bushings do not require any
type of lubrication. Do not attempt to stop bushing
noise by lubricating them. Grease and mineral oil-
base lubricants will deteriorate the bushing.
SHOCK ABSORBER
REMOVAL
(1) Remove the upper shock nut, retainer and
grommet from the shock absorber stud (Fig. 3).
(2) Raise and support the vehicle.
(3) Remove the lower mounting bolts and remove
shock absorber through the lower suspension arm
(Fig. 3).
INSTALLATION
NOTE: Upper shock nut must be replaced or use
Mopar Lock ’N Seal or Loctiteா 242 on existing nut.
(1) Install the lower retainer (lower retainer is
stamped with a L) and grommet on the shock
absorber stud and extend the shock. Insert the shock
absorber through the lower suspension arm and
upper mounting hole.
(2) Install the lower mounting bolts and tighten to
28 N·m (21 ft. lbs.).
(3) Remove support and lower the vehicle.
(4) Install the upper grommet and retainer (upper
retainer is stamped with a U) on the shock
absorber stud. Install a new nut or use Mopar Lock
’N Seal or Loctite௡ 242 on existing nut and tighten to
26 N·m (19 ft. lbs.).
COIL SPRING
REMOVAL
(2) Remove wheel and tire assembly.
(3) Remove the stabilizer bar link from the lower
suspension arm.
(4) Remove the shock absorber.
(5) Install Spring Compressor DD-1278 up through
the lower suspension arm, coil spring and upper
shock mounting hole (Fig. 4).
(6) Tighten the tool lower nut to compress the coil
spring.
(7) Remove the lower ball joint nut and separate
the ball joint from the knuckle with Remover
C-4150A (Fig. 5).
(8) Loosen the spring compressor lower nut to
relieve spring tension.
(9) Remove the tool and pull down on the lower
suspension arm to remove the spring.
Fig. 3 Front Shock Absorber
1 – RETAINER
2 – GROMMET
3 – SHOCK ABSORBER
2 - 8 SUSPENSION DN

INSTALLATION
NOTE: The ramped or open end of the coil spring
is the bottom of the spring.
(1) Tape the isolator pad to the top of the coil
spring. Position the spring in the lower suspension
arm pocket. Be sure that the coil spring is seated in
the pocket.
the lower suspension arm, coil spring upper shock
mounting hole.
(3) Tighten the tool nut to compress the coil
spring.
(4) Install the lower ball joint into the knuckle and
tighten the nut to 127 N·m (94 ft. lbs.). Install cotter
pin.
(5) Remove the spring compressor tool.
(6) Install the stabilizer bar link to the lower sus-
pension arm and tighten nut to 47 N·m (35 ft. lbs.).
(7) Install the shock absorber.
(8) Install the wheel and tire assembly.
STEERING KNUCKLE
REMOVAL
(2) Remove the wheel and tire assembly.
(3) Remove disc brake caliper, rotor, shield and
ABS speed sensor, refer to Group 5 Brakes.
(4) Remove tie-rod from steering knuckle arm,
refer to Group 19 Steering.
(5) Remove the hub/bearing.
(6) Remove the shock absorber.
the lower suspension arm, coil spring and upper
shock mounting hole (Fig. 4).
(8) Tighten the tool lower nut to compress the coil
spring.
(9) Remove the lower ball joint nut and separate
C-4150A (Fig. 5).
(10) Remove the upper ball joint nut and separate
MB-991113 (Fig. 6).
CAUTION: When install Remover MB-991113 to sep-
arate the ball joint, be careful not to damage the
ball joint seal.
(11) Remove steering knuckle.
INSTALLATION
(1) Position steering knuckle on upper and lower
ball joints and install nuts. Tighten lower nut to 127
Fig. 4 Spring Compressor
1 – COIL SPRING
3 – SPRING COMPRESSOR
Fig. 5 Lower Ball Joint
1 – LOWER BALL JOINT
2 – REMOVER
DN SUSPENSION 2 - 9
REMOVAL AND INSTALLATION (Continued)

N·m (94 ft. lbs.). Tighten upper nut to 81 N·m (60 ft.
lbs.) and install new cotter pins.
(2) Remove the spring compressor.
(4) Install the hub/bearing.
(5) Install ABS speed sensor, brake dust shield,
rotor and caliper, refer to Group 5 Brakes.
(6) Install tie rod to steering knuckle arm, refer to
Group 19 Steering.
(8) Remove support and lower the vehicle
LOWER SUSPENSION ARM
REMOVAL
(1) Raise and support vehicle.
(3) Remove disc brake caliper and rotor from steer-
ing knuckle, refer to Group 5 Brakes.
(4) Remove shock absorber.
(5) Remove stabilizer bar link from the lower sus-
pension arm.
(6) Remove the coil spring.
(7) Remove lower suspension arm mounting bolts
(Fig. 7) from the frame mounts and remove the arm.
INSTALLATION
CAUTION: Frame mounting bolts must be installed
to their original location and orientation to avoid
damaging the steering rack boots.
(1) Loosely attach suspension arm to frame
mounts.
(2) Install the coil spring.
(4) Install stabilizer bar link to the lower suspen-
sion arm and tighten nut to 47 N·m (35 ft. lbs.)
(5) Install brake rotor and caliper, refer to Group 5
Brakes.
(6) Install wheel and tire assembly.
(8) Tighten the front suspension arm mounting
nut to 175 N·m (130 ft. lbs.) and the rear nut to 108
N·m (80 ft. lbs.).
UPPER SUSPENSION ARM
REMOVAL
(3) Remove brake hose bracket from the arm.
(4) Position a hydraulic jack under the arm and
raise the jack to unload the rebound bumper.
(5) Remove cotter pin and nut from upper ball
joint.
(6) Separate upper ball joint from steering knuckle
with Remover MB-991113 (Fig. 6).
CAUTION: When installing Remover MB-991113 to
separate the ball joint, be careful not to damage the
ball joint seal.
(7) Remove suspension arm pivot bar mounting
nuts and remove suspension arm (Fig. 8).
INSTALLATION
NOTE: Before installation, insure pivot bar adjust-
ment bolts are in their original location (Fig. 8).
Fig. 6 Upper Ball Joint
1 – UPPER BALL JOINT
2 – REMOVER
3 – KNUCKLE
Fig. 7 Lower Suspension Arm
2 – FRAME MOUNTS
2 - 10 SUSPENSION DN

(1) Position suspension arm pivot bar on adjust-
ment bolts. Install nuts and tighten to 210 N·m (155
ft. lbs.).
(2) Position steering knuckle on upper ball joint.
Tighten the upper ball joint nut to 81 N·m (60 ft.
lbs.) and install a new cotter pin.
(4) Remove support and lower vehicle.
(5) Align front end to specifications.
STABILIZER BAR
REMOVAL
(2) Remove the upper link nut, retainer and grom-
met from each link.
(3) Remove the lower link nut from the lower sus-
pension arm on each side (Fig. 9).
(4) Remove the stabilizer bar retainer bolts and
remove the retainers and stabilizer bar from the
vehicle.
(5) Remove the bushings from the stabilizer bar.
INSTALLATION
(1) Install the bushings on the stabilizer bar.
(2) Install the stabilizer bar on the frame and
install the retainers and the bolts.
(3) Tighten the bolts to 60 N·m (45 ft. lbs.).
NOTE: Ensure the bar is center with equal spacing
on both sides.
(4) Install the link lower retainer and grommet on
the links.
(5) Install the links into the stabilizer bar and
lower suspension arm on each side.
(6) Install the lower link mounting nut and tighten
to 47 N·m (35 ft. lbs.).
NOTE: Ensure both link end caps are facing
straight forward.
(7) Install the upper link grommet, retainer and
nut and tighten to 37 N·m (27 ft. lbs.).
HUB/BEARING
REMOVAL
(3) Remove brake caliper, rotor, and ABS wheel
speed sensor if equipped, refer to Group 5 Brakes.
(4) Remove hub/bearing spindle nut and discard
nut (Fig. 10).
CAUTION: The hub/bearing spindle nut can not be
re-used.
(5) Slide hub/bearing off spindle.
INSTALLATION
(1) Slide hub/bearing on spindle.
Fig. 8 Upper Suspension Arm
Fig. 9 Stabilizer Bar
1 – RETAINER
2 – GROMMET
3 – STABILIZER LINK
DN SUSPENSION 2 - 11

(2) Install new spindle nut and tighten to 251
N·m (185 ft. lbs.).
(3) Install brake rotor, caliper, and ABS wheel
speed sensor if equipped, refer to Group 5 Brakes.
WHEEL MOUNTING STUDS
CAUTION: Do not use a hammer to remove wheel
studs.
REMOVAL
(3) Remove brake caliper, caliper adapter and
rotor, refer to Group 5 Brakes for procedure.
(4) Remove stud from hub with Remover C-4150A
(Fig. 11).
INSTALLATION
(1) Install new stud into hub flange.
(2) Install three washers onto stud, then install
lug nut with the flat side of the nut against the
washers.
(3) Tighten lug nut until the stud is pulled into
the hub flange. Verify that the stud is properly
seated into the flange.
(4) Remove lug nut and washers.
(5) Install the brake rotor, caliper adapter, and cal-
iper, refer to Group 5 Brakes for procedure.
(6) Install wheel and tire assembly, use new lug
nut on stud or studs that were replaced.
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Shock Absorber
Upper Nut . . . . . . . . . . . . . . . 26 N·m (19 ft. lbs.)
Lower Bolts . . . . . . . . . . . . . . 28 N·m (21 ft. lbs.)
Lower Suspension Arm
Front Nut . . . . . . . . . . . . . . 175 N·m (130 ft. lbs.)
Rear Nut . . . . . . . . . . . . . . . 108 N·m (80 ft. lbs.)
Ball Joint Nut . . . . . . . . . . . 127 N·m (94 ft. lbs.)
Upper Suspension Arm
Pivot Shaft Nuts . . . . . . . . 167 N·m (130 ft. lbs.)
Pivot Shaft to Frame Nuts . 210 N·m (155 ft. lbs.)
Ball Joint Nut . . . . . . . . . . . . 81 N·m (60 ft. lbs.)
Stabilizer Bar
Link Upper Nut . . . . . . . . . . . 37 N·m (27 ft. lbs.)
Link Ball Stud Nut . . . . . . . . 47 N·m (35 ft. lbs.)
Retainer Bolts . . . . . . . . . . . . 60 N·m (45 ft. lbs.)
Hub/Bearing
Spindle Nut . . . . . . . . . . . . . . 251 N·m (185 ft. lbs.)
Fig. 10 Hub/Bearing
1 – KNUCKLE
2 – HUB/BEARING
3 – SPINDLE NUT
Fig. 11 Wheel Stud Removal
1 – REMOVER
2 – WHEEL STUD

SPECIAL TOOLS
FRONT SUSPENSION
Compressor, Coil Spring DD-1278
Remover Ball Joint MB-991113
Remover Ball Joint C-4150A
Puller Tie Rod C-3894-A

FRONT SUSPENSION - 4x4
TABLE OF CONTENTS
page page
SUSPENSION COMPONENTS 4x4. . . . . . . . . . . . 14
SHOCK ABSORBERS . . . . . . . . . . . . . . . . . . . . . 15
TORSION BARS. . . . . . . . . . . . . . . . . . . . . . . . . . 15
STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . . 15
SUSPENSION ARMS . . . . . . . . . . . . . . . . . . . . . . 15
STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . 15
LOWER BALL JOINT . . . . . . . . . . . . . . . . . . . . . . 15
UPPER BALL JOINT. . . . . . . . . . . . . . . . . . . . . . . 15
SHOCK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 16
SHOCK ABSORBER. . . . . . . . . . . . . . . . . . . . . . . 16
TORSION BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . 17
STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . . 17
LOWER SUSPENSION ARM . . . . . . . . . . . . . . . . 18
UPPER SUSPENSION ARM . . . . . . . . . . . . . . . . . 19
STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . 20
HUB/BEARING. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
WHEEL MOUNTING STUDS. . . . . . . . . . . . . . . . . 21
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 21
SPECIAL TOOLS
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . 22
SUSPENSION COMPONENTS 4x4
DESCRIPTION
The front suspension is designed to allow each
wheel to adapt to different road surfaces indepen-
dently. The wheels are mounted to hub/bearings
units bolted to cast steering knuckle. The double-row
hub bearings are sealed and lubricated for life. The
steering knuckles turn (pivot) on ball joints. The
upper ball joint is riveted to the outboard portion of
the suspension arm and lubricated for life. The lower
ball joint is pressed into the lower suspension arm
and requires lubrication.
The front suspension is comprised of (Fig. 1):
• Shock absorbers
• Torsion-bar springs
• Suspension arms
• Steering knuckles
• Stabilizer bar
CAUTION: Components attached with a nut and
cotter pin must be torqued to specification. Then if
the slot in the nut does not line up with the cotter
pin hole, tighten nut until it is aligned. Never loosen
the nut to align the cotter pin hole.
urethane bushings (except stabilizer bar) should be
tightened with the vehicle at normal ride height. It is
important to have the springs supporting the weight
of the vehicle when the fasteners are torqued. If
springs are not at their normal ride position, vehicle
ride comfort could be affected and premature bush-
ing wear may occur.
NOTE: Periodic lubrication of the front suspension/
steering system components may be required. Rub-
ber bushings must never be lubricated. Refer to
Group 0, Lubrication And Maintenance for the rec-
ommended maintenance schedule.
Fig. 1 Front Suspension 4x4
2 – SHOCK ABSORBER
5 – TORSION BAR

SHOCK ABSORBERS
DESCRIPTION
The top of the low-pressure gas charged shock are
bolted to the frame. The bottom of the shock are
bolted to the lower suspension arm.
OPERATION
The shock absorbers dampen jounce and rebound
of the vehicle over various road conditions.
TORSION BARS
DESCRIPTION
The front of the bar mounts to the back side of the
lower suspension arm. The rear end of the bar is
mounted in a anchor that rests in the frame cross-
member.
OPERATION
The torsion bars are used to control ride height
and ride quality. The vehicle height is adjusted
through an anchor adjustment bolt that increases or
decreases the angle of the torsion bar. Increasing or
decreasing the bar angle changes the angle of the
suspension arms.
STEERING KNUCKLE
DESCRIPTION
The knuckle is a single casting with legs machined
for the upper and lower ball joints. The knuckle also
has machined mounting locations for the front brake
calipers and hub bearing.
OPERATION
The steering knuckle pivot between the upper and
lower ball joint. Steering linkage attached to the
knuckle allows the vehicle to be steered.
SUSPENSION ARMS
DESCRIPTION
The upper suspension arm bolts on frame brackets
through the arm pivot shaft. The frame brackets
have slotted holes which allow the arms to be
adjusted for caster and camber. Pivot shaft bushings
The lower suspension arms bolt to the lower frame
brackets and pivot through bushings, these bushings
The suspension arms have lube for life riveted ball
studs. The suspension arm travel (jounce) is limited
through the use of urethane bumpers. Rebound
travel is limited by the shock absorber.
STABILIZER BAR
DESCRIPTION
The bar extends across the front underside of the
chassis and connects to the frame crossmember. The
ends of the bar mount to the lower suspension arm.
All mounting points of the stabilizer bar are isolated
by bushings.
OPERATION
The stabilizer bar is used to minimize vehicle front
sway during turns. The bar helps to maintain a flat
attitude to the road surface.
LOWER BALL JOINT
NOTE: If the ball joint is equipped with a lubrica-
tion fitting, grease the joint then road test the vehi-
cle before performing test.
(1) Raise the front of the vehicle. Place safety floor
stands under both lower suspension arms as far out-
board as possible. Lower the vehicle to allow the
stands to support some or all of the vehicle weight.
NOTE: The upper suspension arms must not con-
tact the rebound bumpers.
(2) Remove the tire and wheel assemblies.
(3) Mount a dial indicator solidly to the underside
of the lower suspension arm.
(4) Position indicator plunger against the bottom
surface of the steering knuckle lower ball joint boss.
NOTE: The dial indicator plunger must be perpen-
dicular to the machined surface of the steering
knuckle lower ball joint boss (Fig. 2).
(5) Position a pry bar over the top of the upper
suspension arm and under the pivot bar of the upper
suspension arm. Pry down on the upper suspension
arm and then zero the dial indicator.
(6) Reposition the pry bar under the upper suspen-
sion arm and on top of the jounce/rebound bracket.
Pry up on the upper suspension arm and record the
dial indicator reading.
(7) If the travel exceeds 1.52 mm (0.060 in.),
replace the lower control arm.
UPPER BALL JOINT
(1) Position a floor jack under the lower suspen-
sion arm. Raise the wheel and allow the tire to
lightly contact the floor (vehicle weight relieved from
the tire).

(2) Mount a dial indicator solidly on the upper sus-
pension arm.
(3) Position the indicator plunger against the back
side of the upper ball joint boss of the steering
knuckle (Fig. 3).
(4) Grasp the top of the tire and pull outward,
then zero the dial indicator.
(5) Grasp the top of the tire and push inward and
record the dial indicator reading.
(6) If lateral movement is greater than 1.52 mm
(0.060 in.), replace upper suspension arm.
SHOCK DIAGNOSIS
conditions exist.
The shock absorber bushings do not require any
type of lubrication. Do not attempt to stop bushing
noise by lubricating them. Grease and mineral oil-
base lubricants will deteriorate the bushing.
SHOCK ABSORBER
REMOVAL
(2) Remove the upper shock absorber nut, retainer
and grommet (Fig. 4).
(3) Remove the lower bolt and remove the shock
absorber.
INSTALLATION
(1) Install the lower retainer (lower retainer is
stamped with a L) and grommet on the shock
absorber stud. Insert the shock absorber through the
frame bracket hole.
(2) Install the lower bolt and tighten the bolt to
108 N·m (80 ft. lbs.).
(3) Install the upper grommet, retainer (upper
retainer is stamped with a U) and new nut or use
Mopar Lock ’N Seal or Loctite௡ 242 on existing nut,
on the shock absorber stud. Tighten nut to 26 N·m
(19 ft. lbs.).
Fig. 2 Lower Ball Joint Boss
Fig. 3 Upper Ball Joint Boss

TORSION BAR
CAUTION: The left and right side torsion bars are
NOT interchangeable. The bars are identified and
stamped R or L, for right or left. The bars do not
have a front or rear end and can be installed with
either end facing forward.
REMOVAL
(1) Raise and support the vehicle with the front
suspension hanging.
(2) Turn the adjustment bolt counterclockwise to
release spring load (Fig. 5).
NOTE: Count and record the number of turns for
installation reference.
(3) Remove the adjustment bolt from swivel.
(4) Remove torsion bar and anchor. Remove anchor
from torsion bar.
(5) Remove all foreign material from torsion bar
mounting in anchor and suspension arm.
(6) Inspect adjustment bolt, bearing and swivel for
damage.
INSTALLATION
(1) Insert torsion bar ends into anchor and suspen-
sion arm.
(2) Position anchor and bearing in frame cross-
member. Install adjustment bolt through bearing,
anchor and into the swivel.
(3) Turn adjustment bolt clockwise the recorded
amount of turns.
(4) Lower vehicle and adjust the front suspension
height. Refer to Suspension Height service procedure.
STEERING KNUCKLE
REMOVAL
(3) Remove brake caliper, rotor, shield and ABS
wheel speed sensor if equipped. Refer to Group 5
Brakes.
(4) Remove front driveshaft, refer to Group 3 Dif-
ferential and Driveline.
(5) Remove tie rod end cotter pin and nut. Sepa-
rate the tie rod from the knuckle with Remover
MB-991113 (Fig. 6).
(6) Support the lower suspension arm with a
hydraulic jack and raise the jack to unload the
rebound bumper.
(7) Remove the upper ball joint cotter pin and nut.
Separate the ball joint from the knuckle with
Remover MB-991113 (Fig. 7).
ball joint seal.
Fig. 4 Shock Absorber
1 – NUT
2 – RETAINER
3 – GROMMET
4 – SHOCK
Fig. 5 Torsion Bar
1 – SWIVEL
2 – ANCHOR
3 – BEARING
4 – ADJUSTMENT BOLT
5 – TORSION BAR

(8) Remove the lower ball joint cotter pin and nut.
Separate the ball joint from the knuckle with
Remover C-4150A (Fig. 8) and remove the knuckle.
(9) Remove the hub/bearing from the steering
knuckle.
INSTALLATION
(1) Install the hub/bearing to the steering knuckle
and tighten the bolts to 166 N·m (123 ft. lbs.).
NOTE: When installing hub/bearing with ABS
brakes, position the speed sensor opening towards
the front of the vehicle.
(2) Install the knuckle onto the upper and lower
ball joint.
CAUTION: The ball joint stud tapers must be
CLEAN and DRY before installing the knuckle.
Clean the stud tapers with mineral spirits to remove
dirt and grease.
(3) Install the upper and lower ball joint nuts.
Tighten the upper ball joint nut to 81 N·m (60 ft.
lbs.) and the lower ball joint nut to 183 N·m (135 ft.
lbs.) then install cotter pins. Grease the lower ball
joint.
(4) Remove the hydraulic jack from the lower sus-
pension arm.
(5) Install the tie rod end and tighten the nut to
88 N·m (65 ft. lbs.). Install the cotter pin.
(6) Install the front driveshaft, refer to Group 3
Differential and Driveline.
(7) Install the ABS wheel speed sensor if equipped
and brake shield, rotor and caliper. Refer to Group 5
Brakes.
LOWER SUSPENSION ARM
REMOVAL
(2) Remove the wheel and tire assembly.
(3) Remove front driveshaft, refer to Group 3 Dif-
ferential & Driveline.
(4) Remove torsion bar.
(5) Remove shock absorber lower bolt.
(6) Remove stabilizer bar.
(7) Remove the cotter pin and nut from lower ball
joint. Separate ball joint from the steering knuckle
with Remover C-4150A (Fig. 9).
(8) Remove suspension arm pivot bolts and sus-
pension arm from frame rail brackets (Fig. 10).
Fig. 6 Tie Rod End
2 – REMOVER
3 – TIE ROD END
Fig. 7 Upper Ball Joint
1 – UPPER BALL STUD
2 – REMOVER
1 – REMOVER
2 – LOWER BALL STUD

(9) Inspect lower ball joint seal and replace if dam-
aged. Pry off old seal with screw driver if necessary.
INSTALLATION
(1) Install new lower ball joint seal by tapping on
around the seal flange lightly with a hammer.
(2) Position the lower suspension arm at the frame
rail brackets. Install the pivot bolts and nuts.
Tighten the nuts finger-tight.
(3) Insert the ball joint into steering knuckle.
Install and tighten the retaining nut to 183 N·m (135
ft. lbs.) and install a new cotter pin.
CAUTION: The ball joint stud taper must be CLEAN
and DRY before installing the knuckle. Clean the
stud taper with mineral spirits to remove dirt and
grease.
(4) Install the torsion bar.
(5) Install shock absorber lower bolt and tighten to
108 N·m (80 ft. lbs.).
(6) Install the front driveshaft. Refer to Group 3
Differential & Driveline.
(9) Install the stabilizer bar.
(10) Tighten the lower suspension front pivot nut
to 108 N·m (80 ft. lbs.). Tighten rear pivot bolt to 190
N·m (140 ft. lbs.).
(11) Adjust the front suspension height.
UPPER SUSPENSION ARM
REMOVAL
(3) Remove brake hose brackets from suspension
arm, refer to Group 5 Brakes.
(4) Position hydraulic jack under lower suspension
arm and raise jack to unload rebound bumper.
(5) Remove shock absorber.
(6) Remove the cotter pin and nut from upper ball
joint.
(7) Separate upper ball joint from the steering
knuckle with Remover MB-991113 (Fig. 11).
ball joint seal.
(8) Remove suspension arm pivot bar bolts and
remove suspension arm (Fig. 12).
1 – REMOVER
2 – LOWER BALL STUD
Fig. 10 Lower Suspension Arm
1 – PIVOT BOLTS
Fig. 11 Separate Upper Ball Joint
1 – UPPER BALL STUD
2 – REMOVER

INSTALLATION
(1) Position suspension arm pivot bar on mounting
bracket. Install bolts and tighten (temporarily) to 136
N·m (100 ft. lbs.).
(2) Insert ball joint in steering knuckle and
tighten ball joint nut to 81 N·m (60 ft. lbs.) then
install a new cotter pin.
(3) Install shock absorber.
(4) Remove hydraulic jack.
(5) Attach brake hose brackets to suspension arm,
refer to Group 5 Brakes.
(6) Tighten upper suspension arm pivot bolts to
204 N·m (150 ft. lbs.).
(9) Align front suspension.
STABILIZER BAR
NOTE: To service the stabilizer bar the vehicle
must be on a drive on hoist. The vehicle suspen-
sion must be at curb height for stabilizer bar instal-
lation.
REMOVAL
(1) Remove the stabilizer bar retainer bolts from
the lower suspension arms (Fig. 13) and remove the
retainers.
(2) Remove the stabilizer bar retainer nuts, bolts
and retainers from the frame crossmember (Fig. 13)
and remove the bar.
(3) If necessary, remove the bushings from the sta-
bilizer bar.
INSTALLATION
(1) If removed, install the bushings on the stabi-
lizer bar.
(2) Position the stabilizer bar on the frame cross-
member brackets and install the retainers and nuts
and bolts finger-tight (Fig. 13).
NOTE: Check the alignment of the bar to ensure
there is no interference with the either frame rail or
chassis component. Spacing should be equal on
both sides.
(3) Install the stabilizer bar to the lower suspen-
sion arm.
(4) Install the retainers and bolts to the lower sus-
pension arm and tighten to 34 N·m (25 ft. lbs.).
(5) Tighten the frame retainer nuts to 190 N·m
(140 ft. lbs.).
(6) Tighten the frame retainer bolts to 108 N·m
(80 ft. lbs.).
HUB/BEARING
REMOVAL
(3) Remove axle nut.
(4) Remove ABS wheel speed sensor if equipped,
refer to Group 5 Brakes.
(5) Remove the brake caliper and rotor, refer to
Group 5 Brakes.
(6) Remove hub/bearing mounting bolts from the
steering knuckle (Fig. 14).
Fig. 12 Upper Suspension Arm
1 – PIVOT BAR BOLT
Fig. 13 Stabilizer Bar
2 – FLAG NUT
4 – RETAINER

(7) Slid hub/bearing out of the steering knuckle
and off the axle.
INSTALLATION
(1) Install the hub/bearing into the steering
knuckle and tighten the bolts to 166 N·m (123 ft.
lbs.).
(2) Install the brake rotor and caliper.
(3) Install ABS wheel speed sensor if equipped.
(4) Install axle nut and tighten to 235 N·m (173 ft.
lbs.) and install cotter pin.
WHEEL MOUNTING STUDS
REMOVAL
(3) Remove brake caliper and rotor, refer to Group
5 Brakes for procedure.
(4) Remove stud from hub with Remover C-4150A
(Fig. 15).
INSTALLATION
(1) Install new stud into hub flange.
(2) Install three washers onto stud, then install
lug nut with the flat side of the nut against the
washers.
(3) Tighten lug nut until the stud is pulled into
the hub flange. Verify that the stud is properly
seated into the flange.
(4) Remove lug nut and washers.
(5) Install the brake rotor and caliper, refer to
Group 5 Brakes for procedure.
(6) Install wheel and tire assembly, use new lug
nut on stud or studs that were replaced.
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Shock Absorber
Lower Bolt . . . . . . . . . . . . . . 108 N·m (80 ft. lbs.)
Lower Suspension Arm
Front Bolt . . . . . . . . . . . . . . 108 N·m (80 ft. lbs.)
Rear Bolt . . . . . . . . . . . . . . 190 N·m (140 ft. lbs.)
Ball Joint Nut . . . . . . . . . . 183 N·m (135 ft. lbs.)
Upper Suspension Arm
Pivot Shaft Nuts . . . . . . . . . 129 N·m (95 ft. lbs.)
Pivot Shaft to Frame Bolts . 204 N·m (150 ft. lbs.)
Ball Joint Nut . . . . . . . . . . . . 81 N·m (60 ft. lbs.)
Stabilizer Bar
Frame Retainer Bolt . . . . . . 108 N·m (80 ft. lbs.)
Frame Retainer Nut . . . . . . 190 N·m (140 ft. lbs.)
Control Arm Retainer Bolts . . 34 N·m (25 ft. lbs.)
Hub/Bearing
Bolts . . . . . . . . . . . . . . . . . . 166 N·m (123 ft. lbs.)
Fig. 14 Hub/Bearing
1 – HUB BEARING
Fig. 15 Wheel Stud Removal
1 – REMOVER
2 – WHEEL STUD

SPECIAL TOOLS
FRONT SUSPENSION
Puller Tie Rod C-3894-A
Remover MB-991113
Remover C-4150A

REAR SUSPENSION
TABLE OF CONTENTS
page page
SUSPENSION COMPONENT . . . . . . . . . . . . . . . . 23
SHOCK ABSORBERS . . . . . . . . . . . . . . . . . . . . . 23
STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . 23
LEAF SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SPRING AND SHOCK . . . . . . . . . . . . . . . . . . . . . 24
SHOCK ABSORBER. . . . . . . . . . . . . . . . . . . . . . . 24
STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . 25
LEAF SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DISASSEMBLY AND ASSEMBLY
SPRING EYE BUSHINGS. . . . . . . . . . . . . . . . . . . 26
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 26
SPECIAL TOOLS
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . 26
SUSPENSION COMPONENT
DESCRIPTION
The rear suspension is comprised of (Fig. 1):
• Drive Axle
• Leaf Springs
• Shock Absorbers
• Stabilizer Bar
• Jounce Bumpers
urethane bushings should be tightened with the
vehicle at normal ride height. It is important to have
the springs supporting the weight of the vehicle
when the fasteners are torqued. This will maintain
vehicle ride comfort and prevent premature bushing
wear.
SHOCK ABSORBERS
DESCRIPTION
The top of the shock absorbers are bolted to the
body crossmember. The bottom of the shocks are
bolted to the axle brackets.
OPERATION
Ride control is accomplished through the use of
dual-action shock absorbers. The shocks dampen the
jounce and rebound as the vehicle travels over vari-
ous road conditions.
STABILIZER BAR
DESCRIPTION
The stabilizer bar extends across the underside of
the vehicle and is bolted to the top of the axle. Links
at the end of the bar are bolted to the frame.
OPERATION
The stabilizer bar is used to minimize vehicle body
roll. The spring steel bar helps to control the vehicle
body in relationship to the suspension.
Fig. 1 Rear Suspension
1 – STABILIZER LINK
2 – SHOCK
3 – LEAF SPRING

LEAF SPRINGS
DESCRIPTION
The rear suspension system uses multi-leaf single
stage springs and a solid drive axle. The forward end
of the springs are mounted to the body rail hangers
through rubber bushings. The rearward end of the
springs are attached to the body by the use of shack-
les. The spring and shackles use rubber bushings.
The bushing help to isolate road noise.
OPERATION
The springs control ride quality and maintain vehi-
cle ride height. The shackles allow the springs to
change their length as the vehicle moves over various
road conditions.
SPRING AND SHOCK
conditions exist.
The spring eye and shock absorber bushings do not
require any type of lubrication. Do not attempt to
stop spring bushing noise by lubricating them.
Grease and mineral oil-base lubricants will deterio-
rate the bushing rubber.
If the vehicle is used for severe, off-road operation,
the springs should be examined periodically. Check
for broken and shifted leafs, loose and missing clips,
and broken center bolts. Refer to Spring and Shock
Absorber Diagnosis chart for additional information.
SPRING AND SHOCK ABSORBER
SPRING SAGS 1. Broken leaf. 1. Replace spring.
2. Spring fatigue. 2. Replace spring.
SPRING NOISE 1. Loose spring clamp bolts. 1. Tighten to specification.
2. Worn bushings. 2. Replace bushings.
3. Worn or missing spring tip inserts. 3. Replace spring tip inserts.
SHOCK NOISE 1. Loose mounting fastener. 1. Tighten to specification.
2. Worn bushings. 2. Replace shock.
3. Leaking shock. 3. Replace shock.
SHOCK ABSORBER
REMOVAL
(1) Raise vehicle and support rear axle.
(2) Remove shock absorber lower nut and bolt from
the spring plate (Fig. 2).
(3) Remove shock absorber upper nut and bolt
from the frame bracket and remove the shock
absorber.
INSTALLATION
(1) Install shock absorber into upper frame
bracket. Install bolt and nut and tighten nut to 95
N·m (70 ft. lbs.).
(2) Install shock absorber into the spring plate.
Install the bolt and nut and tighten nut to 95 N·m
(70 ft. lbs.).
(3) Remove axle support and lower vehicle.

STABILIZER BAR
REMOVAL
(2) Remove links upper mounting nuts and bolts.
(3) Remove the cotter pins and nuts from the links
at the stabilizer bar.
(4) Separate the links from the stabilizer bar with
Puller C-3894-A and remove the links.
(5) Remove stabilizer bar retainer bolts and retain-
ers (Fig. 3).
(6) Remove stabilizer bar and remove bushings.
INSTALLATION
(1) Install stabilizer bar bushings.
(2) Install the stabilizer bar and center it with
equal spacing on both sides.
(3) Install stabilizer bar retainers and tighten
bolts to 54 N·m (40 ft. lbs.).
(4) Install link on the frame and the stabilizer bar.
Install mounting bolts and nuts.
(6) Tighten stabilizer link upper nuts to 95 N·m
(70 ft. lbs.).
(7) Tighten stabilizer link lower nuts to 68 N·m
(50 ft. lbs.) and install a new cotter pins.
LEAF SPRINGS
CAUTION: The rear of the vehicle must be lifted
only with a jack or hoist. The lift must be placed
under the frame rail crossmember located aft of the
rear axle. Use care to avoid bending the side rail
flange.
REMOVAL
(1) Raise the vehicle at the frame.
(2) Support the axle to relieve the weight of the
axle from the springs.
(3) Remove the wheel and tire assemblies.
(4) Remove shocks from the spring plates.
(5) Remove the nuts, the U-bolts and spring plate
from the axle (Fig. 4).
(6) Remove the nut and bolt from the front spring
eye.
(7) Remove the nut and bolt form the rear spring
eye.
(8) Remove the spring from the vehicle.
(9) Remove the shackle from the frame bracket.
INSTALLATION
(1) Install shackle on the frame bracket and install
the nut and bolt finger tight.
(2) Position the spring under the rear axle pad.
Make sure the spring center bolt is inserted in the
pad locating hole.
(3) Align front spring eye with the bolt hole in the
front frame bracket. Install the spring eye bolt and
nut and tighten the spring eye nut finger-tight.
(4) Align spring shackle eye with the bolt hole in
the rear frame bracket. Install the bolt and nut and
tighten the spring shackle eye nut finger-tight.
(5) Install the spring seat, U-bolts, spring plate,
and nuts.
(6) Tighten the U-bolt nuts to 122 N·m (90 ft. lbs.).
(7) Install the shocks to the spring plates.
(8) Install the wheel and tire assemblies.
Fig. 2 Shock Absorber
1 – SHOCK
2 – SPRING PLATE
Fig. 3 Stabilizer Bar Mounting
1 – LINK
3 – RETAINER

(9) Remove the support stands from under the
frame rails. Lower the vehicle until the springs are
supporting the weight of the vehicle.
(10) Tighten the spring eye pivot bolt nut and all
shackle nuts to 115 N·m (85 ft. lbs.).
SPRING EYE BUSHINGS
DISASSEMBLE
(1) Remove the spring from the vehicle.
(2) Position the spring eye in a press.
(3) Press the bushing out with an appropriate size
driver.
ASSEMBLE
(1) Press new bushing into the spring eye with an
appropriate size driver. The bushing should be cen-
tered in the spring eye.
(2) Install the spring on the vehicle.
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Shock Absorber
Lower Nut . . . . . . . . . . . . . . . 95 N·m (70 ft. lbs.)
Stabilizer Bar
Link Upper Nut . . . . . . . . . . . 95 N·m (70 ft. lbs.)
Link Lower Nut . . . . . . . . . . . 68 N·m (50 ft. lbs.)
Retainer Bolts . . . . . . . . . . . . 54 N·m (40 ft. lbs.)
Spring
U-Bolt Nuts . . . . . . . . . . . . . 122 N·m (90 ft. lbs.)
Spring Eye Nut . . . . . . . . . . 115 N·m (85 ft. lbs.)
Spring Shackle Nuts . . . . . . 115 N·m (85 ft. lbs.)
Jounce Bumper
Bolts . . . . . . . . . . . . . . . . . . . 61 N·m (45 ft. lbs.)
SPECIAL TOOLS
REAR SUSPENSION
Fig. 4 Leaf Spring
1 – U-BOLTS
2 – SHACKLE
3 – SPRING
4 – SPRING PLATE
Puller C-3894-A

DIFFERENTIAL AND DRIVELINE
TABLE OF CONTENTS
page page
PROPELLER SHAFTS . . . . . . . . . . . . . . . . . . . . . . . 1
FRONT AXLE DRIVESHAFTS . . . . . . . . . . . . . . . . 18
C205F AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8 1/4 AND 9 1/4 AXLE . . . . . . . . . . . . . . . . . . . . . 59
PROPELLER SHAFTS
TABLE OF CONTENTS
page page
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . 1
CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . 2
PROPELLER SHAFT JOINTS. . . . . . . . . . . . . . . . . 4
PROPELLER SHAFT JOINT ANGLE. . . . . . . . . . . . 4
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
UNBALANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE PROCEDURES
DRIVELINE ANGLE MEASUREMENT
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PROPELLER SHAFT ANGLE MEASUREMENT. . . . 7
FRONT PROPELLER SHAFT . . . . . . . . . . . . . . . . . 8
REAR PROPELLER SHAFT . . . . . . . . . . . . . . . . . 10
CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . 11
SINGLE CARDAN UNIVERSAL JOINT . . . . . . . . . 11
DOUBLE CARDAN JOINT . . . . . . . . . . . . . . . . . . 13
CLEANING AND INSPECTION
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . 16
ADJUSTMENTS
REAR AXLE PINION INPUT ANGLE . . . . . . . . . . . 16
CENTER BEARING ADJUSTMENT. . . . . . . . . . . . 17
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SPECIAL TOOLS
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . 17
PROPELLER SHAFT
DESCRIPTION
A propeller shaft (Fig. 2), (Fig. 3), and (Fig. 4) is
the shaft which connects the transmission/transfer
case to the axle differential. This is the link through
which the engine power is transmitted to the axle.
The propeller shaft is designed and built with the
yoke lugs in line with each other which is called zero
phasing. This design produces the smoothest running
condition, an out-of-phase shaft can cause a vibra-
tion.
Tubular propeller shafts are balanced by the man-
ufacturer with weights spot welded to the tube.
PRECAUTIONS
Use the exact replacement parts when installing
the propeller shafts. The use of the correct replace-
ment parts helps to ensure safe operation. All fasten-
ers must be torqued to the specified values for safe
operation.
Also make alignment reference marks (Fig. 1) on
the propeller shaft yoke and axle, or transmission,
yoke prior to servicing. This helps to eliminate possi-
ble vibration.
CAUTION: Do not allow the propeller shaft to drop
or hang from any propeller shaft joint during
removal. Attach the propeller shaft to the vehicle
underside with wire to prevent damage to the joints.
DN DIFFERENTIAL AND DRIVELINE 3 - 1

2000 DODGE DURANGO Service Repair Manual

2000 DODGE DURANGO Service Repair Manual

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2000 DODGE DURANGO Service Repair Manual