Frame Bracket Knockout Removal

Knockout Removal:

As originally installed, the upper control cannot be adjusted for caster and camber. However, if the caster or camber is measured and found to be out of tolerance, the caster and camber can be set to the proper specifications.

Remove or Disconnect

Tools Required:
J 38794 Knockout Removal Tool

^ Raise and support the vehicle.
^ Support the lower control arms with jack or jack stands.

Important
^ The jack or stand must remain under the lower control arm during the removal and installation procedure in order to retain the lower control arm position.

1. Tire and wheel assembly.
2. Nuts (50), cams (49), and bolts (48) from the upper control arm bracket (44).
3. Lift upper control arm (45) up and to the side to gain access to the inner portion of the frame bracket.

Knockout Tool Components:

4. Frame bracket knockout using tool J 38794.
^ Do not distort frame bracket when removing knockout.
^ Apply extreme pressure lubricant to the threads of the T-bolt and insert the bolt through the knockout hole in the bracket support.

Knockout Too Intalled Inside Bracket:

^ Install bridge onto T-bolt. The forward bracket requires the bridge to be installed between the legs of the bracket due to access problems.
^ Assemble the bridge, bearing (chamfered side out), washer, and nut in order.
^ The T-bolt head and bridge must line up horizontally with the knockout; the bridge should span the knockout without interfering with the knockout procedure.
^ Tighten the T-bolt head against the knockout by turning the nut at the opposite end using a socket and torque wrench.
^ An open end or adjustable wrench may be need to prevent the T-bolt fro losing horizontal alignment with the knockout.

NOTICE: Do not subject the tool to more than 100 N.m (75 lbs. ft.) torque. Exceeding the recommended torque may damage the tool and/or bracket.

^ If the torque limit on the T-bolt is met and the knockout does not break free, use a die grinder of appropriate size. using the stamped outline as a guide, remove the knockout. (Remove the wax coating in the knockout area to make the preforation lines more visable).
^ If the outline is not visable, use the T-bolt head installed horizontally, as a template, and scribe the frame bracket.
^ Repeat the procedure on the other upper control arm frame bracket.

Install or Connect

1. Upper control arm (45) into frame brackets (44).
2. Bolts (48) and cams (49) through frame brackets (44), and control arm (45).
3. Cams (49) and nuts (50).
^ Install cams with radius toward frame brackets.
4. Partially tighten nut (50).
5. Front wheel assemblies.
6. Alignment machine heads.





Important
^ Check Front Wheel Alignment Specifications in the illustration for special requirements and alignment adjustments. Check trim height "Z" and "D." Verify alignment specifications before proceeding.

Adjust
^ Caster and camber to the correct specifications by rotating the bolt head installed through adjuster cam.

Tighten
A. Front upper control arm nuts (50) to 190 N.m (140 lbs. ft.).
B. Rear upper control arm nuts (50) to 190 N.m (140 lbs. ft.).

Adjust
^ Toe-in, refer to the illustration.

Tighten
^ Tie rod adjuster sleeve nuts to 19 N.m (14 lbs. ft.).

^ Position clamps properly.
^ Recheck alignment specifications.
^ Lower the vehicle.