Dodge Viper SRT-10 (ZB). Manual — part 10
(7) Remove bolt and nut attaching shock assembly
to bracket on lower control arm (Fig. 17).
(8) Remove cotter pin and nut from lower ball joint
stud (Fig. 19).
CAUTION: Do not strike or apply heat to steering
knuckle in an effort to separate ball joint studs from
steering knuckle.
CAUTION:
Install
Spacer,
Special
Tool
6983,
between grease seal and knuckle as shown to avoid
damaging grease seal (Fig. 20).
NOTE: Use of Spacer, Special Tool 6983, is neces-
sary to allow proper use of Puller, Special Tool
C-4150A, to release lower ball joint from knuckle.
(9) Insert Spacer, Special Tool 6983, between lower
ball joint grease seal and steering knuckle (Fig. 20).
Push Spacer in until it surrounds ball joint stud.
CAUTION: When releasing ball joint from knuckle
using Puller, Special Tool C-4150A, use care not to
pinch and damage ball joint grease seal.
(10) Install Puller, Special Tool C-4150A, over
Spacer and knuckle as shown (Fig. 21). Ball bearing
in bolt of Special Tool C-4150A must be cen-
tered in end of lower ball joint stud.
(11) Release lower ball joint from knuckle using
Puller. Remove tools.
(12) Remove nuts, cam bolts and cam washers
attaching lower control arm to mounting brackets on
frame rail (Fig. 17). Slightly spread ends of mounting
brackets to ease removal of lower control arm from
brackets.
(13) Remove lower control arm.
DISASSEMBLY - LOWER CONTROL ARM
(ISOLATOR BUSHINGS)
NOTE: The following procedure can be used for
either lower control arm isolator bushing.
Fig. 19 Knuckle Mounting
1 - UPPER BALL JOINT COTTER PIN
2 - LOWER BALL JOINT COTTER PIN
3 - TIE ROD NUT
4 - LOWER BALL JOINT NUT
5 - KNUCKLE (WITH HUB AND BEARING)
6 - UPPER BALL JOINT NUT
Fig. 20 Inserting Spacer Between Knuckle And Seal
Fig. 21 Puller And Spacer Positioned To Release
Ball Joint
1 - SPACER 6983
2 - PULLER C-4150A
2 - 14
FRONT SUSPENSION
ZB
LOWER CONTROL ARM (Continued)
CAUTION: Use a vise equipped with soft jaw caps
to protect the surface of the control arm from dam-
age.
(1) Clamp lower control arm securely in vise so
that bushing to be removed is closest to vise jaws
(Fig. 22).
NOTE: Before using Special Tool 6969B, lubricate
threads of Screw Assembly 6969-3 with appropriate
lubricant.
(2) Assemble
pieces
of
Remover,
Special
Tool
6969B, through bushing as shown (Fig. 23).
CAUTION: Do not use any type of impact wrench on
Special Tool 6969B. Use only hand tools.
(3) Hold Screw, Special Tool 6969-3, stationary
while rotating Nut, Special Tool 6969-4 clockwise.
This action will force isolator bushing out of control
arm, into Receiver, Special Tool 6969-2.
(4) Remove tools and bushing from arm. A small
portion of bushing rubber may come loose lodging
itself between Remover and control arm bushing
boar, causing some resistance during tool removal.
NOTE: For bushing installation, (Refer to 2 - SUS-
PENSION/FRONT/LOWER CONTROL ARM - ASSEM-
BLY).
ASSEMBLY - LOWER CONTROL ARM
(ISOLATOR BUSHINGS)
NOTE: The following procedure can be used for
either lower control arm isolator bushing.
(1) Squarely position isolator bushing into control
arm pivot end bore from outboard side.
NOTE: Before using Special Tool 6969B, lubricate
threads of Screw Assembly 6969-3 with appropriate
lubricant.
(2) Assemble
pieces
of
Remover,
Special
Tool
6969B, through bushing and arm as shown (Fig. 24).
Fig. 22 Control Arm Mounted In Vise (Typical)
1 - LOWER CONTROL ARM
Fig. 23 Tool 6969B Installed For Bushing Removal
1 - DOUBLE THREADED NUT 6969-4
2 - SPACER 6969-1
3 - RECEIVER 6969-2
4 - SCREW ASSEMBLY 6969-3
5 - CONTROL ARM
6 - BUSHING
7 - BEARING
Fig. 24 Tool 6969B Installed For Bushing Installation
1 - DOUBLE THREADED NUT 6969-4
2 - CUP 6969-7
3 - INSTALLER 6969-8
4 - SCREW ASSEMBLY 6969-3
5 - NEW BUSHING
6 - CONTROL ARM
7 - BEARING
ZB
FRONT SUSPENSION
2 - 15
LOWER CONTROL ARM (Continued)
CAUTION: Do not use any type of impact wrench on
Special Tool 6969B. Use only hand tools.
(3) Hold Screw, Special Tool 6969-3, stationary
while rotating Nut, Special Tool 6969-4 clockwise.
This action will draw isolator bushing into control
arm.
(4) Continue to rotate Nut until bushing metal
flange squarely contacts control arm. Do not over-
tighten Screw.
(5) Remove tools.
(6) Install lower control arm on vehicle. (Refer to 2
- SUSPENSION/FRONT/LOWER CONTROL ARM -
INSTALLATION)
INSTALLATION
NOTE: When installing cam bolts and washers, be
sure holes in cams are located at 12 O’clock (Fig.
17).
(1) Position lower control arm in mounting brack-
ets on frame. Install cam bolts as shown through
mounting brackets and lower control arm bushings
(Fig. 17). Install cam washers and nuts. DO NOT
FULLY TIGHTEN CAM BOLTS AT THIS TIME.
(2) Install lower ball joint stud into steering
knuckle. Install ball joint castle nut (Fig. 19).
Tighten castle nut to 160 N·m (118 ft. lbs.) torque.
Once nut is tightened to specified torque, it
may be necessary to continue tightening nut a
small amount to allow for cotter pin installa-
tion through castle nut and hole in ball joint
stud. DO NOT LOOSEN NUT.
(3) Install cotter pin through nut and stud of lower
ball joint (Fig. 19).
(4) Install shock assembly into mounting bracket
on lower control arm. Install shock assembly mount-
ing bolt and nut (Fig. 17). DO NOT TIGHTEN
MOUNTING BOLT AT THIS TIME.
(5) Install stabilizer bar link into mounting hole on
lower control arm (Fig. 17). Install stabilizer bar link
nut and tighten to 23 N·m (17 ft. lbs.) torque.
(6) Install ABS wheel speed sensor in steering
knuckle (Fig. 10). Install and tighten mounting bolt
to 11 N·m (100 in. lbs.) torque.
(7) Install
brake
rotor
and
brake
caliper
on
knuckle. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/ROTOR - INSTALLATION)
(8) Install wheel and tire assembly (Refer to 22 -
TIRES/WHEELS - INSTALLATION). Progressively
tighten wheel mounting nuts in proper sequence to
122 N·m (90 ft. lbs.) torque.
(9) Lower vehicle.
(10) Position vehicle on alignment rack/drive-on
hoist.
(11) Set vehicle to design height. (Refer to 2 - SUS-
PENSION/WHEEL
ALIGNMENT
-
STANDARD
PROCEDURE
-
DESIGN
HEIGHT
MEASURE-
MENT)
(12) Tighten shock assembly lower mounting bolt
to 136 N·m (100 ft. lbs.) torque.
(13) Perform wheel alignment (Refer to 2 - SUS-
PENSION/WHEEL
ALIGNMENT
-
STANDARD
PROCEDURE). Once camber and caster have
been set, tighten lower control arm cam bolt
nuts to 102 N·m (75 ft. lbs.) torque.
(14) Road test vehicle to ensure proper operation.
SHOCK ASSEMBLY
REMOVAL
NOTE: Review all Warnings and Cautions. (Refer to
2 - SUSPENSION - WARNING)
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(2) Remove wheel and tire assembly. (Refer to 22 -
TIRES/WHEELS - REMOVAL)
(3) Loosen, but do not remove, nut attaching stabi-
lizer bar link to lower control arm (Fig. 17). Back off
and position nut at end of link stud (Fig. 18).
CAUTION: The nut must be positioned at the end of
the stabilizer bar link stud to help prevent the end
of the stud from being damaged when separating it
from the lower control arm.
(4) Position center punch in dimple on end of sta-
bilizer bar link stud (Fig. 18). Strike center punch
with hammer, releasing link stud from lower control
arm. Remove nut.
(5) Remove bolt and nut attaching shock assembly
to bracket on lower control arm (Fig. 17).
(6) Remove bolt and nut attaching shock assembly
to bracket on frame (Fig. 17).
(7) Using a pry bar, carefully push down on upper
control arm far enough to remove top of shock assem-
bly from frame bracket.
(8) Remove
shock
assembly
from
vehicle,
out
through center of upper front control arm.
DISASSEMBLY
The shock assembly must be removed from the
vehicle for it to be disassembled and assembled.
(Refer
to
2
-
SUSPENSION/FRONT/SHOCK
-
REMOVAL).
2 - 16
FRONT SUSPENSION
ZB
LOWER CONTROL ARM (Continued)
NOTE: If both front shock assemblies are being ser-
viced at the same time, mark the coil spring and
shock assembly according to which side of the
vehicle the shock absorber was removed from, and
which shock absorber the coil spring was removed
from.
(1) Position the shock assembly in the strut coil
spring
compressor
following
the
manufacturers
instructions. First, set the lower hooks on the coil
spring (Fig. 25), then set the upper hooks (Fig. 26).
(2) Compress the coil spring until enough room is
given to remove the coil spring upper seat.
(3) Remove the coil spring upper seat. To remove
the upper seat, pull up on the shock absorber, collar
and jounce bumper, then remove the seat utilizing
the cutout in its side (Fig. 27).
(4) Remove the shock absorber out through the
bottom of the coil spring. Depending on upper
hook positioning, it may be necessary to release
the tension from the coil spring by backing off
the compressor drive first, before the shock col-
lar and upper eye can be pulled through the
coil spring.
NOTE: If the coil spring needs to be serviced, pro-
ceed with the next step, otherwise, proceed with
step 6.
(5) Release the tension from the coil spring by
backing off the compressor drive fully. Push back the
compressor upper hooks and remove the coil spring
from the spring compressor.
Fig. 25 Lower Hooks Positioned
1 - SHOCK ABSORBER ASSEMBLY
2 - COMPRESSOR
3 - LOWER HOOKS
4 - COIL SPRING
Fig. 26 Upper Hooks Positioned
1 - SHOCK ABSORBER ASSEMBLY
2 - COIL SPRING
3 - UPPER HOOKS
Fig. 27 Upper Seat Removal/Installation
1 - COLLAR
2 - COIL SPRING
3 - UPPER SEAT
4 - JOUNCE BUMPER
ZB
FRONT SUSPENSION
2 - 17
SHOCK ASSEMBLY (Continued)
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