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SECTION
FSU
FRONT SUSPENSION
FSU
CONTENTS
PRECAUTIONS .......................................................... 2
Precautions .............................................................. 2
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tools ........................................ 3
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 4
NVH Troubleshooting Chart ..................................... 4
FRONT SUSPENSION ASSEMBLY ........................... 5
Components ............................................................. 5
ON-VEHICLE SERVICE ............................................. 6
Front Suspension Parts ............................................ 6
Front Wheel Alignment ............................................. 6
PRELIMINARY INSPECTION ............................... 6
GENERAL INFORMATION AND RECOMMENDATIONS .............................................................. 6
THE ALIGNMENT PROCESS .............................. 7
CAMBER AND CASTER ....................................... 7
TOE-IN .................................................................. 8
FRONT WHEEL TURNING ANGLE ..................... 8
COIL SPRING AND SHOCK ABSORBER ............... 10
Removal and Installation ........................................ 10
REMOVAL ........................................................... 10
INSTALLATION ................................................... 10
Disassembly and Assembly ................................... 10
DISASSEMBLY ................................................... 10
INSPECTION AFTER DISASSEMBLY ............... 10
ASSEMBLY ..........................................................11
FSU-1
2004 QX56
PRECAUTIONS
PRECAUTIONS
Precautions
PFP:00001
EES0010D
When installing the rubber bushings, the final tightening must be done under unladen condition and with
the tires on level ground. Oil will shorten the life of the rubber bushings, so wipe off any spilled oil immediately.
Unladen condition means the fuel tank, engine coolant and lubricants are at the full specification. The
spare tire, jack, hand tools, and mats are in their designated positions.
After installing suspension components, check the wheel alignment.
Lock nuts are not reusable. Always use new lock nuts for installation. New lock nuts are pre-oiled, do not
apply any additional lubrication.
FSU-2
2004 QX56
PREPARATION
PREPARATION
Special Service Tools
PFP:00002
A
EES0010E
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Description
Tool number
(Kent-Moore No.)
Tool name
ST29020001
(J-24319-01)
Gear arm puller
D
NT694
FSU
HT72520000
(J-25730-A)
Ball joint remover
NT146
EES0010F
Tool name
Description
NT148
Spring compressor
L
NT717
Power tool
PBIC0190E
FSU-3
2004 QX56
Symptom
BRAKES
STEERING
ROAD WHEEL
AXLE
Shudder
DIFFERENTIAL
PROPELLER SHAFT
FSU-6
Shimmy
FSU-6
FSU-6
Suspension looseness
FSU-21
Vibration
Spring fatigue
FSU-5
Parts interference
FSU-5
Shake
FSU-10
Noise
Shock absorber deformation,
damage or deflection
Reference page
FSU-4
PFP:00003
EES0010G
Use the chart below to help you find the cause of the symptom. Repair or replace parts as necessary.
x: Applicable
2004 QX56
PFP:54010
A
EES0010H
FSU
WEIA0083E
1.
Washer
2.
Spacer
3.
4.
5.
Upper seat
6.
Coil spring
7.
Dust cover
8.
Shock absorber
9.
Upper link
14. Bolt
FSU-5
2004 QX56
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
Front Suspension Parts
PFP:00000
EES0010I
Check front suspension parts for excessive play, cracks, wear and
other damage.
: Refer to FSU-5,
"Components" .
SMA525A
SFA392B
EES0010J
PRELIMINARY INSPECTION
WARNING:
Always adjust the alignment with the vehicle on a flat surface.
NOTE:
If alignment is out of specification, inspect and replace any damaged or worn rear suspension parts before
making any adjustments.
1. Check and adjust the wheel alignment with the vehicle under unladen conditions. Unladen conditions
means that the fuel, coolant, and lubricant are full; and that the spare tire, jack, hand tools and mats are in
their designated positions.
2. Check the tires for incorrect air pressure and excessive wear.
3. Check the wheels for run out and damage. Refer to WT-4, "Inspection" .
4. Check the wheel bearing axial end play. Refer to FAX-5, "WHEEL BEARING INSPECTION" .
5. Check the shock absorbers for leaks or damage.
6. Check each mounting point of the suspension components for any excessive looseness or damage.
7. Check each link, arm, and the rear suspension member for any damage.
8.
Check the vehicle height. Refer to FSU-21, "Wheelarch Height (Unladen*1 )" .
For air leveling vehicles, verify the level using Consult-II memory register 1103 and set to 0 10 mm (0
0.39 in) as necessary.
2.
FSU-6
2004 QX56
ON-VEHICLE SERVICE
Check with the manufacturer of your specific alignment machine for their recommended Service/Calibration Schedule.
Measure camber and caster of both the right and left wheels
with a suitable alignment gauge and adjust as necessary to
specification.
Camber
I
SRA096A
2.
M
LEIA0092E
Rear adjusting
bolt
1 In
1 Out
1 In
1 Out
1 In
1 Out
Front adjusting
bolt
1 Out
1 In
1 In
1 Out
1 In
1 Out
Camber
Degree minute
(Decimal degree)
0 (0)
0 (0)
7' (0.11)
-7' (-0.11)
3' (0.11)
-3' (-0.11)
3' (0.11)
-3' (-0.11)
Caster
Degree minute
(Decimal degree)
-14' (-0.11)
14' (0.11)
0 (0)
0 (0)
7' (0.11)
-7' (-0.11)
-7' (-0.11)
7' (0.11)
3.
FSU-7
2004 QX56
ON-VEHICLE SERVICE
TOE-IN
WARNING:
Make sure that no person is in front of the vehicle before pushing it.
1. Bounce the front of vehicle up and down to stabilize the vehicle height (posture).
2. Push the vehicle straight ahead about 5 m (16 ft).
3. Put a mark on base line of the tread (rear side) of both front tires
at the same height as hub center as shown. These marks are
measuring points.
AFA050
4.
5.
6.
7.
a.
b.
Adjust the toe-in by varying the length of the steering outer tierods.
Loosen the outer tie-rod lock nuts.
Adjust the toe-in by screwing the outer tie-rods in or out.
Standard length L
c.
SFA234AC
SFA486A
3.
FSU-8
2004 QX56
ON-VEHICLE SERVICE
Steering gear
Steering column
Front suspension components
If found that they are worn or damaged, replace them with new ones.
FSU
FSU-9
2004 QX56
PFP:56210
EES0010K
REMOVAL
1.
2.
3.
4.
LEIA0093E
INSTALLATION
Installation is in the reverse order of removal.
The step in the shock absorber assembly lower seat faces outside of vehicle.
EES0010L
DISASSEMBLY
1.
2.
3.
SSU002
SSU003
Check for smooth operation through a full stroke, both compression and extension.
Check for oil leakage on welded or gland packing portions.
Check piston rod for cracks, deformation or other damage and replace if necessary.
FSU-10
2004 QX56
ASSEMBLY
1.
FSU
F
SFA508A
2.
3.
J
WEIA0093E
FSU-11
2004 QX56
STABILIZER BAR
STABILIZER BAR
Removal and Installation
PFP:54611
EES0010M
REMOVAL
1.
2.
3.
LEIA0094E
INSTALLATION
Installation is in the reverse order of removal.
FSU-12
2004 QX56
UPPER LINK
UPPER LINK
Removal and Installation
PFP:54524
A
EES0010N
REMOVAL
1.
2.
3.
4.
: ST29020001 (J24319-01)
FSU
LEIA0095E
5.
I
LEIA0096E
INSTALLATION
Installation is in the reverse order of removal.
After installation, check that the front wheel alignment is within specification. Refer to FSU-6, "Front
Wheel Alignment" .
FSU-13
2004 QX56
LOWER LINK
LOWER LINK
Removal and Installation
PFP:55020
EES0010O
REMOVAL
1.
2.
3.
4.
5.
LEIA0097E
6.
Remove lower link adjusting bolts and nuts, then the lower link.
WEIA0079E
INSTALLATION
Installation is in the reverse order of removal.
After installation, check that the front wheel alignment is within specification. Refer to FSU-6, "Front
Wheel Alignment" .
FSU-14
2004 QX56
PFP:40110
A
EES0010P
The ball joints are part of the upper and lower links. Refer to FSU-13, "Removal and Installation" (upper link),
FSU-14, "Removal and Installation" (lower link).
Inspection
EES0010Q
Check the ball joint for excessive play. Replace the upper or lower link assembly if any of the following
exists:
Ball joint stud is worn.
Ball joint is hard to swing.
Ball joint play in axial directions or end play is excessive.
SWINGING FORCE
FSU
NOTE:
Before checking the axial forces and end play, turn the lower ball joint at least 10 revolutions so that the ball
joint is properly broken in.
F
1. Measure the ball joint swinging force using a suitable tool.
Measure at the cotter pin hole for upper ball joint as shown.
Measure at the groove for lower ball joint as shown.
G
WEIA0076E
2.
SFA858A
TURNING FORCE
Check the turning torque using a suitable tool.
NOTE:
Before checking the axial forces and end play, turn the lower ball
joint at least 10 revolutions so that the ball joint is properly broken in.
Turning torque B
SFA858A
FSU-15
2004 QX56
Check dust cover for damage. Replace it and the cover clamp if
necessary.
NOTE:
Before checking the axial forces and end play, turn the lower ball
joint at least 10 revolutions so that the ball joint is properly broken in.
: 0 mm (0 in)
SFA858A
FSU-16
2004 QX56
KNUCKLE
KNUCKLE
On-Vehicle Inspection and Service
PFP:40014
A
EES0010R
Make sure the mounting conditions (looseness, backlash) of each component and component status (wear,
damage) are within specifications. Refer to FSU-21, "Ball Joint" .
EES0010S
FSU
H
WDIA0043E
1.
Disc rotor
2.
4.
Splash guard
5.
Steering knuckle
3.
Wheel stud
REMOVAL
1.
2.
3.
WDIA0044E
4.
5.
6.
Remove ABS sensor from steering knuckle. Refer to BRC-64, "Removal and Installation" .
CAUTION:
Do not pull on ABS sensor harness.
Remove cotter pin, then remove lock nut from drive shaft using power tool.
Remove steering outer socket cotter pin at steering knuckle, then loosen mounting nut using power tool.
FSU-17
2004 QX56
KNUCKLE
7.
: HT72520000 (J-25730-A)
CAUTION:
To prevent damage to threads and to prevent Tool from
coming off suddenly, temporarily install mounting nut
loosely.
WGIA0130E
8.
9.
10.
11.
12.
13.
: ST29020001 (J-24319-01)
LEIA0095E
14. Remove pinch bolt from steering knuckle using power tool. Then
remove steering knuckle from lower link ball joint.
LEIA0097E
FSU-18
2004 QX56
KNUCKLE
INSTALLATION
A
WDIA0044E
FSU
FSU-19
2004 QX56
PFP:00030
EES0010T
Double-acting hydraulic
Stabilizer
Standard equipment
EES0012Y
Drive type
Camber
Degree minute (decimal degree)
2WD
4WD
Minimum
-0 51 (-0.85)
-0 33 (-0.55)
Nominal
-0 6 (-0.10)
0 12 (0.20)
Maximum
0 39 (0.65)
0 57 (0.95)
0 45 (0.75) or less
0 45 (0.75) or less
Minimum
Cross camber
3 15 (3.25)
245 (2.75)
Nominal
4 0 (4.00)
3 30 (3.50)
Maximum
4 45 (4.75)
4 15 (4.25)
0 45 (0.75) or less
0 45 (0.75) or less
13 32 (13.53)
1313 (13.22)
Minimum
Nominal
Maximum
Minimum
0 3 (0.05)
0 3 (0.05)
Nominal
0 5 (0.08)
0 5 (0.08)
Maximum
0 7 (0.12)
0 7 (0.12)
Inside
Degree minute (decimal degree)
34 31 38 31 *2
(34.52 38.52)
34 44 38 44 *4
(34.73 38.73)
Outside
Degree minute (decimal degree)
30 59 34 59 *3
(30.98 34.98)
30 29 34 29 *5
(30.48 34.48)
Caster
Degree minute (decimal degree)
Cross caster
Kingpin inclination
Degree minute (decimal degree)
SFA234AC
Distance (A B)
Total toe-in
Angle (left side and right side)
Degree minute (decimal degree)
*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
*2: Target value 37 31 (37.52)
*3: Target value 33 59 (33.98)
*4: Target value 37 44 (37.73)
*5: Target value 33 29 (33.48)
FSU-20
2004 QX56
EES0013H
D
SFA858A
Swinging force A
WEIA0076E
Turning torque B
FSU
0 mm (0 in)
EES0010W
Unit: mm (in)
LEIA0085E
Air leveling*2
Suspension type
Applied model
2WD
4WD
913
(35.94)
931
(36.65)
912
(35.91)
932
(36.69)
*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
*2: Confirm level using Consult-II, register 1103. Set rear wheel arch height to 0 if necessary.
FSU-21
2004 QX56
FSU-22
2004 QX56