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SUSPENSION AND STEERING
GEM Service Manual
November 2007
TORQUE SPECIFICATIONS
Description Thread
Size
Use
Loctite®
242
Inch-
Pounds
Foot
Pounds
Brake line to wheel/master cylinder
NO
37
---
Caliper assembly to steering knuckle
M8 x 1.25
NO
---
20
Halfshaft to drum brake assembly
M16 x 1.5
YES
---
65
Ball joint pinch bolt
M6 – 1
YES
---
30
Tie rod stud nut
M10 x 1.5
NO
---
35
Wheel lug nuts
12mm NO --- 65
STEERING KNUCKLE
DESCRIPTION
The knuckle is a single casting with legs machined
for the upper and lower ball joints. It also has a
machined surface for mounting the front brake
assembly.
OPERATION
The steering knuckle pivots between the arms of
the upper and lower control arms on the ball joints.
Steering linkage attached to the knuckle allows the
vehicle to be steered.
REMOVAL
1. Raise and support the vehicle using a suitable
hoist.
2. Remove
hubcap.
3. Remove the tire and wheel assembly.
4. Remove the cotter pin and loosen the half-shaft
retaining nut.
5. Remove front brake assembly. See Front Brake
Assembly in Brake section.
6. Remove nut from the bottom of the tie rod end
stud where it joins the knuckle.
7. Use a 2-jaw puller to separate tie rod end stud
from knuckle.
8. Remove the ball joint pinch bolt.
9. Remove the knuckle.
INSTALLATION
1. Install upper and lower ball joint into knuckle.
2. Tighten the ball joint pinch bolts to 30 ft-lbs.
3. Install tie rod end stud in knuckle, tighten nut to
seat stud in knuckle. Back the nut off, and
tighten to 35 ft-lbs.
4. Install front brake assembly. See Front Brake
Assembly in Brake section.
5. Install the tire and wheel assembly, tighten lug
nuts just snug.
6. Lower vehicle to ground, then tighten lug nuts
to 65 ft-lbs.
7. Install the hubcap.
Summary of Contents for GEM E Series
Page 2: ......
Page 87: ...ELECTRICAL 5 40 November 2007 GEM Service Manual ...
Page 95: ...ELECTRICAL 5 48 November 2007 GEM Service Manual ELECTRICAL OVERVIEW ...
Page 97: ...ELECTRICAL 5 50 November 2007 GEM Service Manual POWER DISTRIBUTION ...
Page 98: ...5 51 ELECTRICAL GEM Service Manual November 2007 CHARGING SYSTEM ...
Page 99: ...ELECTRICAL 5 52 November 2007 GEM Service Manual CHARGING SYSTEM CONTINUED e6S eLXD OPTION ...
Page 100: ...5 53 ELECTRICAL GEM Service Manual November 2007 PARK BRAKE CIRCUIT ...
Page 101: ...ELECTRICAL 5 54 November 2007 GEM Service Manual DC DC CONVERTER ...
Page 102: ...5 55 ELECTRICAL GEM Service Manual November 2007 MAIN CONTACTOR ...
Page 103: ...ELECTRICAL 5 56 November 2007 GEM Service Manual MAIN CONTACTOR CONTINUED e6S eLXD OPTION ...
Page 104: ...5 57 ELECTRICAL GEM Service Manual November 2007 MOTOR CONTROLLER SYSTEM ...
Page 105: ...ELECTRICAL 5 58 November 2007 GEM Service Manual MOTOR CONTROLLER SYSTEM CONTINUED ...
Page 106: ...5 59 ELECTRICAL GEM Service Manual November 2007 DISPLAY RD ...
Page 107: ...ELECTRICAL 5 60 November 2007 GEM Service Manual DISPLAY CONTINUED ...
Page 108: ...5 61 ELECTRICAL GEM Service Manual November 2007 DISPLAY CONTINUED ...
Page 109: ...ELECTRICAL 5 62 November 2007 GEM Service Manual HORN POWER OUTLET ...
Page 110: ...5 63 ELECTRICAL GEM Service Manual November 2007 HEATER ...
Page 111: ...ELECTRICAL 5 64 November 2007 GEM Service Manual DASH FAN ...
Page 112: ...5 65 ELECTRICAL GEM Service Manual November 2007 SECURITY LIGHT BAR ...
Page 113: ...ELECTRICAL 5 66 November 2007 GEM Service Manual AUDIO SYSTEM ...
Page 115: ...ELECTRICAL 5 68 November 2007 GEM Service Manual FRONT LIGHTING EXCEPT NEW YORK ...
Page 116: ...5 69 ELECTRICAL GEM Service Manual November 2007 FRONT LIGHTING NEW YORK ...
Page 117: ...ELECTRICAL 5 70 November 2007 GEM Service Manual REAR LIGHTING EXCEPT NEW YORK ...
Page 118: ...5 71 ELECTRICAL GEM Service Manual November 2007 REAR LIGHTING NEW YORK ...
Page 119: ...ELECTRICAL 5 72 November 2007 GEM Service Manual REAR LIGHTING ...
Page 120: ...5 73 ELECTRICAL GEM Service Manual November 2007 REAR LIGHTING CONTINUED ...
Page 121: ...ELECTRICAL 5 74 November 2007 GEM Service Manual TURN SIGNAL REMINDER CIRCUIT ...
Page 122: ...5 75 ELECTRICAL GEM Service Manual November 2007 WIPER WASHER ...
Page 156: ...7 9 BODY INSTALLATION OF SCUFF GUARDS CONTINUED 10 Finish e4 GEM Service Manual November 2007 ...