SUSPENSION - FRONT

1996 Chevrolet Cavalier

1996 SUSPENSION
Front - General Motors Corp.

Chevrolet; Cavalier
Pontiac; Sunfire

DESCRIPTION
Suspension uses combined strut and coil spring assemblies.
Lower control arms pivot on bushings at the frame (engine cradle). See
Fig. 1. Upper end of strut rotates on a bearing. Lower end of strut is
attached to the steering knuckle. Steering knuckle pivots on a ball
joint on the lower control arm.

Fig. 1: Exploded View Of Front Suspension Components

Courtesy of General Motors Corp.

ADJUSTMENTS & INSPECTION

 WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
NOTE: See WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in
WHEEL ALIGNMENT section.

WHEEL BEARING
Bearing Looseness Check
1) Remove wheel and caliper assembly. Use 2 wheel lug nuts to
secure disc to hub. Mount dial indicator support to lower steering
knuckle ball joint or to lower control arm.
2) Position dial indicator plunger onto outer lip of hub (not
onto disc surface). Grasp disc outer edges and using a push-pull
movement, note dial indicator readings. If looseness exceeds .005" (.
127 mm), replace complete hub assembly.

NOTE: Hub and bearing assembly is sealed and requires no

maintenance or adjustment. Replace as a complete assembly.

RIDING HEIGHT
NOTE: See WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in
WHEEL ALIGNMENT section.

BALL JOINT CHECKING

1) Raise and support vehicle. Allow suspension to hang free.
Inspect ball joint seals for cracks or tears. Replace ball joint if
seal is damaged. Grasp tire at top and bottom. Moving tire inward and
outward, note horizontal movement of ball joint. Replace ball joint if
any horizontal movement exists.
2) Ball joint stud tightness in steering knuckle boss should
be checked by shaking wheel and looking for looseness at stud end or
at castle nut. When ball joint is disconnected from steering knuckle,
check ball joint free play by using finger pressure to spin ball joint
stud in its socket. If stud spins in socket, replace ball joint.

REMOVAL & INSTALLATION

CAUTION: When servicing suspension place shop towels underneath outer
joint to protect boot from damage. DO NOT overextend inner
tripot joint or internal parts may separate.

BALL JOINT
Removal
1) Raise and support vehicle. Allow suspension to hang free.
Remove wheel. Remove cotter pin and castle nut that secures ball joint
stud to steering knuckle. Use Ball Joint Separator (J-38892) to
separate ball joint stud from steering knuckle.
2) Drill out rivets securing ball joint to lower control arm,
being careful not to puncture axle shaft boot. Disconnect stabilizer
bar from lower control arm. See STABILIZER BAR. Remove ball joint.

NOTE: If ball joint cannot be removed because axle shaft is in the

way, remove axle shaft nut (hub nut). Using Front Hub
Spindle Remover (J-28733), press end of axle shaft through
hub until enough clearance exists to allow ball joint to be
removed.
 Installation
1) Install ball joint, ensuring bolts are facing upward.
Tighten bolts. See TORQUE SPECIFICATIONS. Engage ball joint stud into
steering knuckle.
2) Install castle nut and new cotter pin.
3) To complete installation, reverse removal procedure. Check
wheel alignment. See WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
article in WHEEL ALIGNMENT section.

HUB & BEARING ASSEMBLY

NOTE: Hub and bearing are not serviceable separately.

Removal
1) Raise and support vehicle. Allow suspension to hang free.
Remove wheel. Leaving brakeline connected, remove disc brake caliper
and wire aside. Remove rotor. Remove axle shaft nut and washer. See
Figs. 1 and 4.
2) Mark hub and bearing assembly in relation to steering
knuckle for installation reference. Remove bolts securing hub and
bearing assembly to steering knuckle. Remove splash shield. Using
Front Hub Spindle Remover (J-28733-A), press axle shaft toward engine.
3) Remove hub and bearing assembly.

Installation
1) Lightly grease steering knuckle bore where hub and bearing
assembly is to be installed. Remove protective plastic cover from new
hub and bearing assembly (if equipped).
2) Install hub and bearing assembly, aligning reference marks
made during removal. Tighten hub and bearing assembly bolts. Install
and tighten new axle shaft nut. See TORQUE SPECIFICATIONS. Install
splash shield. To install remaining components, reverse removal
procedure.

Fig. 2: Exploded View Of Hub & Bearing Assembly

Courtesy of General Motors Corp.

LOWER CONTROL ARM

 Removal
Raise and support vehicle. Allow suspension to hang free.
Remove wheel. Disconnect stabilizer bar from lower control arm.
Separate ball joint from lower control arm. See BALL JOINT. Remove
lower control arm bolts. Remove lower control arm.

NOTE: Tighten lower control arm bolts with vehicle weight on lower
control arms.

Installation
To install, reverse removal procedure. Tighten nuts and bolts
to specification. See TORQUE SPECIFICATIONS. Check wheel alignment.
See WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in WHEEL
ALIGNMENT section.

LOWER CONTROL ARM BUSHINGS

Removal & Installation
Remove lower control arm. See LOWER CONTROL ARM. Remove and
install bushing as illustrated. See Fig. 3.

Fig. 3: Replacing Lower Control Arm Bushings ("J", "L" & "N" Bodies)
Courtesy of General Motors Corp.

STABILIZER BAR
 Removal
1) Raise and support vehicle. Allow suspension to hang free.
Remove wheels. Disconnect stabilizer bar from lower control arms.
Disconnect stabilizer bar from frame.
2) Support rear of crossmember with adjustable jacks. Remove
rear and center crossmember bolts. See Fig. 1. Loosen, but DO NOT
remove, front crossmember bolts. Lower crossmember 3", remove
stabilizer bar. Replace worn, damaged or deteriorated bushings.

Installation
Install stabilizer bar and hand-tighten bolts. Position
crossmember and hand-tighten bolts. Ensure stabilizer bar is centered
from side to side. Tighten fasteners in following sequence. See
TORQUE SPECIFICATIONS.

* Crossmember left rear outboard bolt.

* Crossmember right rear outboard bolt.
* Crossmember front upper bolts.
* Crossmember rear inboard bolts.
* Stabilizer bar-to-frame bolts.
* Stabilizer link-to-control arm nuts.

Install wheels. Check wheel alignment. See

WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT
section.

STEERING KNUCKLE
Removal
1) Remove hub and bearing assembly. See
HUB & BEARING ASSEMBLY. Disconnect stabilizer bar from lower control
arm. See
Fig. 1. Remove tie rod end nut. Disconnect tie rod end.
2) Separate ball joint from steering knuckle. See BALL JOINT.
Mark strut in relation to steering knuckle. Remove bolts securing
strut to steering knuckle. Remove steering knuckle.

Installation
1) Install new grease seal into steering knuckle. Lubricate
seal lips. Set steering knuckle in place. Install steering knuckle
onto strut assembly but do not tighten bolts. Install steering knuckle
onto ball joint stud. Tighten ball joint stud nut. See
TORQUE SPECIFICATIONS.
2) Install hub and bearing assembly. At steering knuckle and
strut assembly, align reference marks made during removal. To install
remaining components, reverse removal procedure. Check wheel
alignment. See WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in
WHEEL ALIGNMENT section.

STRUT ASSEMBLY
WARNING: DO NOT remove nut from top of strut rod unless coil spring
has been compressed. Coil spring is under extreme pressure.
If nut is removed without first compressing spring, coil
spring will violently decompress, possibly resulting in
severe personal injury.

CAUTION: After separating strut from steering knuckle, support

steering knuckle in upright position to prevent damage to
components. DO NOT overextend axle shaft CV joints. DO NOT
chip or crack coil spring coating. Coil spring may fail if
coating is damaged.
 Removal
1) Remove nuts securing upper strut to body mount (DO NOT
remove nut on end of strut rod).
2) Raise and support vehicle, allowing suspension to hang
free. Remove wheel. Disconnect ABS wheel speed sensor connector (if
equipped). Remove brakeline bracket from strut. Disconnect tie rod end
(if necessary). Mark strut in relation to steering knuckle (if reusing
strut). Remove strut bolts. Remove strut.

Disassembly
Wear safety goggles. Slightly compress strut spring in a
spring compressor. While using a socket to prevent strut rod from
turning, remove nut from top of strut rod. Loosen spring compressor
and disassemble strut assembly.

Reassembly
To reassemble, reverse disassembly procedure. Ensure flat on
upper spring seat faces strut mounting flange. See Fig. 4. Ensure
bearing is installed into recess of upper spring seat before fully
assembling. Tighten strut rod nut. See TORQUE SPECIFICATIONS.

Installation
1) Before installation, modify strut mounting flange to allow
for camber adjustment during wheel alignment. File bottom mounting
holes on strut outer flanges to enlarge holes until they match slots
on inner flanges. See Fig. 5.
2) To install, reverse removal procedure. If installing old
strut assembly, align marks made during removal. When installing bolts
that secure strut assembly to steering knuckle, ensure machined flats
on bolt heads are horizontal. Tighten fasteners to specification. See
TORQUE SPECIFICATIONS. Check wheel alignment. See
WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT
section.

Fig. 4: Orienting Spring Seat Flat

Courtesy of General Motors Corp.
Fig. 5: Modifying Strut Flange For Camber Adjustment
Courtesy of General Motors Corp.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLE




























































Application Ft. Lbs. (N.m)

Axle Shaft Nut ................................. 185 (251)

Ball Joint
To Control Arm (Replacement Bolt/Nut) ............. ( 1)
To Steering Knuckle (Nut) .................. ( 2) 41 (56)
Brake Caliper Bolt ............................... 38 (52)
Crossmember Support Bolt ........................ 96 (130)
Hub & Bearing Assembly Bolt ...................... 70 (95)
Lower Control Arm-To-Frame Bolt
Front ......................................... 89 (120)
Rear ......................................... 125 (170)
Stabilizer Bar
To Control Arm (Nut) ........................... 13 (17)
To Crossmember (Bolt) .......................... 49 (66)
Strut Assembly
To Steering Knuckle (Bolt) ................... 133 (180)
To Upper Body Mount (Nut) ...................... 18 (24)
Rod (Shaft) Nut ................................ 52 (70)
Tie Rod End Nut .............................. ( 2) 44 (60)
Suspension Support Bolt ......................... 89 (120)
Wheel Lug Nut .................................. 100 (136)

(1) - Tighten to specification in service ball joint kit.

(2) - Tighten nut to specification, then tighten nut further
only as far as necessary to align cotter pin hole.