For the 4X4 version and any torsion bar suspension types, read this TSB, may be part or all of the problem.
REVISED PROCEDURE FOR ADJUSTING ALIGNMENT ON ALL SUSPENSIONS - NEW RIGHT HAND UPPER CONTROL ARM DESIGN FOR TORSION BAR FRONT SUSPENSIONS TECHNICAL SERVICE BULLETIN Reference Number(s): 04-24-19, Date of Issue: December 13, 2004 Related Ref Number(s): 04-24-19 ARTICLE BEGINNING DESCRIPTION REVISED PROCEDURE FOR ADJUSTING ALIGNMENT ON ALL SUSPENSIONS - NEW RIGHT HAND UPPER CONTROL ARM DESIGN FOR TORSION BAR FRONT SUSPENSIONS ISSUE The cam bolt and nut kit that was used for adjusting caster and camber on all torsion bar and coil spring front suspensions has been discontinued. If the caster and camber settings need to be adjusted, a washer must now be installed. The right hand upper control arm design changed from a two piece design to a single piece design during the 2003 model year. The single piece design is now the only version of the upper control arm available for service of prior model year Rangers. ACTION Use the following Camber And Caster Adjustment procedure when either camber or caster need to be adjusted on any suspension, or if only a caster split adjustment is needed on a vehicle equipped with single piece upper control arm. Use the following Caster Split Adjustment - Two Piece Right Hand Upper Control Arm procedure if only a caster split adjustment is needed on a vehicle equipped with a two piece upper control arm. SERVICE PROCEDURE CAMBER AND CASTER ADJUSTMENT FORD: 1998-2001 Explorer; 1998-2003 Ranger; 2000-2003 Explorer Sport; 2001-2003 Explorer Sport Trac NOTE: THE UPPER CONTROL ARM-TO-FRAME MOUNTING BOLTS HAVE SET SHIMS THAT MUST BE REPLACED WITH WASHERS TO ALLOW FOR ADJUSTMENT OF THE ARM IN THE FRAME SLOT. THE VEHICLE SHOULD BE SUPPORTED BY THE LOWER CONTROL ARM TO EASE MOVEMENT OF THE UPPER ARM IN THE SLOT.
1. Remove and discard the upper control arm-to-frame nuts and shims ( Fig. 1 ). Fig. 1: Upper Control Arm-To-Frame Nut 2. Install new washers (W705040-S900) and nuts (N805480-S427). Tighten the nuts so there is tension, but the upper control arm can be moved for the alignment adjustment. 3. To adjust caster and camber refer to the following chart. Adjustments that require moving the front and rear of the upper control arm should be made equally. CASTER/CAMBER ADJUSTMENT 4. Torque the upper control arm-to-frame nuts to 98 lb-ft (133 N.M). 5. Check and if necessary adjust the front toe. Refer to the appropriate Workshop Manual for information. CASTER SPLIT ADJUSTMENT - TWO PIECE RIGHT HAND UPPER CONTROL ARM 1. To decrease the right hand caster, loosen the ball joint adjustment nuts ( Fig. 2 ) and move the ball joint forward. Fig. 2: Ball Joint Adjustment Nuts 2. To increase the right hand caster, loosen the ball joint adjustment nuts and move the ball joint rearward. 3. Torque the ball joint adjustment nuts to 129 lb-ft (175 N.M). 4. Check and if necessary adjust the front toe. Refer to the appropriate Workshop Manual for information. PARTS INFORMATION PARTS INFORMATION
Adjustment Front of Upper Arm Rear of Upper Arm Increase Caster Out In Decrease Caster Out Out Increase Camber Out Out Decrease Camber In In Increase Caster and Camber Out --- Decrease Caster and Camber In --- Part Number Part Name W705040-S900 Washer (2 Per Package) N805480-S427 Nut (2 Per Package)
Monday, April 20th, 2009 AT 7:52 AM