Push Rod

PUSH ROD

REMOVAL





1. Remove the 2 bolts attaching the support struts to the radiator upper support. Move support struts away from the radiator upper support.
2. Remove the 2 nuts mounting the radiator brackets to the radiator upper support.
3. Remove the 4 bolts mounting the radiator upper support to the front structure of the vehicle. Remove the radiator upper support.





4. Remove the radiator support bar from the vehicle.
5. Remove the mounting plates from the mounting brackets on the radiator.





6. Remove the grille from the vehicle.
7. Raise the vehicle.

NOTE: Wiring harness routing clip must be removed from the frame to allow radiator to be moved rearward far enough to allow removal of the rocker arm attaching bolt.





8. Remove the routing clip attaching the wiring harness to the frame crossmember.





9. Remove the lower mounting bolt and flag nut from the shock absorber assembly on the side of the vehicle requiring removal of the rocker arm.

NOTE: The shock assembly cannot be removed from the frame crossmember unless the lower mounting bolt for the opposite shock assembly is also loosened.

10. Loosen, but do not remove, the lower mounting bolt for the shock absorber assembly on the opposite side of the vehicle.
11. Lower the vehicle until the tires just touch the floor.





12. Remove the shock absorber assembly to rocker arm mounting bolt.





13. Remove the nut and bolt mounting the push rod to the lower control arm.





14. Remove the flag nut from the rocker arm pivot bolt.





15. Remove the nut from the bolt mounting the stabilizer bar link to the rocker arm, then remove the mounting bolt. The bolt is remove by pulling it forward until it is out of the rocker arm, then tilting the stabilizer bar attaching link inward allowing the bolt to be removed from the link.
16. With the aid of a helper, move the radiator as far rearward while lifting it up as high as possible. This is required to gain enough room to remove the rocker arm mounting bolt.
17. Remove the rocker arm mounting bolt from the rocker arm and frame bracket.





18. Remove the rocker arm and push rod as an assembly from the vehicle through the grille opening in the front of the vehicle.





19. Remove the bolt mounting the push rod to the rocker arm, then separate the push rod from the rocker arm.



INSTALLATION

CAUTION: The push rod to rocker arm mounting bolt must be installed so the head of the bolt is located on the forward facing side of the rocker arm when the rocker arm is installed in the vehicle. If the bolt is installed in the wrong direction, there will not be adequate clearance to the upper control arm mounting bolt.

1. Install the push rod on the rocker arm. Install the push rod to rocker arm mounting bolt and nut in a way that the head of the bolt is toward the front of the vehicle once the assembly is installed in the vehicle.
2. Tighten the push rod to rocker arm mounting bolt to a torque of 163 Nm (120 ft. lbs.).
3. Install the rocker arm and push rod assembly in the vehicle using the reverse order of its removal.
4. Position the rocker arm in the frame bracket.
5. With the aid of a helper, move the radiator as far rearward while lifting it up as high as possible. This is required to gain enough room to install the rocker arm mounting bolt.
6. From the radiator side of the frame bracket, install the rocker arm mounting bolt and loosely install the flag nut.





7. Tighten the rocker arm to frame bracket pivot bolt to a torque of 163 Nm (120 ft. lbs.).





NOTE: When installing the push rod to lower control arm attaching bolt, the bolt must be installed so the nut is toward the front of the vehicle. This is required to provide proper clearance to the steering knuckle when the steering is turned to the full lock position.

8. Install the bolt and nut mounting the push rod to the lower control arm. Do not tighten them at this time. The weight of the vehicle must be supported by the suspension (vehicle at curb height) when tightening this bolt.
9. Install the shock absorber.

CAUTION: When installing the shock absorber assembly into the rocker arm, care must be used so the upper bearing/bushing on the shock absorber assembly and the rocker arm are not damaged.

10. Install shock absorber assembly into rocker arm. The bushing can be installed easily installed by first carefully starting the front and back edge of the bushing into the rocker arm and then lightly tapping it into the rocker using a soft faced hammer.





11. Install the shock absorber to rocker arm mounting bolt. Tighten the bolt to a torque of 163 Nm (120 ft. lbs.).





12. Install the mounting bolt for the stabilizer bar attaching link into the rocker arm. Use the reverse sequence of the bolt removal to install it in the rocker arm.








CAUTION: Access to the stabilizer bar link bolt and rocker arm mounting bolt for torquing is from the back side of the rocker arm, between the rocker arm and A/C condenser. Extreme care must be used to avoid damaging the AIC condenser.

13. Tighten the stabilizer bar link to rocker arm mounting bolt to a torque of 61 Nm (45 ft. lbs.).
14. Raise the vehicle.





15. Install the bolt and flag nut mounting the shock absorber assembly to the frame crossmember.





16. Install the wiring harness routing clip on the frame crossmember.
17. Lower the vehicle.
18. Ensure that both rubber isolators are on the mounting pins on the bottom of the radiator.
19. Install bottom of radiator in its mounting holes in the frame crossmember.





20. Install the radiator support bar on the front structure.





21. Install the 2 mounting plates on the radiator upper mounting brackets. The mounting plates are to be installed with the weld nuts facing inward. The weld nuts must line up with the support strut mounting holes in the radiator upper support.
22. Install the radiator upper support on the front structure. Loosely install the 4 bolts mounting the radiator upper support to the front structure.
23. Loosely install the bolts mounting the support struts to the radiator upper support.
24. Tighten the 4 radiator upper support mounting bolts.
25. Tighten the 2 bolts mounting the support struts to the radiator upper support.





26. Install the grille. Install and securely tighten the 4 screws mounting the grille to the front structure.
27. Position the vehicle on a drive-on-hoist or an alignment rack so the full weight of the vehicle is supported by the suspension. Correctly jounce the vehicle to obtain the correct curb height.
28. Tighten the mounting nut and bolt for the push rod to lower control arm bushing attachment to a torque of 163 Nm (120 ft. lbs.).
29. Tighten both shock absorber assembly lower mounting bolts to a torque of 163 Nm (120 ft. lbs.).