SMU - SECTION 3C - FRONT SUSPENSION AND AXLE

SUBJECT: SERVICE MANUAL UPDATE - SECTION 3C - FRONT SUSPENSION AND AXLE - LOWER BALL JOINT REPLACEMENT

MODELS: 1995 CHEVROLET AND GMC TRUCK K MODELS

SOME EARLY PRODUCTION 1995 1500 AND 2500 (BELOW 8,600 GVW) K SERIES TRUCKS WERE BUILT WITH A LOWER CONTROL ARM THAT FEATURED A RIVETED BALL JOINT. HOWEVER, DURING THE MODEL YEAR A PRODUCTION CHANGE WAS MADE AND A PRESSED IN BALL JOINT WAS USED ON THE 1500 AND 2500 (BELOW 8,600 GVW) K SERIES TRUCKS. THE 2500 (8,600 GVW AND ABOVE) AND 3500 K SERIES TRUCKS USED A RIVETED BALL JOINT DURING THE ENTIRE MODEL YEAR. THE FOLLOWING INFORMATION CONTAINS PROCEDURES FOR SERVICING THE RIVETED LOWER CONTROL ARM BALL JOINT AS WELL AS THE PROCEDURES FOR THE PRESSED IN BALL JOINT DESIGN.

LOWER BALL JOINT REPLACEMENT (PRESSED IN)

TOOLS REQUIRED J 24319-01 STEERING LINKAGE PULLER J 29193 STEERING LINKAGE INSTALLER J 39549 BALL JOINT/TIE ROD END SEPARATOR J 9519-E BALL JOINT REMOVER AND INSTALLER SET J 41435 BALL JOINT REMOVER AND INSTALLER KIT CONSISTING OF: J 41435-1 REMOVER J 41435-2 INSTALLER J 41435-3 REMOVER/INSTALLER

REMOVE OR DISCONNECT (FIGURES 1 THROUGH 3)

* RAISE THE VEHICLE AND SUPPORT THE FRAME WITH SUITABLE SAFETY STANDS. 1. TIRE AND WHEEL ASSEMBLY. REFER TO SECTION 3E. 2. PLACE A FLOOR JACK UNDER THE CONTROL ARM AND RAISE IT UNTIL IT SUPPORTS THE CONTROL ARM.

CAUTION:

FLOOR JACK MUST REMAIN UNDER THE CONTROL ARM DURING REMOVAL AND INSTALLATION TO RETAIN THE TORSION BAR AND CONTROL ARM IN POSITION OR PERSONAL INJURY MAY RESULT.

3. DRIVE AXLE (HALFSHAFT). REFER TO SECTION 4C. 4. BRAKE CALIPER. REFER TO SECTION 5B1.

IMPORTANT

* SUPPORT THE CALIPER WITH PIECE OF WIRE TO PREVENT DAMAGE TO THE BRAKE LINE.

5. COTTER PIN AND THE NUT FROM LOWER CONTROL ARM BALL JOINT. * USE J 39549 TO BREAK THE BALL JOINT LOOSE FROM THE KNUCKLE. 6. LOWER CONTROL ARM FROM THE KNUCKLE. 7. KNUCKLE FROM THE VEHICLE. 8. BALL JOINT FROM THE LOWER CONTROL ARM. * USE TOOLS AS SHOWN IN (FIGURE 3).

INSPECT * THE TAPERED HOLE IN THE STEERING KNUCKLE AND REMOVE ANY DIRT. IF THE HOLE IS OUT OF ROUND, DEFORMED OR DAMAGED, THE KNUCKLE MUST BE REPLACED.

INSTALL OR CONNECT (FIGURES 1, 2 AND 4)

CLEAN * LOWER CONTROL ARM BALL JOINT MOUNTING SURFACES AND NEW BALL JOINT PRIOR TO INSTALLATION USING LOCTITE(R) CLEANING SOLVENT 755 OR EQUIVALENT. DO NOT APPLY SOLVENT TO BALL JOINT SEAL.

1. APPLY A 6MM (1/4 INCH) BEAD OF LOCTITE(R) 680 EVENLY TO THE SERRATIONS ON THE TOP OF THE BALL JOINT PRIOR TO INSTALLATION. 2. POSITION BALL JOINT IN CONTROL ARM WITH THE GREASE FITTING TOWARD THE REAR OF THE VEHICLE. 3. WHEN INSTALLING THE BALL JOINT WITH J 41435, ENSURE THAT THE NOTCH IN THE TOOL IS ALIGNED WITH THE GREASE FITTING. 4. PRESS IN THE BALL JOINT USING TOOLS IN (FIGURE 4). THE BALL JOINT WILL BOTTOM IN THE CONTROL ARM. 5. STUD NUT ONTO THE STUD.

TIGHTEN * NUT TO 128 N.M (94 LB. FT.) AND ALIGN THE SLOT IN THE STUD NUT WITH THE HOLE IN THE STUD BY TIGHTENING.

6. NEW COTTER PIN TO THE STUD. 7. DRIVE AXLE (HALFSHAFT). 8. BRAKE CALIPER. 9. TIRE AND WHEEL ASSEMBLY. 10. LOWER THE VEHICLE.

IMPORTANT

* CHECK THE FRONT WHEEL ALIGNMENT. REFER TO SECTION 3A.

LOWER BALL JOINT REPLACEMENT (RIVETED/BOLTED)

TOOLS REQUIRED J 24319-01 STEERING LINKAGE PULLER J 29193 STEERING LINKAGE INSTALLER J 39549 BALL JOINT/TIE ROD END REMOVER

REMOVE OR DISCONNECT (FIGURES 1 AND 2)

1. RAISE THE VEHICLE AND SUPPORT IT WITH SUITABLE SAFETY STANDS. 2. TIRE AND WHEEL ASSEMBLY. REFER TO SECTION 3E. 3. PLACE A FLOOR JACK UNDER THE CONTROL ARM AND RAISE IT UNTIL IT SUPPORTS THE CONTROL ARM. 4. DRIVE AXLE (HALFSHAFT). REFER TO SECTION 4C. 5. BRAKE CALIPER. REFER TO SECTION 5B1.

IMPORTANT

* SUPPORT THE CALIPER WITH A PIECE OF WIRE TO PREVENT DAMAGE TO THE BRAKE LINE.

6. COTTER PIN AND NUT FROM THE LOWER CONTROL ARM BALL JOINT. * USE J 39549 TO BREAK THE BALL JOINT LOOSE FROM THE KNUCKLE. 7. LOWER CONTROL ARM FROM THE KNUCKLE. 8. KNUCKLE FROM THE VEHICLE.

INSPECT * THE TAPERED HOLE IN THE STEERING KNUCKLE AND REMOVE ANY DIRT. IF THE HOLE IS OUT OF ROUND, DEFORMED OR DAMAGED, THE KNUCKLE MUST BE REPLACED.

9. RIVETS. A. CENTER PUNCH THE BOTTOM OF THE RIVETS. B. USING A 3.17 MM (1/8 INCH) DRILL BIT, DRILL A GUIDE HOLE 6.35 MM (1/4 INCH) INTO THE CENTER OF EACH RIVET HEAD. C. USING A 12.7 MM (1/2 INCH) DRILL BIT, DRILL THE RIVET HEAD OFF. D. DRILL A HOLE TWO-THIRDS THE LENGTH OF THE RIVET SHANK, USING AN 8 MM (5/16 INCH) DRILL. E. USING AN 8 MM (5/16 INCH) PIN PUNCH, PUNCH OUT THE RIVETS.

INSTALL OR CONNECT (FIGURES 1, 2 AND 5)

1. BALL JOINT TO THE CONTROL ARM. 2. BOLTS AND NUTS TO THE BALL JOINT.

TIGHTEN * NUTS TO 60 N.M (45 LB. FT.).

3. BALL JOINT INTO THE STEERING KNUCKLE. 4. STUD NUT ONTO THE STUD.

TIGHTEN * NUT TO 128 N.M (94 LB. FT.) AND ALIGN THE SLOT IN THE STUD NUT WITH HOLE IN THE STUD BY TIGHTENING.

5. NEW COTTER PIN TO THE STUD. 6. DRIVE AXLE (HALFSHAFT). 7. BRAKE CALIPER. 8. TIRE AND WHEEL ASSEMBLY. 9. LOWER THE VEHICLE.

IMPORTANT

* CHECK THE FRONT WHEEL ALIGNMENT. REFER TO SECTION 3A.

FIGURES: 5 ATTACHMENTS: 0

GENERAL MOTORS BULLETINS ARE INTENDED FOR USE BY PROFESSIONAL TECHNICIANS, NOT A "DO-IT-YOURSELFER". THEY ARE WRITTEN TO INFORM THOSE TECHNICIANS OF CONDITIONS THAT MAY OCCUR ON SOME VEHICLES, OR TO PROVIDE INFORMATION THAT COULD ASSIST IN THE PROPER SERVICE OF A VEHICLE. PROPERLY TRAINED TECHNICIANS HAVE THE EQUIPMENT, TOOLS, SAFETY INSTRUCTIONS AND KNOW-HOW TO DO A JOB PROPERLY AND SAFELY. IF A CONDITION IS DESCRIBED, DO NOT ASSUME THAT THE BULLETIN APPLIES TO YOUR VEHICLE, OR THAT YOUR VEHICLE WILL HAVE THAT CONDITION. SEE A GENERAL MOTORS DEALER SERVICING YOUR BRAND OF GENERAL MOTORS VEHICLE FOR INFORMATION ON WHETHER YOUR VEHICLE MAY BENEFIT FROM THE INFORMATION.

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