2004 SUSPENSION Front - TSX DESCRIPTION NOTE: For system description and component location, see Fig. 1. Fig. 1: Identifying Front Suspension Components Wednesday, March 12, 2008 8:30:45 8:30:55 PM Page 1
ADJUSTMENTS WHEEL ALIGNMENT See SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT. WHEEL BEARING END PLAY 1. Raise vehicle, and ensure it is securely supported. 2. Remove wheels, and reinstall wheel nuts to the specification. See TORQUE SPECIFICATIONS. 3. Attach dial gauge against hub flange. 4. Measure bearing end play moving the brake disc inward or outward. See Fig. 2. 5. If the bearing end play measurement is more than.002" (.05 mm), replace the wheel bearing. Wednesday, March 12, 2008 8:30:45 PM Page 2
Fig. 2: Identifying Wheel Bearing End Play REMOVAL & INSTALLATION Wednesday, March 12, 2008 8:30:45 PM Page 3
BALL JOINT NOTE: Always use a ball joint remover to disconnect a ball joint. Do not strike the housing or any other part of the ball joint connection to disconnect it. Removal 1. Install a hex nut (A) onto the threads of the ball joint (B). See Fig. 3. Make sure the nut is flush with the ball joint pin end to prevent damage to the threaded end of the ball joint pin. 2. Apply grease to the special tool on the areas shown (A). See Fig. 4. 3. Loosen the pressure bolt (A), and install the ball joint boot clip guide. See Fig. 5. Insert the jaws carefully, making sure not to damage the ball joint boot. Adjust the jaw spacing by turning the adjusting bolt (B). 4. After adjusting the adjusting bolt, make sure the head (C) of the adjusting bolt is in the position shown to allow the jaw to pivot. 5. With a wrench, tighten the pressure bolt until the ball joint pin pops loose from the steering arm or knuckle. If necessary, apply penetrating type lubricant to loosen the ball joint pin. NOTE: Do not use pneumatic or electric tools on the pressure bolt. 6. Remove the tool, then remove the nut from the end of the ball joint pin, and pull the ball joint out of the steering arm or knuckle. Inspect the ball joint boot, and replace it if damaged. Wednesday, March 12, 2008 8:30:45 PM Page 4
Fig. 3: Installing Hex Nut Wednesday, March 12, 2008 8:30:45 PM Page 5
Fig. 4: Applying Grease To Ball Joint Remover Wednesday, March 12, 2008 8:30:45 PM Page 6
Fig. 5: Installing Ball Joint Remover BALL JOINT BOOT Replacement 1. Remove the boot clip and the boot. 2. Pack the interior and lip (A) of a new boot with grease. See Fig. 6 Keep the grease off of the boot-toknuckle mating surface (B). 3. Wipe the grease off the tapered portion of the pin (C), and pack fresh grease into the base (D). Do not let dirt, or other foreign materials get into the boot. 4. Install the boot on the ball joint, then squeeze it gently to force out any air. 5. Adjust the special tool with the adjusting bolt (A) until its base is just above the groove around the bottom Wednesday, March 12, 2008 8:30:45 PM Page 7
of the boot. See Fig. 7. Then slide the clip (B) over the tool and into position on the boot. 6. After installing a boot, wipe any grease off the exposed portion of the ball joint pin. Fig. 6: Inspecting Ball Joint Boot Wednesday, March 12, 2008 8:30:45 PM Page 8
Fig. 7: Installing Ball Joint Boot KNUCKLE/HUB/WHEEL BEARING NOTE: For component locations and exploded view of Knuckle & Hub, see Fig. 8. Wednesday, March 12, 2008 8:30:45 PM Page 9
Fig. 8: Exploded View Of Knuckle & Hub Knuckle Hub (Removal & Installation) 1. Raise the front of the vehicle, and support it with safety stands in the proper locations. 2. Remove the wheel nuts and front wheel. See Fig. 9. 3. Remove the brake hose mounting bracket (A). See Fig. 10 4. Remove the brake caliper bracket mounting bolts (B), and remove the caliper assembly (C) from the knuckle. To prevent damage to the caliper assembly or brake hose, use a short piece of wire to hang the caliper assembly from the undercarriage. Do not twist the brake hose with force. 5. Remove the wheel sensor (A) from the knuckle. Do not disconnect the wheel sensor connector. See Fig. 11 6. Raise the stake (A), and remove the spindle nut (B). See Fig. 12. 7. Remove the 6 mm brake disc retaining screws (A). See Fig. 13. 8. Screw two 8 x 1.25 mm bolts (B) into the disc to push it away from the hub. Turn each bolt two turns at a time to prevent cocking the disc excessively. Wednesday, March 12, 2008 8:30:45 PM Page 10
9. Remove the brake disc (C) from the knuckle. NOTE: During installation, install the new cotter pin after tightening the nut, and bend its end as shown. 10. Remove the cotter pin (A) from the tie-rod end ball joint, and loosen the nut (B). See Fig. 14. 11. Disconnect the tie-rod end ball joint from the knuckle using the ball joint remover. NOTE: Do not force or hammer on the lower arm, or pry between the lower arm and the knuckle. You could damage the ball joint. Insert the new cotter pin in to the ball joint pin from the front to the rear of the vehicle, and bend its end as shown. 12. Remove the cotter pin (A) from the lower arm ball joint, and loosen the nut (B). See Fig. 15. 13. Disconnect the lower arm ball joint from the lower arm using the ball joint remover. NOTE: During installation, insert the new cotter pin into the ball joint pin from the front to the rear of the vehicle, and bend its end as shown. 14. Remove the cotter pin (A) from the upper arm ball joint, and loosen the nut (B). See Fig. 16. 15. Disconnect the upper arm ball joint from the knuckle using the ball joint remover. NOTE: Do not pull the axle shaft end outward. The inner axle shaft joint may come apart. 16. Remove the axle shaft outboard joint (A) from the knuckle (B) by tapping the axle shaft end (C) with a plastic hammer while drawing the hub outward, then remove the knuckle. See Fig. 17. 17. Install the knuckle/hub in the reverse order of removal, and note these items: Be careful not to damage the ball joint boot when installing the knuckle. Tighten all mounting hardware to the specified torque values. Before connecting the lower arm ball joint to the lower arm, degrease the threaded section and tapered portion of the ball joint pin, and the lower arm connecting hole, and the threaded section and mating surface of the castle nut. First install all the components and lightly tighten the bolts and nuts, then raise the suspension to load it with the vehicle's weight before fully tightening to the specified torque values. See TORQUE SPECIFICATIONS. Do not place the jack against the ball joint pin of the knuckle. Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the ball joint pin hole. Do not align the castle nut by loosening it. Install a new cotter pin on the castle nut after tightening. Use a new spindle nut on reassembly. Before installing the spindle nut, apply a small amount of engine oil to the seating surface of the nut. After tightening, use a drift to stake the spindle nut shoulder against the axle shaft. Wednesday, March 12, 2008 8:30:45 PM Page 11
Replace the self-locking nuts with new ones. Before installing the brake disc, clean the mating surface of the front hub and the inside of the brake disc. Before installing the wheel, clean the mating surface of the brake disc and the inside of the wheel. Check the front wheel alignment, and adjust it if necessary (see page 18-5). Fig. 9: Removing Wheel Nuts & Front Wheel Wednesday, March 12, 2008 8:30:45 PM Page 12
Fig. 10: Removing Brake Hose Mounting Bracket Wednesday, March 12, 2008 8:30:45 PM Page 13
Wednesday, March 12, 2008 8:30:45 PM Page 14
Fig. 11: Removing Wheel Sensor From Knuckle Fig. 12: Removing Spindle Nut Wednesday, March 12, 2008 8:30:45 PM Page 15
Fig. 13: Locating Brake Disc Screws Wednesday, March 12, 2008 8:30:45 PM Page 16
Fig. 14: Removing Cotter Pin From Tie-Rod End Ball Joint Wednesday, March 12, 2008 8:30:45 PM Page 17
Fig. 15: Removing Cotter Pin From Lower Arm Ball Joint Wednesday, March 12, 2008 8:30:45 PM Page 18
Fig. 16: Removing Cotter Pin From Upper Arm Joint Wednesday, March 12, 2008 8:30:45 PM Page 19
Fig. 17: Removing Hub From Axle Shaft Wheel Bearing (Removal & Installation) 1. Separate the hub (A) from the knuckle (B) using the hub dis/assembly tool and a hydraulic press. See Fig. 18. Hold the knuckle with the attachment (C) of the hydraulic press or equivalent tool. Be careful not to deform the splash guard. Hold onto the hub to keep it from falling when pressed clear. 2. Press the wheel bearing inner race (A) off of the hub (B) using the hub dis/assembly tool, a commercially availabe bering separator (C), and a press. See Fig. 19. 3. Remove the snap ring (A) and the splash guard (B) from the knuckle (C). See Fig. 20. 4. Check the front knuckle ring (A) for damage or deformation, and replace it if necessary. See Fig. 21. 5. Press the wheel bearing (A) out of the knuckle (B) using driver, attachment, and a press. See Fig. 22. Wednesday, March 12, 2008 8:30:45 PM Page 20
6. Wash the knuckle and hub thoroughly in high flash point solvent before reassembly. 7. Press a new wheel bearing (A) into the knuckle (B) using the old bearing (C), and steel plate (D), the support base, attachment, and a press. See Fig. 23. 8. Install the new front knuckle ring (A) on the inside of the knuckle by aligning the cutout portion (B) on the ring with the wheel sensor hole (C) in the knuckle. See Fig. 24. Be careful not to damage or deform the ring when installing it. 9. Install the snap ring (A) securely in the knuckle (C). See Fig. 20. 10. Install the splash guard (B), and tighten the screws to specifications. See TORQUE SPECIFICATIONS. 11. Press a wheel bearing (A) onto the hub (B) using attachment, driver, support base, and a press. See Fig. 25. Fig. 18: Separating Hub From Knuckle Wednesday, March 12, 2008 8:30:45 PM Page 21
Fig. 19: Pressing Wheel Bearing Inner Race Off Wednesday, March 12, 2008 8:30:45 PM Page 22
Fig. 20: Removing Snap Ring & Splash Guard Wednesday, March 12, 2008 8:30:45 PM Page 23
Fig. 21: Separating Hub From Knuckle Wednesday, March 12, 2008 8:30:45 PM Page 24
Fig. 22: Pressing Wheel Into Knuckle Wednesday, March 12, 2008 8:30:45 PM Page 25
Fig. 23: Pressing Wheel Bearing Into The Knuckle Wednesday, March 12, 2008 8:30:45 PM Page 26
Fig. 24: Installing Front Knuckle Ring Wednesday, March 12, 2008 8:30:45 PM Page 27
Fig. 25: Pressing Wheel Bearing Onto Hub LOWER ARM Wednesday, March 12, 2008 8:30:45 PM Page 28
Removal & Installation 1. Raise the front of the vehicle, and support it with safety stands in the proper locations. NOTE: During installation, insert the damper fork into the damper lower end so the aligning tab (D) is aligned with slot (E) in the damper fork. Replace the damper fork mounting nut (F) with a new one. 2. Remove the front wheels. 3. Remove the damper fork (A) from the damper (B) and lower arm (C). See Fig. 26. 4. Remove the flange nut (A) while holding the joint pin (B) with a hex wrench (C), disconnect the stabilizer link (D) from the lower arm (E). See Fig. 27. NOTE: To avoid damaging the ball joint, install a hex nut on the threads of the ball joint. Be careful not to damage the ball joint boot when installing the remover. Do not force or hammer on the lower arm, or pry between the lower arm and knuckle. You could damage the ball joint. Insert the new cotter pin into the ball joint pin hole from the front to the rear of vehicle, and bend its end as shown. See Fig. 15. 5. Remove the cotter pin (A) from the lower ball joint castle nut (B), remove the nut. 6. Disconnect the lower arm ball joint from the knuckle using ball joint remover. 7. Remove the flange bolts, nuts and washers, remove the lower arm (A). See Fig. 28. 8. Install the lower arm in the reverse order of removal, and note these items: Be careful not to damage the ball joint boot when connecting the lower arm to knuckle. Tighten all mounting hardware to the specified torque. See TORQUE SPECIFICATIONS. First install all the components and lightly tighten the bolts and nuts, then raise the suspension to load it with the vehicle's weight before fully tightening it to specified torque. See TORQUE SPECIFICATIONS. DO NOT place the jack against the ball joint pin of the knuckle. Tighten the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the ball joint pin hole. DO NOT align the castle nut by loosening it. Install a new cotter pin on the castle nut after tightening. Before installing the wheel, clean the mating surface of the brake disc and the inside of the wheel. Check the wheel alignment and adjust it if necessary. See SPECIFICATIONS & PROCEDURES - TSX article in WHEEL ALIGNMENT. Before connecting the lower arm ball joint to the lower arm, degrease the threaded section and tapered portion of the ball joint pin, and the lower arm connecting hole, and the threaded section and mating surface of the castle nut. Wednesday, March 12, 2008 8:30:45 PM Page 29
Fig. 26: Removing/Installing Damper Fork Wednesday, March 12, 2008 8:30:45 PM Page 30
Wednesday, March 12, 2008 8:30:45 PM Page 31
Fig. 27: Disconnecting Stabilizer Link From Lower Arm Fig. 28: Removing Lower Arm STABILIZER LINK Removal & Installation 1. Raise the front of the vehicle, and support it with safety stands in the proper locations. 2. Remove the self-locking nut (A) and flange nut (B) while holding the respective joint pin (C) with a hex wrench (D), remove the stabilizer link (E). See Fig. 29. NOTE: The left stabilizer link has a yellow paint mark (D), while the right stabilizer Wednesday, March 12, 2008 8:30:45 PM Page 32
link has a white paint mark. 3. Install the stabilizer link (A) on the stabilizer bar (B) and lower arm (C) with the joint pins set at the center of their range of the movement. See Fig. 30. NOTE: Use a new self-locking nut on reassembly. 4. Install a new self-locking nut and flange nut, and lightly tighten them. NOTE: Do not place the jack against the ball joint pin of the knuckle. 5. Place the floor jack under the lower arm, and raise the suspension to load it with the vehicle's weight. 6. Tighten the new self-locking nut (A) and flange nut (B) to the specification while holding the respective joint pins (C) with a hex wrench (D). See TORQUE SPECIFICATIONS. See Fig. 30. 7. After 5 minutes of driving, tighten the self-locking nut to the specification. See TORQUE SPECIFICATIONS. Wednesday, March 12, 2008 8:30:45 PM Page 33
Fig. 29: Removing Stabilizer Link Wednesday, March 12, 2008 8:30:45 PM Page 34
Wednesday, March 12, 2008 8:30:45 PM Page 35
Fig. 30: Installing Stabilizer Link STABILIZER BAR Removal & Installation 1. Raise the front of the vehicle, and support it with safety stands in the proper locations and remove the front wheels. 2. Disconnect the stabilizer links from the stabilizer bar on the right and left. 3. Remove the front suspension subframe (A) from the body. See Fig. 31. 4. Remove the flange bolts (B) and bushing holders (C), then remove the bushings (D) and the stabilizer bar (E). 5. Install the stabilizer bar in reverse order of removal and note the following items: Note the right and left direction of the stabilizer bar. Align the ends of the paint marks (A) on the stabilizer bar with each end of the bushings (B). See Fig. 32. Note the before/after direction of the bushing holders. See STABILIZER LINK connect the stabilizer bar to the links. Wednesday, March 12, 2008 8:30:45 PM Page 36
Fig. 31: Removing Front Suspension Subframe Wednesday, March 12, 2008 8:30:45 PM Page 37
Fig. 32: Aligning Ends Of Paint Marks On Stabilizer Bar STRUT/SPRING Wednesday, March 12, 2008 8:30:45 PM Page 38
NOTE: Strut assembly may also be known as damper assembly. NOTE: For exploded view of strut components, see Fig. 33. Removal 1. Raise the front of the vehicle, and support it with safety stands in the proper locations. 2. Remove the front wheel. 3. Remove the damper fork (A) from the damper (B) and lower arm. See Fig. 34. 4. Remove the two 8 mm flange nuts (A) and three 10 mm flange nuts (B) from the top of the damper, and remove the damper assembly (C). See Fig. 35. Wednesday, March 12, 2008 8:30:45 PM Page 39
Fig. 33: Exploded View Of Strut Wednesday, March 12, 2008 8:30:45 PM Page 40
Fig. 34: Removing Damper Fork From Damper Wednesday, March 12, 2008 8:30:45 PM Page 41
Fig. 35: Removing Flange Nuts From Top Of Damper Disassembly/Inspection 1. Compress strut spring with appropriate available strut spring compressor (A), according to the manufacturer's instructions. See Fig. 36. Remove the self-locking nut (B) while holding the damper shaft (C) with a hex wrench (D). DO NOT compress the spring more than necessary to remove the nut. 2. Release pressure from strut spring compressor, disassemble strut. See Fig. 33. 3. Reassemble all parts, except for the spring. Compress strut assembly by hand, and check for smooth operation through a full stroke, both compression and extension. The strut should extend in a smooth, continuous motion when compression is released. If it does not (no compression or no extension), gas is leaking, and strut should be replaced. See Fig. 37. Wednesday, March 12, 2008 8:30:45 PM Page 42
4. Check for oil leaks, abnormal noises, or binding during these tests. Fig. 36: Compressing Strut Wednesday, March 12, 2008 8:30:45 PM Page 43
Fig. 37: Checking Strut For Leaks Reassembly Wednesday, March 12, 2008 8:30:45 PM Page 44
NOTE: For exploded view of strut components, see Fig. 33. 1. Assemble the damper disassembled parts except for the washer and self-locking nut. 2. Install the damper assembly on the appropriate available strut spring compressor (A), and compress the spring lightly. See Fig. 38. 3. Align the bottom of the spring and the stepped part (B) of the lower spring seat. 4. Position the damper mounting base (A) so the stud bolt in it is aligned with aligning tab in the damper unit. See Fig. 39. 5. Compress the damper spring. DO NOT compress the spring excessively. 6. Install the washer (A) and a new 10 mm self-locking nut (B). See Fig. 40. Hold the damper shaft with a hex wrench, and tighten the 10 mm self-locking nut to specification. See TORQUE SPECIFICATIONS. 7. Remove the damper assembly from the strut spring compressor. Wednesday, March 12, 2008 8:30:45 PM Page 45
Fig. 38: Installing Damper On Strut Spring Compressor Wednesday, March 12, 2008 8:30:45 PM Page 46
Fig. 39: Positioning Strut Unit For Reassembly Wednesday, March 12, 2008 8:30:45 PM Page 47
Fig. 40: Tightening Strut Self-Locking Nut Installation 1. Position the damper assembly (A) in the body with the aligning tab (B) facing inside, loosely install the flange nuts. See Fig. 41. 2. Install the damper fork (A) over the axle shaft and onto the lower arm. Install the front damper in the damper fork so the aligning tab (D) is aligned with the slot (E) in the damper fork. See Fig. 26. 3. Loosely install the damper pinch bolt into the damper fork. NOTE: Use a new damper fork mounting nut on reassembly. 4. Install the flange bolt to the damper fork and lower arm, lightly tighten the new damper fork mounting Wednesday, March 12, 2008 8:30:45 PM Page 48
nut (F). See Fig. 26. 5. Place the floor jack under the lower arm, and raise the suspension to load it with the vehicle's weight. 6. Tighten the flange nuts on the top of the damper to the specification. See TORQUE SPECIFICATIONS. 7. Tighten the damper pinch bolts to the specification. 8. Tighten the flange nut on the damper fork. 9. Clean the mating surface of the brake disc and the inside of the wheel, install the front wheel. Fig. 41: Installing Strut To Frame UPPER ARM Removal & Installation 1. Remove the front damper. 2. Remove the wheel sensor bracket (A) from the upper arm (B). See Fig. 42. Wednesday, March 12, 2008 8:30:45 PM Page 49
NOTE: During installation, insert the new cotter pin into the ball joint pin hole from the front to the rear of vehicle, and bend its end. See 3. Remove the cotter pin (A) from the upper arm ball joint, and loosen the nut (B). See Fig. 43. 4. Disconnect the upper arm ball joint from the knuckle using the ball joint remover. See BALL JOINT. 5. Remove the upper arm mounting bolts (A), and remove the upper arm (B). See Fig. 44. 6. Install the upper arm in the reverse order of removal, and not the following items: Be careful not to damage the ball joint boot when connecting the upper arm to the knuckle. Tighten all mounting hardware to specified torque. See TORQUE SPECIFICATIONS, except for the upper arm mounting bolts. Tighten the castle nut to the lower torque value. See TORQUE SPECIFICATIONS, then tighten it only far enough to align the slot with the hole in the stud. DO NOT align the castle nut by loosening it. Use new cotter pin on the castle nut. Before installing the wheel, clean the mating surface on the brake disc and the inside of the wheel. Check front wheel alignment, and adjusting it if necessary. See SPECIFICATIONS & PROCEDURES - TSX article in WHEEL ALIGNMENT. Insert a rod (A) of appropriate size (O.D.6 mm/l: 300 mm) into the positioning holes (B), and place the upper arm (C) on the rod to position it before tightening the upper arm mounting bolts. See Fig. 45. Wednesday, March 12, 2008 8:30:45 PM Page 50
Fig. 42: Locating Wheel Sensor Bracket Wednesday, March 12, 2008 8:30:45 PM Page 51
Fig. 43: Inserting New Cotter Pin Into Ball Joint Wednesday, March 12, 2008 8:30:45 PM Page 52
Fig. 44: Removing Upper Arm Mounting Bolts Wednesday, March 12, 2008 8:30:45 PM Page 53
Fig. 45: Removing/Installing Upper Arm TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Knuckle/Hub Assembly Brake Caliper Mounting Bolts 80 (108) Spindle Nut (1) 181 (245) Tie Rod End-To-Knuckle Nut 40 (54) Upper Ball Joint Castle Nut 29-35 (39-47) Lower Arm Assembly Lower Arm Flange Bolt 76 (103) Lower Arm Flange Nut 32 (43) Wednesday, March 12, 2008 8:30:46 PM Page 54
Lower Arm Mounting Bolt & Self Locking Nut 47 (64) Lower Arm, Ball Joint Castle Nut 58-65 (78-88) Radius Rod-To-Lower Arm Bolts 119 (162) Stabilizer Link Flange Nut 22 (29) Stabilizer Link Self Locking Nut 28 (38) Strut Assembly Self Locking Nut (Top) (2) 22 (29) Upper Flange Nuts 37 (50) Strut Fork-To-Strut Assembly Pinch Bolt 32 (43) Strut Fork-To-Lower Arm Self Locking Nut (2) 47 (64) Upper Arm-To-Body Flange Bolt 47 (64) Wheel Lug Nuts 80 (108) INCH Lbs. (N.m) Knuckle/Hub Assembly Splash Guard Washer-Screw 88 (10) Brake Disc Retaining Screw 88 (10) Brake Hose Mounting Bolts 88 (10) Upper Arm Assembly Wheel Sensor Bracket Bolt 88 (10) (1) Non-reusable part. Replace axle spindle nut during installation. Stake nut after tightening. (2) Non-reusable part. Replace self-locking nut during installation. Wednesday, March 12, 2008 8:30:46 PM Page 55