How to change rear suspension springs on Polaris snowmobile

Removal:

1. Disconnect the negative battery cable.
2. Raise and safely support the vehicle with jackstands.
3. Remove the rear wheel and tire assembly.
4. Scribe the strut-to-knuckle for proper installation.
5. If equipped, remove the auxiliary spring, as outlined in this section.
6. Remove the jack pad.
7. Install rear leaf spring compressor tool J-35778, or equivalent. Refer to the Transverse Spring Assembly procedures in this section for installation details.
8. Fully compress the spring, but do NOT remove the retention plates or the spring.
9. Unfasten the two strut-to-body bolts.
10. Remove the brake hose bracket from the strut.
11. Remove the strut and auxiliary spring upper bracket from the knuckle.

To install:

1. Position the strut to the body and knuckle bracket.
2. Install the strut-to-body bolts and tighten to 34 ft. lbs. (46 Nm).
3. Install the strut to the knuckle, aligning the scribe marks and tighten the bolts to 133 ft. lbs. (180 Nm) for 1988-94 vehicles. For 1995-96 vehicles, tighten the bolts to 122 ft. lbs. (165 Nm).
4. Install the brake hose bracket.
5. Remove the spring compressing tool.
6. Install the jack pad and tighten the retaining bolts to 18 ft. lbs. (25 Nm).
7. If equipped, install the auxiliary spring.
8. Install the wheel and tire assembly and install the lug nuts finger-tighten
9. Carefully lower the vehicle, then tighten the lug nuts to 100 ft. lbs. (136 Nm).
10. Connect the negative battery cable.

• Air Suspension
• Front Suspension
• Rear Suspension
• • Coil Spring Rear Suspension
  • Coil Springs
  • Lower Ball Joint
  • Lower Control Arms
  • Shock Absorbers
  • Stabilizer Bar Sway Bar
  • Strut Macpherson Strut Assembly
  • Upper Control Arms
  • Wheel Bearings
• Specifications
• Wheel Alignment

• HOME
• REPAIR INFO
• 1999 LEXUS ES300 3.0L SFI DOHC 6CYL REPAIR GUIDE
• SUSPENSION
• REAR SUSPENSION
• COIL SPRING REAR SUSPENSION

Lexus Car ES, IS, LS 1998-06
Coil Spring Rear Suspension

• HUB & BEARINGS
• STABILIZER BAR
• STRUT & COIL SPRING

Print

Hub & Bearings

Adjustment
Check the backlash in bearing shaft direction and the axle hub deviation. Maximum for backlash should be 0.0020 in. (0.05mm) and for axle hub deviation 0.020 in. (0.05mm).

Fig. Checking wheel bearings for excessive play


NOTE The rear wheel bearings are non-adjustable. If the wheel bearing is out of specifications, replace the wheel bearing.
Removal & Installation

1. Before servicing the vehicle, refer to the Precautions section.
2. Raise and safely support the vehicle.
3. Remove or disconnect the following:
   
   Rear tire and wheel assembly Rear stabilizer link Rear axle shaft nut Rear disc brake caliper and disc Speed sensor Parking brake assembly at the wheel hub No. 1 and 2 upper control arm assembly No. 1 and 2 rear suspension arm assembly Toe control link Rear axle from hub assembly using a plastic hammer No. 2 rear wheel bearing dust deflector using a screwdriver 4 bolts and rear axle hub and bearing assembly from the axle carrier assembly
   

To install:

1. Install or connect the following:
   
   Hub on the carrier and tighten the bolts to 52 ft. lbs. (70 Nm) No. 2 rear wheel bearing dust deflector using a screwdriver Rear axle into hub assembly No. 1 and 2 upper control arm assembly. Torque the new nut to the No. 2 rear upper control arm to 52 ft. lbs. (70 Nm). Temporarily tighten the No. 1 arm bolt. No. 1 and 2 rear suspension arm assembly. Temporarily tighten. Toe control link. Torque new nut to 52 ft. lbs. (70 Nm). Rear stabilizer link. Torque to 20 ft. lbs. (27 Nm). Parking brake assembly at the wheel hub Rear speed sensor Rear axle shaft nut. Torque to 214 ft. Lbs. (290 Nm) and stake the nut with a chisel and hammer. Rear brake disc and disc brake caliper
   
2. Adjust the parking brake.
3. Stabilize the suspension as follows :
   1. Install the wheel(s).
   2. Lower the vehicle and bounce it up and down several times to stabilize the rear suspension.
   3. Raise the vehicle.
   4. Remove the wheel.
   5. Jack up the rear lower suspension armplacing a wood block in between. Apply a load to the suspension so that the lower suspension arm is plkaced in a horizontal position.
   
   
4. Fully tighten the No. 1 rear upper control arm assembly to 119 ft. lbs. (161 Nm).
5. Fully tighten the No. 1 rear suspension arm assembly to 70 ft. lbs. (95 Nm).
6. Fully tighten the No. 2 rear suspension arm assembly to 119 ft. lbs. (161 Nm).
   
   Rear tire and wheel assembly
   

1. Before servicing the vehicle, refer to the Precautions section.
2. Raise and safely support the vehicle.
3. Remove or disconnect the following:
   NOTE If it is necessary to replace the hub or bearing, replace the components as an assembly.
   
   
   Rear tire and wheel assembly If equipped with rear disc brakes, the caliper mounting bolts. Leave the brake line connected and suspend the assembly out of the way. Brake rotor or drum 4 bolts and pull off the rear axle hub O-ring
   

To install:

1. Install or connect the following:
   
   Hub on the carrier and tighten the bolts to 59 ft. lbs. (80 Nm) Rotor or drum Caliper, f equipped with rear disc brakes and tighten the bolts to 34 ft. lbs. (64 Nm) Wheel
   

1. Before servicing the vehicle, refer to the Precautions section.
2. If equipped with air suspension, move the height control switch in the trunk area to the OFF position.
3. Remove or disconnect the following:
   
   Negative battery cable Rear wheel(s) Height control sensor link from the lower control arm Anti-lock Brake System (ABS) speed sensor and wiring harness Brake caliper bracket from the rear axle carrier by removing the 2 bolts. Support the caliper with a piece of wire. Brake rotor Parking brake shoes and cable Cotter pin, lock cap and the nut holding the halfshaft to the rear axle Suspension member brace by removing the 2 bolts Halfshaft bolts and washers Halfshaft from the vehicle Strut rod
   
4. Place matchmarks on the adjusting cam and body for the No. 1 control arm.
5. Remove or disconnect the following:
   
   Nut and adjusting cam Nut on the axle carrier side of the No. 1 lower control arm Separate the control arm from the axle carrier No. 1 lower control arm Stabilizer bar link from the No. 2 lower control arm.
   
6. Place matchmarks on the adjusting cam and body.
7. Remove or disconnect the following:
   
   Nut and adjusting cam from the No. 2 lower control arm Nut and bolt holding the No. 2 lower control arm to the axle carrier No. 2 control arm from the vehicle Nut and bolt on the lower side of the strut assembly 2 upper control arm set nuts and bolts Axle carrier with the upper control arm
   
8. Secure the axle carrier in a vise.
9. Remove or disconnect the following:
   
   Nut holding the upper control arm to the axle carrier and remove the control arm Dust deflector. Use a suitable prytool. Oil seal
   
   

   Fig. Removing the oil seal (inner)-LS 430
   
   

10. Remove the 2 bolts and nuts and shift the backing the plate towards the hub side (outside).
11. Remove or disconnect the following:
    
    Axle hub
    
    

    Fig. Removing the axle hub from the axle carrier-LS 430
    Backing plate. Inner race (outside) from the axle hub
    
    

    Fig. Removing the inner race (outside) from the axle hub-LS 430
    Oil seal (outer) from the axle
    
    

    Fig. Removing the oil seal (outer)-LS 430
    Snapring from inside the axle housing Bearing from the axle housing
    

To install:

1. Install or connect the following:
   
   New bearing to the axle housing Snapring to the axle carrier, using snapring pliers New outer oil seal. Coat the oil seal lip with multipurpose grease.
   
   

   Fig. Installing the oil seal (outer)-LS 430
   Backing plate to the axle housing. Do NOT install the bolts or nuts at this time. Inner race (inside) to the axle housing Axle hub to the axle housing Backing plate in position. Tighten the bolts and nuts to 43 ft. lbs. (59 Nm). New oil seal (inner) to the axle housing. Coat the oil seal lip with multipurpose grease.
   
   

   Fig. Installing the oil seal (inner)-LS 430
   New dust deflector. Be sure to align the hose for the ABS speed sensor in the dust deflector and axle carrier. Upper control arm to the axle carrier by installing the nut. Tighten the nut to 80 ft. lbs. (108 Nm). Axle carrier and upper control arm to the vehicle as an assembly 2 upper control arm set bolts and tighten the bolts to 121 ft. lbs. (164 Nm) Bolt and nut holding the strut to the axle carrier. Tighten to 101 ft. lbs. (137 Nm). Bolt and nut connecting the No. 2 lower control arm to the axle carrier. Tighten the bolt to 60 ft. lbs. (81 Nm). Nut and adjusting cam to hold the No. 2 lower control arm to the body. Align the adjusting cam marks and tighten the nut to 57 ft. lbs. (78 Nm). Stabilizer bar link to the No. 2 lower control arm and tighten the nut to 48 ft. lbs. (65 Nm) No. 1 lower control arm to the axle carrier and body. Install the nut to hold the No. 1 lower control arm to the axle carrier. Tighten the nut to 43 ft. lbs. (59 Nm). Nut and adjusting cam to hold the No. 1 lower control arm to the body. Align the matchmarks and tighten the nut to 57 ft. lbs. (78 Nm). Strut rod to the axle carrier and body. Install the bolt and nut to hold the strut rod to the body. Tighten to 57 ft. lbs. (78 Nm). Bolt and nut to hold the strut rod to the axle carrier. Tighten to 136 ft. lbs. (184 Nm) Parking brake shoes and cable Outboard joint side of the halfshaft and align the matchmarks on the side gear shaft and the halfshaft. Coat the threads with clean oil and install the hexagon bolts. Tighten bolts to 61 ft. lbs. (83 Nm). Suspension member brace with the 2 bolts. Tighten the 2 bolts to 37 ft. lbs. (50 Nm). Nut to hold the halfshaft to the rear axle. Tighten the nut to 213 ft. lbs. (289 Nm). Lock cap and cotter pin Brake disc to the axle hub with the matchmarks aligned. Install the 2 screws and tighten the screws to 48 inch lbs. (5 Nm). Brake caliper to the vehicle and install the 2 bolts. Tighten the bolts to 77 ft. lbs. (104 Nm). ABS speed sensor and wiring harness Height control sensor link with the matchmarks aligned. Tighten the nut to 48 inch lbs. (5 Nm). Rear wheel(s) Negative battery cable
   

2. Lower the vehicle and turn ON the air suspension switch.

Fig. Exploded view rear carrier assembly, hub and bearing-

1. Before servicing the vehicle, refer to the Precautions section.
2. Remove or disconnect the following:
   WARNING Be careful not to damage the boot and ABS sensor
   
   
   Rear wheel(s) Height control sensor link from the lower control arm Anti-lock Brake System (ABS) speed sensor and wiring harness Brake caliper bracket from the rear axle carrier by removing the 2 bolts. Support the caliper with a piece of wire. Brake rotor Parking brake shoes and cable Toe control link Separate upper control arm assembly Shock absorber from axle carrier Suspension arms No 1 and 2 from axle carrier Rear axle from carrier
   
   
   Wheel bearing dust deflector 4 bolts and axle & bearing hub assembly
   

To install:

1. Install or connect the following:
   
   4 bolts and axle & bearing assembly. Tighten to 48 ft. lbs (65 Nm) Rear wheel bearing dust deflector Rear drive axle Upper control arm. Temporarily tighten No 2 and No 1 suspension arms. Tighten to 52 ft. lbs. (70 Nm) Shock absorber. Temporarily tighten Toe control link. Tighten to 37 ft. lbs. (50 Nm) Fully tighten upper control arm. Tighten to 52 ft. lbs. (70 Nm) Height control sensor Parking brake shoes and cable Speed sensor Rear disc brake caliper Fully tighten shock with new nut to 52 ft. lbs. (70 Nm) Rear tire
   
2. Inspect and adjust rear wheel alignment
3. Check ABS speed sensor signal

1. Before servicing the vehicle, refer to the Precautions section.
2. Remove or disconnect the following:
   
   Rear wheel Wheel speed sensor Axle halfshaft Brake caliper and rotor Parking brake shoes Parking brake cable No. 1 lower suspension arm bolt No. 2 lower suspension arm bolt Toe control link Upper ball joint Axle carrier from the vehicle
   
3. Press the hub out of the wheel bearing, then remove the backing plate.
4. Remove the snapring, then press the wheel bearing out of the axle carrier.

To install:

NOTE Use a new toe control link nut for assembly.

1. Installation is the reverse of the removal procedure, while using the following torque values:
   
   Backing plate bolts: 43 ft. lbs. (59 Nm) No. 1 lower suspension arm bolt: 55 ft. lbs. (75 Nm) No. 2 lower suspension arm bolt: 81 ft. lbs. (110 Nm) Toe control link nut: 36 ft. lbs. (49 Nm) Upper ball joint nut: 80 ft. lbs. (108 Nm) Brake caliper support bolts: 77 ft. lbs. (104 Nm) Rear wheel lug nuts: 76 ft. lbs. (103 Nm)
   

Fig. Exploded view rear Axle carrier and hub assembly-ES 330

1. Before servicing the vehicle, refer to the Precautions section.
2. Remove or disconnect the following:
   
   Rear tire and wheel assembly Brake caliper support bracket Brake rotor Skid control sensor wire 4 bolts and rear hub and bearing assembly Skid control sensor
   

To install:

1. Install or connect the following:
   NOTE Inspect bearing back lash and hub deviation
   
   
   Skid control sensor Rear axle hub and bearing assembly with 4 bolts. Tighten to 59 ft. lbs. (80 Nm) Skid control sensor wire
   
   
   Rear disc Rear disc brake caliper assembly. Tighten to 46 ft. lbs (62 Nm) Flexible brake hose Rear tire and wheel
   
2. inspect and adjust rear wheel alignment
3. Check ABS speed sensor signal

Stabilizer Bar

Removal & Installation

1. Remove the rear wheels.
2. Remove the 2 nuts and left stabilizer bar link. If the ball joint turns together with the nut, use a hexagon wrench (5 mm) to hold the stud. Repeat for the right side.
3. Remove the 8 bolts, 2 No. 1 brackets and 2 bushings. Two types of bolts are used, so make sure the correct bolts are installed.
4. Remove the stabilizer bar.

To install:

1. Install the stabilizer bar.
2. Install the bushing and bracket with the 2 bolts and tighten to 14 ft. lbs. (19 Nm). Install the bushing to the inner side of the bushing stopper on the stabilizer bar.
3. Connect the stabilizer bar links and tighten the nuts to 29 ft. lbs. (39 Nm). Repeat for the right side.
4. Install the rear wheels.
5. Inspect and adjust rear wheel alignment.

Strut & Coil Spring

Removal & Installation

1. Before servicing the vehicle, refer to the Precautions section.
2. Remove or disconnect the following:
   CAUTION Do NOT remove the center nut to the strut at this time. The spring on the strut is under high pressure and can cause serious injury.
   
   
   No. 2 luggage compartment trim cover Left and right deck side trim box Rear luggage compartment trim cover Front luggage compartment trim cover Left and right side luggage compartment trim covers Rear wheel Rear wheel fender liner No. 2 differential support protector Rear suspension member brace Rear No. 2 lower control arm Mounting bolts and strut assembly
   
3. Secure the strut in a vise.
4. Compress the coil spring
5. Remove or disconnect the following:
   
   Upper strut retaining nut Suspension support Upper insulator Bumper Coil spring Insulator

1994-96 VEHICLES
( see Figures 6 and 7 / click image for zoom )

Fig. 6: Oil pan mounting bolt locations-1996 3.1L engine shown

Fig. 7: Oil pan sealant application points-1996 3.1L engine shown

1. Disconnect the negative battery cable.
   

It may be necessary to remove the hood, with the help of an assistant, for access.

1. Remove the engine mount strut and A/C compressor (if equipped) and the engine mount strut bracket assemblies.
   
2. Remove the electric cooling fan assemblies. -28467 and J 26462, or equivalent.
   
3. Raise and safely support the vehicle. Drain the engine oil.
   
4. Remove the front exhaust manifold pipe.
   
5. Remove the intermediate shaft bolt/screw.
   
6. Remove the oil level sensor.
   
7. Remove the engine splash shield.
   
8. Suitable support the drivetrain and front suspension with jack stands.
   
9. Remove the transaxle mount side frame retaining nuts from the drivetrain and suspension frame assembly.
   
10. Remove the engine mount side frame nuts from the drivetrain and suspension frame assembly.
    
11. Unfasten the rear drivetrain and front suspension frame bolts/screws.
    
12. If equipped, remove the lower drivetrain and front suspension frame bolts/screws.
    
13. Remove the engine mount assembly.
    
14. Remove the flywheel inspection cover.
    
15. Remove the starter.
    
16. Disconnect the transaxle mount assembly from the oil pan.
    
17. Unfasten the side bolts and screws and the retaining bolts and screws, then remove the oil pan. Remove and discard the oil pan gasket.

To install:

1. Clean the gasket mating surfaces.
   
2. Apply a small amount of sealer on either side of the rear main bearing cap, where the seal surface on the cap meets the cylinder block. Install a new gasket on the oil pan.
   
3. Position the oil pan and secure with the retaining bolts and screws. Tighten the retaining bolts and screws to 18 ft. lbs. (25 Nm) and the side bolts/screws using tool J 39505 or equivalent.
   
4. Fasten the transaxle mount assembly to the oil pan.
   
5. Install the starter motor.
   
6. Install the flywheel inspection cover.
   
7. Install the engine mount assembly.
   
8. Carefully raise the drivetrain and front suspension assembly. Install the rear drivetrain and front suspension frame bolts/screws.
   
9. Fasten the engine mount frame side nuts to the drivetrain and front suspension frame assembly. Install the transaxle mount frame side nuts to the drivetrain and suspension frame assembly.
   
10. Remove the jackstands from the drivetrain and front suspension frame assembly.
    
11. Install the engine splash shield and the oil level sensor.
    
12. Install the intermediate steering shaft bolt/screw. Connect the front exhaust manifold pipe.
    
13. Carefully lower the vehicle.
    
14. Remove the engine support tools.
    
15. Install the electric cooling fan assemblies.
    
16. Install the engine mount strut and A/C compressor, bracket and the engine mount strut bracket.
    
17. If removed, install the hood assembly.
    
18. Fill the crankcase to the correct level. Connect the negative battery cable. Run the engine to normal operating temperature and check for leaks.

Hope this helps (remember to rate this answer).

Adjustment

1. Place parking brake lever in -full released- position.
2. Raise and support vehicle.
3. Remove plug in parking brake shoe support to access adjuster star-wheel.
4. Through the access hole, rotate the adjuster star wheel in the following direction to expand the shoes outward against the drum:
   1. Left brake - Rotate star-wheel toward rear of vehicle.
   2. Right brake - Rotate star-wheel toward front of vehicle.
5. Using an appropriate tool, turn adjuster star wheel until wheel will not rotate (dead lock).
6. Back off adjuster six detents (teeth).
7. Rotate wheel, checking for light drag. If drag is too heavy, continue to back off adjuster one detent at a time until light drag is present. Do not back off star-wheel more than 17 detents from wheel lock.
8. Install access plug.
9. Adjust opposite wheel parking brake shoes using same method.
10. Lower vehicle.
11. Apply and release parking brake lever once to ensure proper operation of parking brakes.

Removal & Installation NOTE The following procedure may be used to remove shoes on either side of the vehicle.

1. Lock out automatic adjuster in parking brake lever.
2. Raise and support vehicle.
3. Access and remove rear hub and bearing.
4. Remove parking brake cable bolt at knuckle.
5. Completely back off parking brake shoe adjustment.
6. Remove parking brake shoe adjuster spring.
7. Remove shoe adjuster.
8. Remove upper brake shoe hold-down clip and pin.
9. Remove lower brake shoe hold-down clip and pin.
10. Remove upper and lower shoes with return spring from shoe actuator.
11. Remove return spring from shoes.
    
    

    Fig. View of the actuator (1), support (2), adjuster spring (3), return spring (4), caliper adapter (5), shoes (6), hold-down clips and pins (7) and adjuster (8)
    

To install:

1. Install return spring between upper and lower shoes.
   NOTE Before installing shoes on actuator, make sure actuator hooked to rear cable is positioned with word -UP- facing outward.
2. Install upper and lower shoes with return spring on shoe actuator located on parking brake cable.
3. Install lower brake shoe hold-down pin through rear of support and lower shoe, then install hold-down clip.
4. Install upper brake shoe hold-down pin through rear of support and upper shoe, then install hold-down clip.
5. Install shoe adjuster. Place end of adjuster with star wheel upward.
6. Install parking brake shoe adjuster spring.
7. Install bolt securing parking brake cable to knuckle and tighten bolt to 21 ft. lbs. (28 Nm).
8. Using Brake Shoe Gauge, Special Tool C-3919, or equivalent, measure inside diameter of parking brake drum portion of rotor.
9. Place Gauge over parking brake shoes at widest point.
10. Using adjuster star wheel, adjust parking brake shoes until linings on both park brake shoes just touch jaws on gauge. This will give a good preliminary adjustment of parking brake shoes, before a final adjustment is made at end of this procedure.
11. Install hub and bearing with wheel speed sensor as well as all components necessary to access it.
12. Lower vehicle.
13. Unlock automatic adjuster in parking brake lever.
14. Perform final adjustment of parking brake shoes

15. 
    Adjustment This vehicle is equipped with permanently sealed rear wheel bearings. There is no periodic lubrication or maintenance recommended for these units.
    

    
    Removal & Installation

    1. Raise and support vehicle.
    2. Remove wheel mounting nuts, then tire and wheel assembly.
    3. If equipped with AWD:
       1. Remove cotter pin, nut lock and spring washer from half shaft.
       2. While a helper applies brakes to keep hub from turning, remove hub nut and washer.
    4. Remove brake caliper and rotor from hub and bearing assembly.
       
       

       Fig. Hub assembly
       

    5. Disconnect vehicle wiring harness connector at wheel speed sensor connector.
    6. Unclip wheel speed sensor connector from spare tire mounting support.
    7. Disconnect two sensor cable routing clips on rear suspension crossmember.
    8. Disconnect two sensor cable routing clips along toe link.
    9. Disconnect sensor cable from bracket on brake support.
       
       
    10. Completely loosen, but do not remove four bolts fastening hub and bearing in place. Once loosened from threads in hub and bearing, push bolts up against rear of hub and bearing to keep brake support plate in place when hub and bearing is removed.
        
        

        Fig. Rear hub and bearing mounting bolts
        

    11. Pull hub and bearing off knuckle and half shaft (if equipped with AWD), then thread wheel speed sensor cable through hole in brake support plate as it is removed with hub and bearing.
        
        
    To install:
    
    1. Position hub and bearing bolts though rear of knuckle and parking brake support just enough to hold support in place as hub and bearing is installed.
    2. Install hub and bearing by first feeding end of wheel speed sensor cable through hole in bottom of parking brake support. As this is being done, if equipped with AWD, slide hub and bearing onto half shaft. Place hub and bearing through brake support, onto knuckle, lining up mounting bolt holes with bolts and placing wheel speed sensor head at bottom.
    3. Install four bolts fastening hub and bearing in place. Tighten mounting bolts to 60 ft. lbs. (81 Nm).
    4. Place wheel speed sensor cable routing grommet into bracket on parking brake support.
    5. Route wheel speed sensor cable along toe link and rear suspension crossmember connecting routing clips where shown.
    1. Connect vehicle wiring harness to wheel speed sensor connector.
    2. Install brake rotor and caliper.
    3. If equipped with AWD:
       1. Install washer and hub nut on end of half shaft.
       2. While a helper applies brakes to keep hub from turning, tighten hub nut to 180 ft. lbs. (244 Nm).
       3. Install spring washer, nut lock and cotter pin on end of half shaft.
    4. Install tire and wheel assembly. Install and tighten wheel mounting nuts to 100 ft. lbs. (135 Nm).
    
    
    

    
    
    

General Description
The front suspension allows each wheel to compensate for changes in the road surface without affecting the opposite wheel. Each wheel independently connects to the frame with a steering knuckle, ball joint assemblies, and upper and lower control arms.
The control arms specifically allow the steering knuckles to move in a three-dimensional arc. Two tie rods connect to steering arms on the knuckles and an intermediate rod. These operate the front wheels.
The two-wheel drive vehicles have coil chassis springs. These springs are mounted between the spring housings on the frame and the lower control arms. Double, direct acting shock absorbers are inside the coil springs. The coil springs attach to the lower control arms and offer ride control.
The upper part of each shock absorber extends through the upper control arm frame bracket. This bracket has two grommets, two grommet retainers, and a nut.
A spring stabilizer shaft controls the side roll of the front suspension. This shaft is mounted in rubber bushings that are held by brackets to the frame side rails. The ends of the stabilizer shaft connect to the lower control arms with link bolts. Rubber grommets isolate these link bolts. Rubber bushings attach the upper control arm to a cross shaft. Frame brackets bolt the cross shaft.
A ball joint assembly is riveted to the outer end of the upper control arm. A rubber spring in the control arm assures that the ball seats properly in the socket. A castellated nut and a cotter pin join the steering knuckle to the upper ball joint.
The inner ends of the lower control arm have pressed-in bushings. The bolts pass through the bushings and join the arm to the frame. The lower ball joint assembly is a press fit in the lower control arm and attaches to the steering knuckle with a castellated nut and a cotter pin.
Ball socket assemblies have rubber grease seals. These seals prevent entry of moisture and dirt and damage to the bearing surfaces.
Four-wheel drive models have a front suspension that consists of the control arms, a stabilizer bar, a shock absorber, and right and left torsion bars. The torsion bars replace the conventional coil springs. The lower control arm attaches to the front end of the torsion bar. The rear end of the torsion bar mounts on an adjustable arm at the crossmember. This arm adjustment controls the vehicle trim height.
Two-wheel drive vehicles have tapered roller sheel bearings. These bearings are adjustible and need lubrication.
Four-wheel drive models and RWD Utilities have sealed front-wheel bearings. These bearings are pre-adjusted and need no lubrication.
Heat treatment may create darkened areas on the bearing assembly. This discoloration does not signal a need for replacement.
Hope this helps?

I will check the shop manual, but the module does control ride for stiffness, increased stiffness at higher speeds, etc. If the bags are inflated, then the module cintrols how much air to allow in or out based on inputs to the module. See if you can get one from a salvage yard form a cash for clunkers car.

A dealer can run a test for fault codes in the computer. Call and ask how much for just a scan for fault codes in the air suspension module.

-----------------------------
Vehicle Dynamic Suspension The vehicle dynamic suspension consists of the following components:

• Rear air suspension control (RAS) module (5A919)
• Snorkel
• Drier
• Air compressor (5319)
• Air suspension switch (5K761)
• Solenoid valve (5311)
• Air spring (5560)
• Air suspension height sensor (5359)
• Air line

----------------------------------------------------------------------------
Rear Air Suspension Control Module
A microprocessor controls the air suspension system. The microprocessor and its supporting hardware are contained in the rear air suspension control module. The rear air suspension control module responds to signals from various sensors in the vehicle to maintain the programmed ride height while the vehicle is either moving or stopped. The rear air suspension control module accomplishes this by opening and closing solenoid valves to control the amount of air in the air spring(s). The rear air suspension control module turns on the compressor by applying voltage through the compressor relay to inflate the air spring(s) and raise the vehicle. The rear air suspension control module opens the vent solenoid to lower the vehicle by releasing air from the air spring(s) in response to signal inputs from the air suspension height sensor(s).
Air Suspension Switch
CAUTION: The air suspension switch must be turned to the OFF position when the vehicle is hoisted, jacked, towed, jump started, or raised off the ground, to avoid unnecessary operation of the system and possible damage to the air suspension system components.
The air suspension switch provides a signal to the rear air suspension control module in the ON position to activate the system to maintain the programmed vehicle height.
Air Compressor
NOTE: The compressor contains a thermal overload circuit breaker. The circuit breaker automatically resets after a cool down period and after being tripped by excessive compressor motor heat.
The air compressor assembly consists of the compressor pump, electric motor and vent solenoid (must be installed as an assembly).
Air Suspension Height Sensor
The air suspension height sensor sends signals to the air suspension control module. There are three possible conditions that the air suspension control module interprets from the signals of the air suspension height sensors. The conditions are trim height, below trim height, or above trim height.
Solenoid Valve, Air Spring
WARNING: Never rotate an air spring solenoid valve to the release slot in the air spring end cap fitting until all pressurized air has escaped from the air spring to prevent vehicle damage or personal injury.
The air spring solenoid valve allows air to enter and exit the rear air springs during height adjustment operations. The air spring solenoid valve is electrically operated and controlled by the air suspension control module.
Steering Sensor
The steering sensor provides the steering rate and position to the air suspension control module to avoid overcompensation of the air suspension during turns.
Inspection and Verification

1. Verify the customer concern.

1. NOTE: If the door ajar indicator is illuminated, repair the door ajar indicator. For additional information, refer to Section 413-09 .
   Visually inspect for obvious signs of mechanical and electrical damage.

Visual Inspection Chart Mechanical Electrical

• Restricted suspension movement
• Excessive vehicle load
• Cut, severed or crimped air line(s)
• Incorrectly mounted, damaged or disconnected height sensor
• Damaged air spring(s)

• Central junction box (CJB) Fuse:
  • 8 (10A)
  • 17 (10A)
• Battery junction box (BJB) Fuse 12 (30A)
• Loose or corroded connectors
• Air suspension switch
• Damaged air spring solenoid(s)

1. If the concern remains after the inspection, connect New Generation STAR (NGS) Tester to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS Tester menu. If NGS Tester does not communicate with the vehicle:
   • check that the program card is properly installed.
   • check the connections to the vehicle.
   • check the ignition switch position.

1. If the NGS still does not communicate with the vehicle, refer to the New Generation STAR Tester manual.

1. Carry out the DATA LINK DIAGNOSTIC TEST. If NGS Tester responds with:
   • CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP. Refer to Section 418-00 .
   • NO RESP/NOT EQUIP for rear air suspension control module, go to Pinpoint Test A.
   • SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the rear air suspension control module.

1. If the DTCs retrieved are related to the concern, go to Rear Air Suspension Control Module Diagnostic Trouble Code (DTC) Index to continue diagnostics.

1. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics.

Rear Air Suspension Control Module Diagnostic Trouble Code (DTC) Index
NOTE: If rear air suspension control module C251 is disconnected before rear air suspension control module C250, DTCs C1830, C1770, C1790 and C1795 will be retrieved and must be cleared before an accurate list of continuous DTCs can be retrieved. The DTCs C1441 and C1442 will only be retrieved when running the electronic variable orifice (EVO) functional test on NGS Tester. The DTC C1897 will only be retrieved once per ignition switch cycle.

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Module —Air Suspension Control Removal
WARNING: Before performing maintenance on any air suspension components, disconnect the power to the system by turning off the air suspension switch located on the LH side of the luggage compartment to prevent vehicle damage or personal injury.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result.

1. Turn the air suspension switch off.

1. Disconnect the battery ground cable (14301).

1. Pull out the lower instrument panel insulator.
   1. Remove the pushpins.
   1. Pull out the lower instrument panel insulator.

1. Remove the lower instrument panel insulator.
   1. Disconnect the power point.
   1. Disconnect the courtesy lamp.
   1. Remove the lower instrument panel insulator.

1. Remove the rear air suspension control module.
   1. Remove the screws.
   1. Disconnect the electrical connectors.
   1. Remove the rear air suspension control module.

Installation

1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.
   To install, reverse the removal procedure.

Removal

1. Raise the rear of the vehicle, and support it with safety stands in the proper locations.
2. Remove the rear wheel.
   1. Position a floor jack at the connecting point of the trailing arm (A) and the knuckle (B). Raise the floor jack until the suspension begins to compress.
   2. Remove the flange bolt (C) from the bottom of the damper. Discard the bolt.
   3. Remove the trunk side trim panel.
   4. Remove the self-locking nut (A) while holding the damper shaft (B) with a hex wrench (C).
      1. Compress the damper unit (A) by hand, and remove it from the vehicle.
      Inspection
      
      1. Push on the damper as shown.
      2. Compress the damper assembly by hand, and check for smooth operation through a full stroke, both compression and extension. The damper should extend smoothly and constantly when compression is released. If it does not, the gas is leaking and the damper should be replaced.
      3. Check for oil leaks, abnormal noises, or binding during these tests.
      Installation
      Install the damper mounting bushing (A) onto the damper unit. Position the damper assembly (B) between the body and trailing arm. Be careful not to damage the body
      
      
      1. Position a jack under the trailing arm to support the suspension, then install a new damper mounting bolt (A).
      2. Loosely tighten the damper mounting bolt.
      3. Raise the rear suspension with the jack until the vehicle just lifts off the safety stands, then tighten the damper mounting bolt to the specified torque value.
      4. Install the damper mounting bushing (A), the damper mounting washer (B), and a new self-locking nut (C) on the damper shaft.
      5. Tighten the self-locking nut to the specified torque value while holding the damper shaft (A) with a hex wrench (B).
      6. Remove the trunk side trim panel.
      7. Install the rear wheel. NOTE: Before installing the wheel, clean the mating surface of the brake disc or brake drum and the inside of the wheel.
      8. Check the wheel alignment, and adjust it if necessary

Rear Axle Notes

1. Raise and support vehicle.
2. Remove rear wheels.
3. Scribe alignment marks on propeller shaft and axle for proper assembly, then disconnect propeller shaft from axle.
4. Disconnect the track bar from axle mounting bracket.
5. Disconnect parking brake cable at equalizer.
6. Disconnect shock absorbers at axle tubes.
7. Disconnect hydraulic brake hose at rear axle Tee-fitting, then tape ends of hose and fitting to prevent contamination.
8. Disconnect axle vent tube from axle.
9. Remove U-bolts and tie plates.
10. Loosen spring mounting bolts.
11. If equipped, disconnect ABS wiring connections at axle.
12. Support axle with suitable jack.
13. Remove spring-to-shackle attaching bolts and lower spring to the floor.
14. Remove axle assembly.
15. Reverse procedure to install.

Front Axle Notes

1. Raise and support vehicle at frame behind front springs.
2. Remove front wheels.
3. Scribe alignment marks on propeller shaft and axle yoke for proper assembly, then disconnect propeller shaft at axle yoke.
4. Disconnect connecting rod at steering knuckles.
5. Disconnect shock absorbers at axle housing.
6. Remove stabilizer bar connecting links to spring tie plates attaching bolts, if equipped.
7. Disconnect breather tube at axle housing.
8. Disconnect stabilizer bar link bolts at spring clips.
9. Remove disc brake calipers, rotors and brake shields.
10. Remove U-bolts and tie plates.
11. Support axle assembly with suitable jack to relieve spring tension.
12. Loosen rear spring shackle to spring attaching bolts.
13. Remove front spring shackle to spring attaching bolts and lower spring to floor.
14. Remove axle from under vehicle.
15. Reverse procedure to install.

Block the front tires. Break the rear lugs loose. Jack up the rear of the truck at the center if possible. remove the wheels & brake drums. Remove the brake shoes,return springs & all the other hardware. Remove the differential cover & drain oil. If you have a posi the next step sucks. You need to remove the threaded pin from the housing & remove the axle retaining clips. All the while,being carefull of the spring in the posi unit. If no posi,then same procedure,minus the "pucker factor". After the axle is out,take a large flat blade screw driver or pry bar & pop the seal out. Keep in mind the axle bearing is probably gone too , so that's another procedure. Keep it apart,you'll be glad you did.

i don't think you have to do any repairs from the top end. I will list most fromFord shop manual. Please rate as Fixya if this answers your questions. Please report back. Good luck.

Section 04-02: Suspension and Wheel Hubs, Rear 1994 Town Car, Crown Victoria/Grand Marquis. Workshop Manual
REMOVAL AND INSTALLATION Spring Rear
Removal

1. Position a hoist under the rear axle housing, and raise the vehicle. Refer to Section 00-02 . Place jackstands under frame side rails.

1. Remove rear stabilizer bar as outlined.

1. Disconnect the lower studs of the two shock absorbers from the mounting brackets on the rear axle assembly .

1. Unsnap the RH parking brake rear cable and conduit (2A635) from RH upper arm retainer before lowering the rear axle assembly .

1. Lower the hoist and axle housing until the rear springs are released.

1. Remove rear spring and rear spring center mounting insulators (5741) from vehicle.
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Shock Absorber Removal
Raise the vehicle on a hoist. 1. To assist in removing the upper attachment on shock absorbers using a plastic dust tube, place an open end wrench on the hex stamped into the dust tube's metal cap. For shock absorbers with a steel dust tube, simply grasp the tube to prevent stud rotation when loosening the retaining nut.

1. Remove the shock absorber retaining nut, washer, and insulator assembly from the stud on the upper side of the frame. Discard nut. Compress the shock absorber to clear the hole in the frame, and remove the inner insulator and washer from the upper retaining stud.
2. Remove the self-locking retaining nut, and disconnect the shock absorber lower stud from the mounting bracket on the rear axle tube.
3. Perform Shock Absorber Checks. Refer to Section 04-00 to determine shock absorbers performance.

Installation

1. Properly prime the new shock absorber . Refer to Section 04-00 , Shock Absorber Checks.

1. Place the inner washer and rear spring insulator (5536) on the upper retaining stud, and position the shock absorber so that the upper retaining stud enters the hole in the frame. While holding the shock absorber in this position, install a new rear spring insulator , washer and nut assembly on the upper side of the upper frame. Be sure to seat the rear spring insulator in the frame attaching hole. Tighten nut to 34-46 Nm (25-34 lb-ft).

1. Extend the shock absorber , and place the lower stud in the mounting bracket hole on the rear axle assembly housing. Install a new self-locking retaining nut. Tighten nut to 76.5-103.5 Nm (56-76 lb-ft).

1. Lower vehicle.

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Arm Lower
Removal
Refer to the illustration in Description and Operation. NOTE: To improve rear axle assembly noise and vibration concerns, the rear suspension should be fastened to the frame and rear axle assembly at the curb height position.
NOTE: If one rear suspension lower arm requires replacement, also replace the opposite rear suspension lower arm .
WARNING: TURN REAR SUSPENSION LEVELER COMPRESSOR SWITCH OFF (IF SO EQUIPPED).
NOTE: If both rear suspension arm and bushings and both rear suspension lower arms are to be removed at the same time, remove both rear springs as outlined under Rear Spring Removal. For air spring removal, refer to Section 04-05 .

1. Mark rear suspension shock absorber relative to protective sleeve with the vehicle in a static, level ground condition.

1. Remove rear stabilizer bar as outlined.

1. Raise the vehicle on a hoist, and place jackstands under the rear axle assembly . Refer to Section 00-02 .

1. Lower the hoist until the shock absorbers are fully extended to relieve rear spring pressure.

1. Support rear axle assembly under differential pinion nose as well as under rear axle assembly .

1. Remove and discard the lower arm pivot bolt and nut from the axle bracket. Then, disengage the rear suspension lower arm from the bracket.

1. Remove and discard the pivot bolt and nut from the frame bracket, and remove the rear suspension lower arm .

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Upper
Removal
SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Suspension Bushing Service Set T79P-5638-A1, A2 and A5 Rear Axle Control Arm Bushing Tools T86P-5638-AH
WARNING: TURN OFF REAR SUSPENSION LEVELER COMPRESSOR SWITCH (IF SO EQUIPPED).

1. Raise the vehicle, and support the frame side rails with jackstands. Refer to Section 00-02 .
2. Support the rear axle assembly .
3. Lower the rear axle assembly , and support the rear axle assembly under differential pinion nose as well as under rear axle assembly .
4. Unsnap parking brake rear cable and conduit from upper arm retainer.
5. Remove and discard the nut and bolt retaining the rear suspension arm and bushing to the rear axle assembly housing. Disconnect the rear suspension arm and bushing from the housing.
6. Remove and discard the nut and bolt that secures the rear suspension arm and bushing to the frame bracket, and remove the rear suspension arm and bushing . If upper arm rear bushing is to be replaced, use Suspension Bushing Service Set T79P-5638-A and Rear Axle Control Arm Bushing Tools T86P-5638-AH and the following procedure:
7. Place the upper arm rear bushing remover tool in position, and pull bushing out. Using Suspension Bushing Service Set T79P-5638-A install bushing assembly into bushing ear of rear axle assembly.

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Stabilizer Bar
WARNING: TURN OFF REAR SUSPENSION LEVELER COMPRESSOR SWITCH (IF SO EQUIPPED).
Removal

1. Raise vehicle on hoist, and place jackstands under the frame side rails. Refer to Section 00-02 .

1. Lower the hoist and rear axle assembly housing until the shock absorbers are fully extended.

1. Disconnect rear stabilizer bars from rear stabilizer bar link and bushing (5C488) . Remove bolts and stabilizer bar bracket (5486) retaining rear stabilizer bar to rear axle assembly .