Tools Required

1. Install the strut assembly in the J 45400 using the following procedure.

1.1.	Adjust the lower legs of the J 45400 to the lowest possible coil of the spring.

1.2.	Adjust the upper legs of the J 45400 to the highest possible coil of the spring.

1.3.	Inspect the strut assembly to insure hooks on the strut compress legs are properly installed on the spring coils.

1.4.	Verify the strut assembly is parallel with the J 45400 .

2. Compress the spring enough to unload the upper strut mount.




Notice: Do not allow the absorber rod to rotate during disassembly/reassembly. Use hand tools to keep the absorber rod from rotating. If air tools are used, and the rod is allowed to rotate, damage to the absorber may occur.

3. Use the J 42991 or equivalent hand tools to remove the strut shaft nut.




Important: Leave the spring in the spring compressor.

4. Lower the strut from the spring assembly.




Notice: Do not handle the top mount assembly by the plastic portion. Handle the top mount assembly by the metal portion when removing/installing the top mount from/to the strut assembly. Holding the top mount assembly by the plastic portion may loosen the snap fit of the bearing components and cause the bearing to fall apart.

5. Remove the upper mount assembly, inspect for damage and deterioration. Replace as necessary.
6. Remove the strut dust shield and inspect for damage and deterioration. Replace as necessary.
7. Remove the hollow bumper from the strut shaft and inspect for damage and deterioration. Replace as necessary.
8. Inspect the spring for damage. Replace as necessary.

1. Extend the strut to its limit of travel.
2. Install the hollow bumper and dust boot to the strut shaft.




Important: The tag identifying the spring will be closer to the bottom of the spring. The end of the cold sits up against the tab on the spring seat.

3. With the spring in the compressor, install the strut into the spring.

Important: The anti-rotation tab on the spring seat must face 180 degrees from the direction that the knuckle bracket points.

4. Assemble the upper spring seat onto the strut shaft and align the flat with the strut to knuckle mounting bracket.

Notice: Do not handle the top mount assembly by the plastic portion. Handle the top mount assembly by the metal portion when removing/installing the top mount from/to the strut assembly. Holding the top mount assembly by the plastic portion may loosen the snap fit of the bearing components and cause the bearing to fall apart.

Important: The flat on the metal plate of the top mount assembly must face the same direction of the anti-rotation tab on the spring seat.

5. Assemble the top mount onto the strut shaft and align the flat 180 degrees from flat on the upper spring seat.



6. Loosely install the strut shaft nut.

Notice: Refer to Fastener Notice in the Preface section.

Notice: Do not allow the absorber rod to rotate during disassembly/reassembly. Use hand tools to keep the absorber rod from rotating. If air tools are used, and the rod is allowed to rotate, damage to the absorber may occur.

7. Hold the strut shaft and use the J 42991 or equivalent hand tools to tighten the shaft while verifying that the upper spring seat flats align with the top mount.

Tighten
Tighten the strut shaft to 85 N·m (63 lb ft).




8. Release the tension on the J 45400 .
9. Remove the strut assembly from the J 45400 .

Special Tools

1. Install the strut assembly in the J 45400 using the following procedure.

1.1.	Adjust the lower legs of the J 45400 to the lowest possible coil of the spring.

1.2.	Adjust the upper legs of the J 45400 to the highest possible coil of the spring.

1.3.	Inspect the strut assembly to insure hooks on the strut compress legs are properly installed on the spring coils.

1.4.	Verify the strut assembly is parallel with the J 45400 .

2. Compress the spring enough to unload the upper strut mount.




Caution: Do not allow the absorber rod to rotate during disassembly/reassembly. Use hand tools to keep the absorber rod from rotating. If air tools are used, and the rod is allowed to rotate, damage to the absorber may occur.

3. Use the J 42991 or equivalent hand tools to remove the strut shaft nut.




Note: Leave the spring in the spring compressor.

4. Lower the strut from the spring assembly.




Caution: Do not handle the top mount assembly by the plastic portion. Handle the top mount assembly by the metal portion when removing/installing the top mount from/to the strut assembly. Holding the top mount assembly by the plastic portion may loosen the snap fit of the bearing components and cause the bearing to fall apart.

5. Remove the upper mount assembly, inspect for damage and deterioration. Replace as necessary.
6. Remove the strut dust shield and inspect for damage and deterioration. Replace as necessary.
7. Remove the hollow bumper from the strut shaft and inspect for damage and deterioration. Replace as necessary.
8. Inspect the spring for damage. Replace as necessary.

1. Extend the strut to its limit of travel.
2. Install the hollow bumper and dust boot to the strut shaft.




Note: The tag identifying the spring will be closer to the bottom of the spring. The end of the cold sits up against the tab on the spring seat.

3. With the spring in the compressor, install the strut into the spring.

Note: The anti-rotation tab on the spring seat must face 180 degrees from the direction that the knuckle bracket points.

4. Assemble the upper spring seat onto the strut shaft and align the flat with the strut to knuckle mounting bracket.

Caution: Do not handle the top mount assembly by the plastic portion. Handle the top mount assembly by the metal portion when removing/installing the top mount from/to the strut assembly. Holding the top mount assembly by the plastic portion may loosen the snap fit of the bearing components and cause the bearing to fall apart.

Note: The flat on the metal plate of the top mount assembly must face the same direction of the anti-rotation tab on the spring seat.

5. Assemble the top mount onto the strut shaft and align the flat 180 degrees from flat on the upper spring seat.



6. Loosely install the strut shaft nut.

Caution: Refer to Fastener Caution in the Preface section.

Caution: Do not allow the absorber rod to rotate during disassembly/reassembly. Use hand tools to keep the absorber rod from rotating. If air tools are used, and the rod is allowed to rotate, damage to the absorber may occur.

7. Hold the strut shaft and use the J 42991 or equivalent hand tools to tighten the shaft while verifying that the upper spring seat flats align with the top mount.

Tighten the strut shaft to 75 N·m (55 lb ft).




8. Release the tension on the J 45400 .
9. Remove the strut assembly from the J 45400 .