Strut Cartridge: Service and Repair

When repair or adjustment procedures require that vehicle be raised on a hoist, it is important that the rear axle assembly remains in the normal trim height position at all times. When a frame contact hoist is used, two additional jack stands should be used to support the rear axle or control arms in the normal trim height position.

Fig. 27 Removing Upper Strut Mount:

Fig. 28 Removing Outer Clamp:

Fig. 29 O-ring Replacement:

Fig. 30 Removing Inner Clamp:

Removal
1. Remove strut from vehicle.
2. Scribe alignment marks between upper mount and outer tube.
3. Clamp strut in a suitable vise using wooden blocks.
4. Remove upper mount from strut, Fig. 27.
5. Cut and remove outer clamp with a hacksaw, Fig. 28.
6. Cut air bladder from outer tube and slide the inner tube upward.
7. Remove O-ring from inside top of outer tube, Fig. 29.
8. Cut and remove inner clamp with a hacksaw, Fig. 30.
9. Remove air bladder from inner tube.

Fig. 31 Replacing Air Bladder:

Fig. 32 Inner Clamp & Air Bladder Position:

Installation
1. Lubricate new O-ring and O-ring groove with silicone lubricant. Install O-ring in groove, Fig. 29.
2. Apply silicone lubricant to inside top of new air bladder and the entire outside of air bladder, Fig. 31.
3. Fold bottom of air bladder before installation on inner tube. Place air bladder over inner tube, continuing to fold bladder from the bottom up. Position top of air bladder as shown in Fig. 32. Do not use tools to fold air bladder as damage may occur, causing air leakage.
4. Place inner clamp in position as shown in Fig. 32. Tighten clamp with tool J-34649.
5. Fold bottom of air bladder upward and fold top of 4 inch section downward.
6. Apply silicone lubricant to polished diameter of inner shaft tube.
7. Place outer tube over air bladder and push downward against folded portion of bladder. The outer tube must be completely seated over shaft.

Fig. 33 Air Fitting Position:

8. Install upper mount onto strut, aligning marks made during disassembly, and torque nut to 74 ft.lbs. The upper mount and tube air fitting must be properly positioned with the bottom strut mount, Fig. 33.
9. Apply silicone lubricant to outer tube.
10. Install air bladder over outer tube by folding upward over tube and push over tube.
11. Install and tighten hose clamp over grooved area of air bladder.
12. Support strut and partially inflate air bladder. Check for leaks with soap solution.
13. Install strut into vehicle.