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1 Page 1 of 8 SECTION : Suspension System - General Information 1998 Contour/Mystique Workshop Manual DIAGNOSIS AND TESTING Procedure revision date: 09/14/2001 Suspension System Special Tool(s) Dial Indicator Bracketry, or equivalent 100-D004 (D78P-4201-F) Dial Indicator, or equivalent 100-D005 (D78P-4201-G) WARNING: Make sure the tires are deflated to their correct pressures after this check is completed. Vibration, roughness, tramp, shimmy and thump may be caused by excessive tire or wheel runout, worn or cupped tires, or wheel and tire imbalance. These conditions may also be caused by rough or undulating road surfaces. Driving the vehicle on different types of road surfaces will indicate if the road surfaces are actually causing the conditions. Do not immediately suspect the tires when attempting to diagnose a vibration concern. Other sources of vibration include: Loose or worn front wheel bearing. Loose or worn suspension or steering components. Excessive front brake disc runout. Loose powertrain/drivetrain mounts. Engine driven accessories. This section covers those vibrations related to the suspension, tires and wheels. A thumping noise usually means that the tire has flat or soft spots making a noise as they slap the roadways. Tire whine can be distinguished from axle noise because axle noise diminishes or changes according to load or speed. Tire noise remains the same over a range of speeds. To verify that tire noise is not associated with shake or vibration, over inflate the tires one at a time and check for a change in the sound. The pitch or whine will change as the increased pressure changes the tire frequency. Diagnostic procedures and service for other types of vibration are included in section REFER to Section Inspection and Verification NOTE: A complete road test procedure is described in Section REFER to Section A vibration diagnostic procedure always begins with a road test. The road test and customer interview (if available) will provide much of the information needed to find the source of a vibration. During the road test, drive the vehicle on a road that is smooth and free of undulations. If vibration is apparent, note and record the following: The speed at which the vibration occurs. What type of vibration occurs in each speed range mechanical or audible. How the vibration is affected by changes in engine torque, vehicle speed and engine speed. Type of vibration sensitivity torque sensitive, vehicle speed sensitive, or engine speed sensitive. If the road test indicates the vibration is related to the tires or wheels, use the Tire Wear Condition Chart to help pinpoint the cause of the concern. If the road test indicates that there is tire whine but no shake or vibration, the noise originates with the contact between the tire and the road surface. Use the following explanation of terms to help isolate the source of the vibration: Torque Sensitive This means that the condition can be improved or worsened by accelerating, decelerating, coasting or maintaining a steady vehicle speed. Vehicle Speed Sensitive This means that the vibration always occurs at the same vehicle speed and is not affected by the application of engine torque, engine speed, or transaxle gear. Engine Speed Sensitive This means that the vibration occurs at varying vehicle speeds when a different transaxle gear is selected and the engine speed is constant. It can sometimes be isolated by increasing or decreasing engine speed with the transaxle in NEUTRAL or by stall testing with the transaxle in gear. If the condition is engine speed sensitive, the condition is not related to tires. Front End NOTE: Do not check or perform a front suspension alignment without first making the following inspection for front end damage or wear. 1. Check all tires for correct inflation pressure. 2. Raise and support the front of the vehicle. REFER to Section Grasping upper and lower surfaces of the tire, move each front wheel in and out to check front suspension ball joints and mounts for looseness, wear and damage. Tighten all loose nuts and bolts to specification. When parts are worn install new parts. REFER to Section Check the steering gear mountings and tie-rod connections for looseness. Tighten all mountings to specification. If tie-rod ends are worn or bent, install new parts. REFER to Section Remove the front wheels. Check the wheels for out-of-round and bent rims. Balance the wheel and tire assemblies on high-speed balancing equipment.

2 Page 2 of 8 5. Check the action of struts and the condition of their attachment. Refer to Strut and Spring Assembly Checks. A sticking or binding strut may not allow the vehicle to settle in a normal level position, possibly affecting the front wheel alignment. Ball Joint Lower, Inspection Have an assistant grasp the lower edge of tire and move the wheel in and out. 3. As the wheel is being moved in and out, observe the lower end of the front wheel knuckle and lower arm. Any free movement of the lower arm ball joint and its mount indicates abnormal ball joint wear. Strut and Spring Assembly Checks All vehicles are equipped with low-pressure gas pressurized hydraulic struts. These struts are not adjustable or refillable. 1. Oil Leak: A light film of oil (seepage) on the upper portion of the front or rear struts is permissible and is a result of correct strut lubrication. Seepage is a condition in which a thin film of oil may be deposited on the strut outer tube (body) and is normally noticed due to the collection of dust in this area. Struts which exhibit this seepage condition are functional units and new parts should not be installed. Leakage is a condition in which the entire strut body is covered with oil and the oil will drip from the strut onto the road. If this condition exists: Make sure that fluid observed is not from sources other than the strut. When the unit is worn or damaged install a new strut. 2. Vehicle Sag: Many new front and rear struts are installed in an effort to solve a vehicle sag concern. The struts by design are hydraulic damping units only and unlike suspension springs, do not support any suspension loads. Therefore, installing a new strut will not correct a vehicle sag concern. 3. NOTE: New struts do not need to be installed in pairs when only one unit is worn or damaged. Installing new struts in pairs: In the past it was recommended that new struts or springs be installed in pairs if one unit became unserviceable. Improved sealing, due to new technology and improved manufacturing quality checks, have added to the functional reliability of the strut. Installation of new front struts or rear struts in pairs is not required. Vehicle Inspection 1. Check all tires for correct inflation pressure. 2. Check tire condition to confirm correct front end alignment, tire balance and over all tire condition such as separation or bulges. 3. Check the vehicle for optional suspension equipment such as heavy-duty handling or trailer tow suspensions. These suspensions will have a firmer ride feeling than standard suspensions. 4. Check vehicle attitude for evidence of possible overload or sagging. Check luggage compartment area for heavy objects. 5. Road test the vehicle to confirm customer concern after carrying out the above steps. Lift Check 1. ise: ise can be caused by loose suspension or strut attachments. Verify that all attachments for the suspension components are securely fastened. If struts have a damaged integral lower mounting bushing, install new units. Check the front and rear struts for external damage. 2. Bottom/Hopping: Check condition of the rubber suspension travel stops (front strut jounce bumper). Install new parts if worn or missing. Examine for evidence of previous overload which may have damaged components. 3. Only install one new strut in place of the worn or damaged component. Bench Test The struts are gas-pressurized which results in them being fully extended when not restrained. If a strut does not fully extend, it is damaged and a new unit should be installed. Check the overall length. If the strut does not meet the overall length requirements, there is a good indication something internal is out of specification and a new strut should be installed. With the strut in the normal upright position, compress it and allow it to extend three times to purge the pressure chamber of any gas that may have been introduced during handling. CAUTION: If the combination dust shield/jounce bumper has been removed from the damper, care must be taken to avoid excessive bottoming of the rod during the compression stroke to avoid internal damage. Place the strut right side up in a vise. Operate the strut as fast as possible using as much travel as possible. The strut action should be smooth and uniform throughout each stroke. Higher resistance on extension than on compression is normal. The following conditions are abnormal: A lag or skip at reversal of travel near mid-stroke when the strut is correctly aligned and in the installed position. Seizing. ise, other than a faint swish, such as a clicking upon fast stroke reversal. Excessive fluid leakage. With the rod fully extended, any lateral motion of the rod in relation to the outer strut body. If the strut action remains erratic after purging air, install a new strut. REFER to Section REFER to Section Rear Suspension At regular intervals, the following rear suspension checks should be made: 1. Check for evidence of fluid leaks on the rear struts. (A light film of fluid is permissible. Verify fluid is not from other sources). 2. Check the rear strut operation. 3. Check the condition of the upper and lower rear suspension arm bushings and rear suspension tension strut and bushings.

3 Page 3 of 8 Symptom Chart Symptom Chart Condition Possible Sources Action Drift left or right Incorrect wheel alignment. GO to Pinpoint Test A. Steering wheel off center Vehicle attitude incorrect (front or rear, high or low). CHECK for abnormal loading, front coil spring sag, or non-standard springs. Steering gear or linkage worn or defective. CHECK the steering system. REFER to Section Tire(s). CHECK and ADJUST the tire air pressure. INSPECT the tire for excessive wear. Brake system. CHECK the brakes. REFER to Section Vehicle attitude incorrect (front or rear, high or low). CHECK for abnormal loading, spring sag or non-standard springs. Power steering gear or linkage. CHECK the steering system. REFER to Section Suspension lower arm ball joint. GO to Ball joint - Lower, Inspection. REFER to Inspection and Verification in this section. Incorrect wheel alignment. GO to Pinpoint Test B. Wheels/tires. CHECK the wheels/tires. BALANCE or INSTALL new wheels/tires as necessary. REFER to Section Tracks incorrectly Rear suspension damage. GO to Pinpoint Test C. Rough ride Front or rear stabilizer bar, connecting links or bushings. CHECK or INSTALL new suspension components as necessary. REFER to Section REFER to Section Front suspension lower arm bushing. CHECK or INSTALL new suspension components as necessary. REFER to Section Rear suspension lower arm bushing. CHECK or INSTALL new suspension components as necessary. REFER to Section Front strut and spring assembly inoperative. Rear strut and spring assembly inoperative. CHECK the front strut and spring assembly. REFER to Section CHECK the rear strut and spring assembly. REFER to Section Incorrect tire pressure. CHECK the tire pressure. REFER to Section Excessive noise Poor lubrication/wear of front wheel bearings. Poor lubrication/wear of front suspension lower arm ball joint. Incorrect tire wear Incorrect wheel alignment. GO to Pinpoint Test F. GO to Pinpoint Test E. LUBRICATE or INSTALL new suspension components as necessary. REFER to Section Incorrect tire pressure. CORRECT the tire pressure. REFER to Section Vibration Wheel/tire imbalance or excessive runout. GO to Pinpoint Test G. Wheels/tires. CHECK the tires. BALANCE or INSTALL new wheels/tires as necessary. REFER to Section Incorrect wheel alignment. GO to Pinpoint Test A. Steering system inoperative. CHECK the steering system. REFER to Section Front strut and spring assembly inoperative. GO to Pinpoint Test D. Front strut and spring assembly mounting. TIGHTEN the front strut and spring assembly mounting. CHECK and INSTALL new suspension components as necessary. Damaged front suspension lower arm. GO to Pinpoint Test E. Damaged or worn front suspension lower arm bushing. GO to Pinpoint Test E. Damaged or worn front wheel bearing. GO to Pinpoint Test G. Pinpoint Tests PINPOINT TEST A: DRIFT LEFT OR RIGHT A1 CHECK DRIFT LEFT OR RIGHT WARNING: To avoid personal injury due to the loss of vehicle control, the inspection should be carried out by two people to maintain safe driving conditions. One person should drive while the other checks the time. Adequate grip should always be maintained on the steering wheel. Failure to follow these instructions may result in personal injury. NOTE: The following conditions must be met when evaluating the vehicle. Check the cold tire pressures. Drive the vehicle at 88 km/h (55 mph) on a level and straight road. Drive in the center lane of a three lane motorway. Make sure that no crosswinds or gusting breezes are present. Drive the vehicle in both (opposing) directions at least twice. If the vehicle changes one complete 12 foot wide lane within 7 seconds, it has a drift. Does the vehicle have drift? GO to A2. GO to B2. A2 CHECK THE STEERING LINKAGE

4 Page 4 of 8 Check the steering linkage for indications of excessive wear or damage. Is there indication of excessive wear or damage? INSTALL new steering linkage components as necessary. REFER to Section TEST the system for normal operation. GO to A3. A3 CHECK THE VEHICLE ALIGNMENT Place the vehicle on an alignment rack. Check the vehicle alignment. Is the steering wheel straight and alignment within specification? A4 CHECK THE TIRES GO to A4. INSTALL new suspension components as necessary. REFER to Section (Front). REFER to Section (Rear) ADJUST the alignment to specification. TEST the system for normal operation. Inspect the tires for excessive wear or damage. Are the tires excessively worn or damaged? A5 ROTATE THE TIRES INSTALL new tires as necessary. GO to A5. Raise and support vehicle. REFER to Section Rotate the wheels in a cross pattern. Does the vehicle drift? INSTALL new suspension components as necessary. CHECK the wheel alignment. REFER to Section (Front). REFER to Section (Rear). ADJUST the alignment to specification. TEST the system for normal operation. System operational. PINPOINT TEST B: STEERING WHEEL OFF CENTER B1 INSPECT THE STEERING COMPONENTS Inspect the steering components for excessive wear or damage. Are the steering components excessively worn or damaged? INSTALL new steering components as necessary. REFER to Section TEST the system for normal operation. GO to B2. B2 CHECK THE VEHICLE ALIGNMENT Place the vehicle on an alignment rack. Is the steering wheel centered? GO to Pinpoint Test C. CHECK and INSTALL new suspension components as necessary. REFER to Section (Front). REFER to Section (Rear). ADJUST the alignment to specification. TEST the system for normal operation. PINPOINT TEST C: TRACKS INCORRECTLY C1 CHECK THE CASTER Place the vehicle on an alignment rack.

5 Page 5 of 8 Is the caster angle within specification? GO to C2. INSTALL new suspension components as necessary. REFER to Section (Front). REFER to Section (Rear). ADJUST the alignment to specification. TEST the system for normal operation. C2 CHECK THE REAR SUSPENSION Measure the vehicle wheel base left-hand and right-hand. Compare the measurements. Are the measurements the same? GO to Pinpoint Test Step D. INSPECT the rear suspension components for wear or damage. INSTALL new suspension components as necessary. REFER to Section TEST the system for normal operation. PINPOINT TEST D: ROUGH RIDE D1 CHECK THE STRUTS Make sure the tires are at the correct pressure. Inspect the struts for oil leaks or damage. Are the struts damaged or leaking? INSTALL new suspension components as necessary. REFER to Section (front). REFER to Section (rear). TEST the system for normal operation. System operational. PINPOINT TEST E: EXCESSIVE NOISE E1 INSPECT THE SUSPENSION Inspect the strut mounting bolts. Are the mounting bolts loose or broken? TIGHTEN or INSTALL new strut mounting bolts. REFER to Section (front). REFER to Section (rear). TEST the system for normal operation. GO to E2. E2 INSPECT THE SPRINGS Inspect the springs for damage. Are the springs damaged? INSTALL new springs. REFER to Section (front). REFER to Section (rear). TEST the system for normal operation. GO to E3. E3 INSPECT THE FRONT SUSPENSION LOWER ARM Inspect the front suspension lower arm bushings for excessive wear or damage. Are the lower arm bushings worn or damaged? INSTALL a new lower arm. REFER to Section TEST the system for normal operation. GO to E4. E4 INSPECT THE TIRES

6 Page 6 of 8 Inspect the tires for uneven wear. Is there uneven wear? INSTALL new tires as necessary. Adjust the alignment to specification. TEST the system for normal operation. GO to E5. E5 INSPECT THE FRONT WHEEL BEARINGS Rock each front wheel by gripping the top and bottom and alternately pushing and pulling in and out. Feel for excess looseness of the bearings. Spin each front wheel by hand and check for roughness. Are the bearings loose or rough? INSTALL new wheel bearings as necessary. REFER to Section TEST the system for normal operation. System operational. PINPOINT TEST F: INCORRECT TIRE WEAR F1 INSPECT THE TIRES Inspect the tires for uneven wear on inner or outer shoulder, or saw tooth pattern. Is there uneven tire wear? INSTALL new tire(s) as necessary. ADJUST the alignment to specification. TEST the system for normal operation. GO to F2. F2 CHECK FOR CUPPED TIRE With vehicle supported on a hoist, inspect the tires for cupping or dishing. Are tires cupped or dished? INSTALL new tire(s) as necessary. TEST the system for normal operation. Vehicle OK. PINPOINT TEST G: VIBRATION G1 INSPECT THE TIRES Inspect the tires for damage or excessive wear. Are the tires the damaged or worn? INSTALL new tire(s) as necessary. TEST the system for normal operation. GO to G2. G2 INSPECT THE FRONT WHEEL BEARINGS Rock each front wheel by gripping the top and bottom and alternately pushing and pulling in and out. Feel for excess looseness of the bearings. Spin each front wheel by hand and check for roughness. Are the bearings loose or rough? GO to G3. GO to G4.

7 Page 7 of 8 G3 MEASURE THE FRONT WHEEL BEARING END PLAY Remove the front brake disc. REFER to Section Position a dial indicator D78P-4201-G with dial indicator bracketry D78P-4201-F against the wheel hub. Push and pull the wheel hub in the axle direction and measure the end play of the wheel hub and front wheel bearing assembly. The maximum allowable end play is 0.05 mm (0.002 inch). Is the front wheel bearing end play within limits? CHECK the ball joint as outlined. GO to G4. INSTALL a new wheel hub. REFER to Section TEST the system for normal operation. G4 INSPECT THE REAR WHEEL BEARINGS Rock each rear wheel by gripping the top and bottom and alternately pushing and pulling in and out. Feel for excessive looseness of the bearings. Spin each rear wheel by hand and check for roughness. Are the bearings loose or rough? GO to G5. GO to G6. G5 MEASURE THE REAR WHEEL BEARING END PLAY Remove the rear brake drum or rear brake disc. REFER to Section REFER to Section Position a dial indicator D78P-4201-G with dial indicator bracketry D78P-4201-F against the wheel hub. Push and pull the wheel hub in the axle direction and measure the end play of the wheel hub and rear wheel bearing assembly. The maximum allowable end play is 0.05 mm (0.002 inch). Is the rear wheel bearing end play within limits? TIGHTEN the hub retaining nut. INSTALL a new the wheel bearing as necessary. REFER to Section TEST the system for normal operation. G6 MEASURE THE WHEEL/TIRE RUNOUT ON THE VEHICLE Measure the wheel and tire runouts on the vehicle using suitable equipment. Assembly runout should be less than 1.14 mm (0.045 inch) radial and lateral. Is the measurement to within specification? GO to G12. GO to G7. G7 MEASURE THE WHEEL/TIRE RUNOUT OFF THE VEHICLE Measure the wheel and tire from any position that exceeds 1.14 mm (0.045 inch) radial or lateral. Before removing the wheel, mark a wheel stud and corresponding stud hole so the wheel can be installed in same position. Remove the wheel and mount on a wheel balancer. Measure the wheel and tire runout. GO to PInpoint Test G. Wheel and tire runout should be less than 1.14 mm (0.045 inch) radial and lateral. Is the measurement to within specification? GO to G10. GO to G8. G8 MATCH MOUNTING Mark the high runout location on the tire and also on the wheel. Break the wheel and tire down and rotate the tire 180 degrees (half-way around) on the wheel. Inflate the tire and measure the runouts. If high spot is not within mm (4 inches) of first high spot on the tire. If high spot is not within mm (4inches) of first high spot on the tire. Are the wheels and tires balanced within specification? INSTALL the wheel. TEST the system for normal operation. GO to G9. G9 MEASURE THE WHEEL RUNOUT Remove the tire and mount the wheel on a wheel balancer. Measure the runout on both flanges. Runout should be less than 1.14 mm (0.045 inch) radial and lateral.

8 Page 8 of 8 Is the runout to within specification? LOCATE and MARK the low spot on the wheel and INSTALL the tire to the matching high spot on the wheel. BALANCE the wheel and tire assembly. TEST the system for normal operation. INSTALL a new wheel. CHECK the runout on the new wheel. If the new wheel is within specifications, LOCATE and MARK the low spot. INSTALL the tire, matching the high spot of the tire with low spot of the wheel. BALANCE the assembly. INSTALL on the vehicle. TEST the system for normal operation. G10 CHECK THE REAR HUB AND STUD CIRCLE RUNOUT Remove the rear wheel. Remove the rear brake disc or brake drum. Measure the hub flange face runout (greater than [0.010 inch]). Bolt circle runout (greater than 0.08 mm [0.003 inch]) and pilot radial runout (greater than 0.05 mm [0.002 inch]). Are the measurements to with specification? GO to G11. INSTALL a new rear hub. REFER to Section TEST the system for normal operation. G11 CHECK THE FRONT HUB AND STUD CIRCLE RUNOUT Remove the front brake disc. REFER to Section Measure the stud circle runout (greater than 0.06 mm [0.002 inch]) and the front brake disc radial runout (greater than 0.05 mm [0.002 inch]). Are the measurements to within specification? GO to G12. INSTALL a new hub. REFER to Section TEST the system for normal operation. G12 CHECK THE WHEEL BALANCE Balance all wheels. Road test the vehicle. Is a vibration felt? REFER to Section TEST the system for normal operation. Vehicle OK.

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