1988 Chevrolet Pickup V SUSPENSION - FRONT (4WD)' 'Front Suspension - "V" Series 1988 SUSPENSION - FRONT (4WD) Front Suspension - "V" Series

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1 1988 SUSPENSION - FRONT (4WD) Front Suspension - "V" Series DESCRIPTION NOTE: Vehicle serial numbers used in this article has been abbreviated for common reference to Chevrolet and GMC models. Chevrolet models use numerical designations as listed; GMC models are identified as follows: 10 = 1500; 20 = 2500; 30 = Leaf spring assembly attaches to front axle through "U" bolts. At the wheel ends of the axle tubes the 4WD V10/20 model knuckle is attached with ball joints. All 2WD models and V30 model use a kingpin attachments. The tapered upper kingpin fits in a tapered nylon bushing. The lower kingpin is part of the bearing cap and rides in a tapered roller bearing. See Fig. 1 and Fig. 2. ADJUSTMENTS & CHECKING WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES On "V" series, caster and camber is designed into the front axle assembly and is nonadjustable. Toe-in is adjusted using the same procedure as 2WD vehicles with zero degree (nominal) as the standard setting. See WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES in WHEEL ALIGNMENT section. NOTE: Spindle needle bearings should be checked and lubricated at the same time as the front wheel bearings. Lubrication interval is 12,000 miles under normal conditions. Off road use requires shorter intervals. Spindle bearings are accessible after removing the spindle. WHEEL BEARING ADJUSTMENT 2WD Models Raise and support vehicle. Remove bearing cap and cotter pin. Tighten adjusting nut to 12 ft. lbs. (16 N.m) while rotating wheel to seat bearing. Back off adjusting nut approximately one flat. Check rotor and hub end play. End play should be " ( mm). Install cotter pin and bearing cap. 4WD Models 1. Remove locking hub. See appropriate LOCKING HUBS article. Remove outer lock nut and tighten inner adjusting nut to 50 ft. lbs. (60 N.m) while rotating hub to seat bearings. 2. Back off inner adjusting nut. Rotate hub and retighten to 35 ft. lbs. (47 N.m) on automatic hubs or 50 ft. lbs. (60 N.m) on manual hubs. Back off adjusting nut 3/8 turn maximum on automatic hubs, or enough on manual hubs to free bearing. 3. Assemble and tighten outer lock nut to 160 ft. lbs. (217 N.m). Check hub/rotor assembly end play with a Page 11

2 dial indicator. Standard end play is " ( mm). If not to specification, repeat steps 1) through 3). If end play is within specification, install locking hub assembly. Page 2

3 Page 3

4 Fig. 1: Exploded View Of Front Suspension (4WD Models) Courtesy of GENERAL MOTORS CORP. Page 4

5 Page 5

6 Fig. 2: Exploded View of Front Suspension (2WD Models) Courtesy of GENERAL MOTORS CORP. REMOVAL & INSTALLATION BRAKE ROTOR & HUB ASSEMBLY Removal (2WD Models) Raise and support vehicle. Remove tire and wheel. Remove caliper from mounting bracket and support. Do not allow caliper to hang by brake hose. Remove bearing cap and cotter pin. Remove adjusting nut, washer, outer bearing, brake rotor and hub assembly. Remove grease seal and inner bearing if necessary. Inspection Wash all bearings in solvent and check for cracked bearing cages and worn, chipped or pitted rollers. Wash hub I.D. and inspect bearing races for cracks, scoring or looseness in hub. Replace components as needed. NOTE: Always replace bearings and races as matched sets. Install new grease seal whenever hub assembly is disassembled. Ensure all parts are thoroughly lubricated. Install outer bearing race, using Bearing Installer (J ). To complete installation, reverse removal procedure. Adjust wheel bearings. Removal (4WD Models) 1. Raise and support vehicle. Remove tire and wheel. Remove brake caliper from mounting bracket and support. Do not allow caliper to hang by brake hose. Remove locking hub assembly. See appropriate LOCKING HUBS article. 2. Remove hub/rotor assembly and outer wheel bearing from spindle. Using a brass drift, remove inner wheel bearing and grease seal by tapping out with hammer. If bearing(s) and/or race(s) require replacement, drive old race out of hub. Insert brass drift, through hub, behind race. Using hammer, strike drift (alternating on each side of race) until race is removed or pressed out with arbor press. Inspection Wash all bearings in solvent. Check for cracked bearing cages and worn, chipped or pitted rollers. Wash hub I.D. and inspect bearing races for cracks, scoring or looseness in hub. Replace components as needed. NOTE: Always replace bearings and races as matched sets. Install new grease seal whenever hub assembly is disassembled. Ensure all parts are thoroughly lubricated. Page 6

7 1. If bearing races were removed, use Driver Handle (J-8092) and Front Axle Bearing Race Installer (J ) to install outer wheel bearing race into hub. Install inner race using driver handle and Front Axle Bearing Race Installer (J ). 2. Pack wheel bearings with lithium grease and install in hub. Position hub/rotor assembly onto spindle. Install adjusting nut and adjust wheel bearings. See ADJUSTMENTS & CHECKING. To complete installation, reverse removal procedure. SPINDLE CAUTION: Lubrication MUST be applied to hub and bearing components to prevent deterioration before the unit is placed in service. NOTE: For spindle removal on 2WD models, see STEERING ARM, KNUCKLE, BALL JOINTS & KINGPINS. Removal (4WD) 1. Raise and support vehicle. Remove wheel and tire assembly. Remove locking hub. See appropriate LOCKING HUBS article. Remove hub and rotor assembly. Detach spindle retaining bolts. 2. Remove spindle and thrust washer by tapping end of spindle lightly with soft-faced hammer. Inspect thrust washer and replace if excessive wear has occurred. With spindle removed from vehicle, install assembly in vise. 3. Ensure machined surface of spindle will not be damaged by vise jaws. Remove grease seals and discard. Remove needle roller bearing and inspect for excessive wear or damage. 1. If necessary, install new bearing assembly into spindle using Driver Handle (J-8092 ) and Needle Bearing Installer (J for V10-20 or J for V30). 2. Install new grease seal onto slinger with lip toward spindle. Install new "V" block oil seal with "V" block portion facing thrust washer. See Fig. 3. Relubricate needle bearing and spindle with lithium grease. Install new thrust washer over axle shaft (with chamfer toward slinger). 3. Install spindle over axle shaft. Position spindle onto knuckle. Using new spindle nuts, tighten to 65 ft. lbs. (88 N.m). Install hub/rotor assembly and automatic or manual locking hub in reverse of removal procedure. Adjust wheel bearings. Lubricate suspension components as necessary. Page 7

8 Fig. 3: Front Spindle Inspection Courtesy of GENERAL MOTORS CORP. STEERING ARM, KNUCKLE, BALL JOINTS & KINGPINS Removal (2WD Models) Raise and support vehicle. Remove tire and wheel. Remove hub/rotor assembly. Remove brake mounting bracket, steering arm and splash shield. Remove kingpin caps. Remove lock pin nut and washer. Tap out lock pin. Using a drift, remove kingpin, spacers and bushings. Remove steering knuckle and spindle assembly. Remove dust seal, shim and thrust bearing. See Fig. 7. Install new kingpin bushings. Ream bushings to " ( mm). Lubricate thrust bearing. Install steering knuckle, thrust bearing, shim and dust seal. Lubricate kingpin. Install kingpin and spacers. Install lockpin, washer and nut. Install kingpin caps. To complete installation, reverse removal procedure. NOTE: The lower ball joint must be removed before servicing the upper ball joint. Left knuckle steering arm must be removed to service upper ball joint. Removal (4WD V10/20 With Ball Joints) Page 8

9 1. Raise and support vehicle. Remove locking hub, hub/rotor assembly and spindle components. If steering arm must be removed, detach tie rod. Remove cotter pin and loosen tie rod stud nut. Tap on nut with softfaced hammer to loosen from knuckle steering arm. 2. Remove nuts and disconnect tie rod. If steering arm must be removed (to service left-hand knuckle upper ball joint), detach and discard self-locking mounting nuts. Remove arm. Remove cotter pin from upper ball joint stud. See Fig Remove stud retaining nuts. To remove knuckle assembly from yoke, insert a wedge-shaped tool between lower ball joint stud and yoke. Tap on knuckle assembly to release. Repeat procedure on upper ball joint. NOTE: Do not remove yoke upper ball joint stud adjusting sleeve unless new ball joints are being installed. If it is necessary to loosen sleeve to remove knuckle, do not loosen more than 2 threads using Ball Stud Nut Wrench (J ). CAUTION: Use caution during removal as non-hardened threads in yoke can be easily damaged by hardened threads of adjusting sleeve. 4. Before removing ball joints, detach snap ring from lower ball joint. Lower ball joint must be removed before service to upper ball joint can be performed. Install knuckle assembly in vise. 5. Using "C" Clamp (J ), Receiver (J ) and Sleeve (J ), remove lower ball joint from knuckle. Remove upper ball joint using "C" clamp, receiver, flat washer and Sleeve ( , J or J ). 1. Position new lower ball joint into knuckle bore, ensuring joint stud is straight. Using "C" clamp and Sleeve (J , J or J ), press lower ball joint into knuckle until completely seated in bore. Install new snap ring. 2. Position new upper ball joint in knuckle bore. Using "C" clamp, Installer (J ) and Sleeve (J , J or J ), press upper joint completely into knuckle bore. Position knuckle and ball joints into yoke. Install new retainer nuts (finger tight) onto studs. 3. Push up on knuckle (to keep stud from turning) while tightening lower ball joint retainer nut to 30 ft. lbs. (40 N.m). Tighten yoke upper ball joint stud adjusting sleeve to 50 ft. lbs. (70 N.m) using Spanner Wrench (J ). 4. Retighten lower ball joint retainer nut to 70 ft. lbs. (95 N.m). Tighten upper ball joint stud retainer nut to 100 ft. lbs. (136 N.m). Install new cotter pin. Do not loosen stud nut to insert cotter pin. Tighten only enough to align slot in nut to stud hole. 5. If tie rod and steering arm were removed, assemble steering arm to knuckle. Install 3 new stud adapters. Tighten 3 new self-locking mounting nuts to 90 ft. lbs. (120 N.m). 6. Install tie rod end stud in knuckle arm bore. Tighten stud nut to 45 ft. lbs. (60 N.m). Install new cotter pin. To complete installation, reverse removal procedure. Lubricate suspension components with proper grease. Removal (4WD K30 With Kingpins) Page 9

10 1. Raise and support vehicle. Remove wheel and tire assembly. Remove locking hub assembly. Remove hub and rotor assembly and spindle. If necessary, tap spindle with soft-faced hammer to free it from knuckle. Inspect bronze spacer (located between axle shaft joint assembly and bearing). If excessive wear is evident, replace spacer. 2. Remove upper kingpin cap nuts alternately (compression spring will force cap up). Remove cap, compression spring and gasket. From underside of knuckle, detach 4 screws from lower kingpin bearing cap. Remove bearing cap and lower kingpin. See Fig Remove upper kingpin tapered bushing and knuckle from yoke. Remove kingpin felt seal and knuckle. With yoke mounted in vise, remove upper kingpin with large breaker bar and Kingpin Socket (J ). Using hammer and Front Kingpin Bearing Race Remover/Installer (J-7817 ), remove lower kingpin bearing race, bearing, grease retainer and seal (all at the same time). 1. Install new grease retainer and lower kingpin bearing race using hammer and Front Kingpin Bearing Race Remover/Installer (J-7817 ). Fill grease retainer with specified grease, then lubricate bearing and install. 2. Using hammer and Kingpin Bearing Oil Seal Installer (J ), tap in seal until properly seated. Do not distort seal. It will protrude slightly from surface of yoke flange when fully installed. 3. Using hammer and Kingpin Socket (J ), install upper kingpin. Tighten to 550 ft. lbs. (748 N.m). Install new felt seal onto kingpin. Assemble knuckle. Install tapered bushing over kingpin. Install lower bearing cap and kingpin with 4 screws. Tighten (alternately and evenly) to 80 ft. lbs. (108 N.m). 4. Install compression spring onto upper kingpin bushing. Install bearing cap, with new gasket, over 4 studs. Tighten nuts (alternately and evenly) to ft. lbs. ( N.m). To complete installation, reverse removal procedure. Lubricate suspension components with proper grease. SHOCK ABSORBER Removal Raise and support vehicle. Detach nuts and eye bolts retaining upper and lower shock absorber mounts. Remove shock from vehicle. Inspect rubber mounting bushings for excessive wear or deterioration. Check shock body for damage or fluid leakage. To install, reverse removal procedure. STABILIZER BAR Removal 1. Raise and support vehicle on frame hoist. Detach nuts and bolts attaching stabilizer brackets and bushings at frame locations. Detach pivot bolts and washers at lower spring anchor plates. See Fig Remove stabilizer bar from vehicle. Inspect rubber bushings for excessive wear or deterioration. Check bar for damage. Replace components as necessary. Page 10

11 1. Apply rubber grease to stabilizer bar bushing locations. Position bar-to-frame bushings with slit toward front of vehicle. Place stabilizer bar in position on frame and install frame brackets over bushings. Ensure brackets are positioned properly over bushings. 2. Install bolts and nuts finger tight. Install pivot bolts and washers through stabilizer bar bushings and into lower spring anchor plates. See Fig. 4. Tighten all nuts and bolts. Lower vehicle. Fig. 4: Typical Stabilizer Bar Mounting Attachments Courtesy of GENERAL MOTORS CORP. LEAF SPRING & BUSHINGS Page 11

12 Removal (2WD Models) 1. Raise and support vehicle. Place adjustable jack stand under axle. Lift axle until all tension is relieved from leaf spring assembly. Disconnect shock absorber. Disconnect stabilizer bar from leaf springs and frame. Detach shackle-to-frame upper mounting nut and bolt. Detach front spring eye bolt and nut. 2. Detach "U" bolt mounting nuts and remove spring-to-axle "U" bolts. Remove spring leafs, upper anchor plate and spring spacer pads. Detach shackle-to-spring lower mounting nut and bolt. 3. Remove bushings, spacers and shackles. See Fig. 5. Inspect bushings for excessive wear or deterioration. Check spring leafs for cracks, damage or loss of arc. Replace components as necessary. To install, reverse removal procedure. Removal (4WD Models) 1. Raise and support vehicle. Place adjustable jack stand under axle. Lift axle until all tension is relieved from leaf spring assembly. Detach shackle-to-frame upper mounting nut and bolt. Detach front spring eye bolt and nut. 2. On V10-20 and left side of V30 models, remove nuts, washers, "U" bolts, plate and spacers. On right side of V30 models, remove bolts, nuts, washers, "U" bolts, plate and spacers. Remove spring. Remove shackle from springs. Page 12

13 Fig. 5: Leaf Spring Assembly & Mount Components Courtesy of GENERAL MOTORS CORP. Bushing Replacement Place spring leaf on hydraulic press and press out bushing using proper sized rod, pipe or remover tool. Press in new bushing. Ensure installer tool presses on steel outer shell of bushing. Install bushing until it protrudes an equal amount on each side of spring. To install, reverse removal procedure. Tighten "U" bolt nuts in positions No. 1 and 3 to ft. lbs. (14-34 N.m), then tighten all mounting nuts to 150 ft. lbs. (203 N.m) in sequence of See Fig. 6. Page 13

14 Fig. 6: Leaf Spring "U" Bolt Tightening Sequence Courtesy of GENERAL MOTORS CORP. Page 14

15 Fig. 7: Knuckle Hub/Rotor Assembly (Except V30/3500) Courtesy of GENERAL MOTORS CORP. Page 15

16 Fig. 8: Knuckle Hub/Rotor Assembly (V30/3500) Courtesy of GENERAL MOTORS CORP. TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Adjusting Ring-to-Spindle 50 (68) Anchor Plate-to-Knuckle Bolt 65 (88) Kingpin Cap Bolt 80 (109) Kingpin-to-Steering Knuckle (K30 Models) 550 (748) Page 16

17 Leaf Spring Eye Bolt 90 (122) Shackle Nut 2WD 90 (122) 4WD 50 (68) Axle "U" Bolt 2WD 80 (109) 4WD 150 (203) Shackle-to-Frame Nut 2WD 92 (125) 4WD 50 (68) Front Support-To-Frame Bolt 25 (34) Lock Pin-to-Steering Knuckle (4WD) 160 (217) Lock Pin Nut (2WD) 29 (40) Lower Ball Joint Nut 70 (95) Spindle-To-Knuckle Mounting Nut (1) 65 (88) Stabilizer Bar Control Arm Anchor Plate Bolt 130 (176) Frame Bracket Bolt 2WD 21 (29) 4WD K30 52 (70) All Other Models 70 (95) Stabilizer Link Bolt (2WD) 50 (68) Steering Arm-to-Steering Knuckle Nut 2WD 230 (312) 4WD 90 (122) Suspension Bumper 2WD 25 (34) 4WD 15 (20) Tie Rod End Stud Nut 45 (60) Upper Ball Joint Nut (2) 100 (136) INCH Lbs. (N.m) Kingpin Cap Bolt 60 (7) (1) Use new mounting nuts whenever spindle is removed from knuckle. (2) Plus additional torque to align cotter pin, not to exceed 130 ft. lbs. (176 N.m). Page 17

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