Undertaking the task of replacing front struts and springs on a 1996-2002 4Runner may seem daunting, but with the right tools and a systematic approach, it can be accomplished successfully. This comprehensive guide will provide step-by-step instructions, highlighting essential safety precautions and offering valuable tips to ensure a seamless repair process. By meticulously following these guidelines, you can restore your 4Runner’s suspension system to optimal functionality, enhancing both driving comfort and handling.
Before embarking on this endeavor, it is crucial to gather the necessary tools and materials. These include a jack, jack stands, a socket wrench set, a torque wrench, spring compressors, and new struts and springs specifically designed for your 4Runner’s make and model. Additionally, it is highly recommended to consult your vehicle’s service manual for specific torque specifications and any additional safety instructions relevant to your particular 4Runner.
Safety should always be paramount when performing any automotive repairs. Ensure you have a safe and stable work environment by parking your 4Runner on a level surface and engaging the parking brake. Position the jack stands securely under the designated jack points on the frame to support the vehicle once it is lifted. Once the 4Runner is securely raised, remove the front wheels to gain access to the suspension components. Disconnect the brake line bracket and the ABS sensor from the strut assembly, taking care not to damage the lines or connectors.
Materials and Tools Required
Replacing your front struts and springs on your 1996-2002 4Runner requires some essential materials and tools. Here’s a detailed list of what you’ll need to get the job done:
Safety Gear:
- Safety glasses
- Gloves
- Ear protection (optional)
- Sturdy shoes
Tools:
- Jack and jack stands
- 19mm and 21mm sockets with ratchet
- 14mm and 17mm wrenches
- Ball joint separator
- Spring compressor
- Hammer
- Pry bar
- Torque wrench (optional but recommended)
Materials:
- New front struts and springs
- Strut mount and bearing assembly (if needed)
- Strut boot (optional but recommended)
- Thread locker
- Anti-seize compound (optional but recommended)
- Penetrating oil (optional but recommended)
Make sure you have all the necessary materials and tools gathered before starting the replacement process. Having them on hand will ensure a smooth and efficient repair.
Safety Precautions and Considerations
Safety Gear
Always prioritize safety by wearing appropriate personal protective equipment (PPE) during this task. This includes:
- Safety glasses to protect your eyes from debris
- Gloves to safeguard your hands from sharp edges and chemicals
- Earplugs or earmuffs to minimize noise exposure
- Respirator to prevent inhalation of harmful fumes
Safety Precautions
Take the following precautions to ensure a safe work environment:
- Choose a well-lit and well-ventilated area.
- Park your vehicle on a flat and stable surface with the parking brake engaged.
- Use jack stands or ramps to support the vehicle and prevent it from falling.
- Check for any loose wires or hoses before disconnecting components.
- Tighten all bolts and nuts securely to the specified torque values.
Considerations
| – Before starting, inspect the struts and springs for signs of damage or wear. |
| – Ensure you have the right tools and replacement parts for your specific vehicle model. |
| – Follow the correct torque specifications when tightening bolts and nuts. |
| – Be cautious when compressing the new springs, as they can store a significant amount of energy. |
Removing the Front Wheels and Tires
Step 1: Safety First
Park your 4Runner on a flat, stable surface. Engage the parking brake to prevent the vehicle from rolling. Gather the necessary tools, including a jack, jack stands, lug wrench, and tire iron.
Step 2: Loosen the Lug Nuts
Use the lug wrench to loosen the lug nuts on the front wheels, but do not remove them completely. You can use the weight of the vehicle to help you loosen the nuts by sitting in the driver’s seat and applying the brake.
Step 3: Jack Up the Vehicle
Position the jack under the designated jack point near the front wheel you are working on. Refer to your vehicle’s owner’s manual for the specific jack point locations. Slowly pump the jack to raise the vehicle until there is approximately 6 inches of clearance between the tire and the ground.
Step 4: Place Jack Stands
Place a jack stand near the jack, close to the jack point. Slowly lower the vehicle onto the jack stand. Repeat this process for the other side of the vehicle.
Step 5: Remove the Lug Nuts and Tires
Once the vehicle is securely supported by the jack stands, remove the lug nuts completely. grip the tire firmly and pull it straight toward you to detach it from the wheelbase.
Disconnecting the Stabilizer Bar End Link
To disconnect the stabilizer bar end link, you will need to:
1. Locate the stabilizer bar end link on the lower control arm.
2. Use a 14mm wrench to loosen the nut on the end of the end link.
3. Use a pry bar to pry the end link off the lower control arm.
| Tools Needed: | Size: |
|---|---|
| Wrench: | 14mm |
| Pry bar: | Small |
Reattaching the end link is simply a matter of reversing these steps. First, insert the end link into the lower control arm. Then, tighten the nut on the end of the end link using a 14mm wrench. Finally, torque the nut to 55 ft-lbs.
Unbolting the Upper Strut Mount
Unbolting the upper strut mount is a critical step in this process. You need to be careful not to damage the mount or the strut itself. Here’s how you do it:
- Locate the nuts that hold the upper strut mount in place. There should be two or three nuts.
- Use a wrench or socket to loosen the nuts, but do not remove them completely.
- Carefully pry the upper strut mount away from the strut body. You may need to use a pry bar or a large screwdriver.
- Once the mount is loose, remove the nuts completely.
- Lift the upper strut mount off the strut body. Be careful not to damage the mount or the strut during this step.
| Tip | Description |
|---|---|
| If the upper strut mount is seized to the strut body, you may need to use a penetrating oil or lubricant to loosen it. | Do not use excessive force when prying the upper strut mount away from the strut body. This could damage the mount or the strut. |
Installing the Front Strut and Spring Assembly
Step 1: Clean the Strut Assembly
Remove any dirt or debris from the strut assembly using a wire brush or compressed air.
Step 2: Install the Spring Seat
Place the spring seat on the top of the strut assembly and secure it with the bolt and washer.
Step 3: Install the Spring
Position the spring on the spring seat and compress it using a spring compressor.
Step 4: Install the Strut Mount
Place the strut mount on the top of the spring and secure it with the three bolts and washers.
Step 5: Install the Strut Assembly
Insert the strut assembly into the wheel well and align the bolt holes.
Step 6: Tighten the Bolts
Tighten the bolts that secure the strut assembly to the wheel well, the spring seat to the strut assembly, and the strut mount to the spring.
| Bolt | Torque |
|---|---|
| Strut Assembly to Wheel Well | 113 ft-lb (153 Nm) |
| Spring Seat to Strut Assembly | 51 ft-lb (69 Nm) |
| Strut Mount to Spring | 18 ft-lb (24 Nm) |
Step 7: Install the Wheel
Install the wheel and tighten the lug nuts to the specified torque.
Removing the Old Strut and Spring Assembly
1. Gather Tools and Materials
Collect necessary tools, including a socket wrench, torque wrench, spring compressors, and a penetrating lubricant.
2. Prepare the Vehicle
Park the vehicle on a level surface and engage the parking brake. Raise and support the vehicle safely with jack stands.
3. Remove the Wheel
Remove the lug nuts and detach the tire from the hub.
4. Disconnect the Brake Line
Carefully disconnect the brake line from the caliper. Be cautious not to damage the line.
5. Remove the Caliper and Rotor
Unbolt the caliper and suspend it with a bungee cord. Remove the rotor from the hub.
6. Disconnect the Sway Bar
Locate the sway bar links and remove their bolts. Disconnect the sway bar from the suspension.
7. Remove the Strut Assembly
a. Compress the Spring
Using spring compressors, slowly compress the spring to relieve tension. Follow all safety precautions and use extreme caution.
b. Remove Upper Mount Bolts
Locate the bolts securing the strut to the upper mount and remove them.
c. Remove Pinch Bolt
Identify the pinch bolt connecting the strut to the lower control arm and remove it.
d. Separate Strut Assembly
Carefully guide the strut assembly out of the vehicle.
Installing the New Spring and Strut
8. Installing the Spring and Strut Assembly
Before you begin this step, consult the torque specifications table below. You will need these values when tightening the nuts and bolts involved in this process. Double-check that the spring is correctly oriented, then carefully slide the spring and strut assembly up into the strut tower. Ensure that the strut rod is aligned with the hole in the knuckle. Use a pry bar or a large flat-head screwdriver to compress the spring slightly, allowing the strut rod to be inserted into the hole.
Once the strut rod is fully inserted, use a torque wrench to tighten the strut-to-knuckle bolts. The exact torque values may vary depending on your specific 4Runner model and year, so refer to the table below for the correct specifications.
| Bolt/Nut | Torque (ft-lbs) |
|---|---|
| Strut-to-Knuckle Bolts | 87-101 |
| Upper Strut Mount Nuts | 25-33 |
| Strut Bar (if applicable) | 22-29 |
With the strut assembly securely in place, connect the brake line and ABS sensor wire (if equipped). Finally, tighten the upper strut mount nuts to the torque specified in the table above.
Tightening and Reassembling the Components
1. Tightening the Castle Nut
Tighten the castle nut using a 19mm socket wrench until it’s snug. Then, insert a cotter pin through the holes in the castle nut and spindle and spread the ends to secure it.
2. Installing the Wheel Bearing
Press the wheel bearing into the spindle, using a bearing press or a suitable tool. Ensure it’s fully seated and secure.
3. Installing the Brake Rotor
Slide the brake rotor over the wheel bearing and onto the spindle. Tighten the lug nuts by hand.
4. Installing the Brake Caliper
Reattach the brake caliper to the spindle and tighten the bolts using a 17mm socket wrench. Connect the brake line to the caliper.
5. Installing the Wheel
Place the wheel on the hub and tighten the lug nuts using a torque wrench. Follow the manufacturer’s recommended torque specifications.
6. Tightening the Upper and Lower Control Arms
Tighten the upper and lower control arm bolts using a combination wrench or a socket wrench. Ensure they are tightened to the proper specifications.
7. Adjusting the Tie Rod Ends
Adjust the length of the tie rod ends to center the steering rack. Tighten the locknuts and recheck the alignment.
8. Installing the Sway Bar Link
Attach the sway bar link to the sway bar and tighten the bolts using a 19mm socket wrench.
9. Bleeding the Brake System
Connect a bleeder bottle to the brake caliper and pump the brake pedal repeatedly until clear fluid exits. Repeat the process for all four wheels. Check the brake fluid level and top up as needed.
| Tool | Size |
|---|---|
| Socket wrench | 17mm, 19mm |
| Combination wrench | 17mm, 19mm |
| Bearing press | – |
Aligning the Vehicle
Once the new struts and springs are installed, it is important to have the vehicle aligned. Misalignment can cause uneven tire wear, poor handling, and reduced fuel efficiency. To align the vehicle, you will need to take it to a mechanic or have access to a specialized alignment machine.
The alignment process involves adjusting the angles of the wheels so that they are parallel to each other and perpendicular to the road. This is done by adjusting the tie rods, which connect the steering rack to the steering knuckles. The mechanic will also need to adjust the camber and caster angles, which affect the way the wheels turn.
After the alignment is complete, your vehicle will drive better and handle more smoothly. It is a good idea to have your vehicle aligned whenever you replace the struts or springs, or if you notice any signs of misalignment, such as uneven tire wear.
Signs of Misalignment
Here are some signs that your vehicle may need an alignment:
- Uneven tire wear
- Poor handling
- Reduced fuel efficiency
- The steering wheel is not centered when driving straight
- The vehicle pulls to one side when driving
If you notice any of these signs, it is important to have your vehicle aligned as soon as possible.
| Alignment Angle | Description |
|---|---|
| Camber | The angle of the wheel when viewed from the front |
| Caster | The angle of the steering axis when viewed from the side |
| Toe | The angle of the wheels when viewed from above |
The alignment angles are measured in degrees. The ideal alignment angles for your vehicle can be found in the owner’s manual.
How to Replace Front Struts and Springs on a 1996-2002 4Runner
Tools and Materials Required:
Tools:
- Jack and jack stands
- Lug wrench
- Socket wrench
- Torque wrench
- Spring compressor
Materials:
- New front struts
- New front springs
- Strut mount nuts
- Strut mount bolts
- Spring seat bolts
Step-by-Step Instructions:
1. Safety First:
- Park the 4Runner on a flat, stable surface.
- Engage the parking brake.
- Place wheel chocks behind the rear wheels.
2. Remove the Wheel:
- Use the lug wrench to loosen the lug nuts on the front wheel you’ll be working on.
- Lift the 4Runner and support it securely using jack stands.
- Remove the loosened lug nuts and detach the wheel.
3. Compress the Spring:
- Position the spring compressor around the spring.
- Slowly tighten the compressor to compress the spring.
- Ensure the spring is compressed enough to allow you to remove the strut.
4. Remove the Strut Mount Nuts and Bolts:
- Locate the three strut mount nuts and bolts.
- Use the socket wrench to remove these nuts and bolts.
5. Remove the Strut:
- Carefully grasp the strut and pull it straight out of the vehicle.
- Be cautious as the spring may still be under tension.
6. Install the New Spring:
- Position the new spring onto the strut.
- Ensure the spring is seated correctly in the spring seat.
7. Install the New Strut:
- Insert the new strut into the vehicle.
- Align the strut mount with the holes on the suspension.
- Hand-tighten the strut mount nuts and bolts.
8. Tighten the Strut Mount Nuts and Bolts:
- Use the torque wrench to tighten the strut mount nuts and bolts to the specified torque.
9. Release the Spring Compressor:
- Slowly loosen the spring compressor to release the tension on the spring.
- Remove the spring compressor.
10. Reinstall the Wheel:
- Mount the wheel back onto the hub.
- Hand-tighten the lug nuts.
- Lower the 4Runner and use the lug wrench to fully tighten the lug nuts.
11. Repeat for Other Side:
- Repeat the process for the other front wheel.
12. Final Torque:
- Check the torque of all nuts and bolts after driving a few miles.
People Also Ask About How to Replace Front Struts and Springs on a 1996-2002 4Runner
Is it difficult to replace front struts and springs on a 4Runner?
Replacing front struts and springs is a moderate to difficult task. It requires specialized tools and mechanical knowledge. It is recommended to consult a mechanic if you are not comfortable performing this repair yourself.
How long does it take to replace front struts and springs on a 4Runner?
The replacement process typically takes 2-4 hours per side, depending on the experience of the mechanic. Allow for additional time for the initial preparations and final inspection.
What are the signs of worn-out struts and springs?
Worn-out struts and springs can cause various issues, including:
– Uneven tire wear
– Poor handling
– Bouncing or swaying
– Increased braking distance
– Reduced ride comfort
