NOTE: Do not lower the vehicle beyond just
touching the jack stand. Do not put tension on
the coil spring.
Figure SR1
2. Disconnect the following items:

Do not remove

• Remove clip and take the brake hydraulic line
loose from its support.
¾ Discard the clip, use new clip for
reassembly.

Brake line support

• Remove the bolt for ABS sensor harness
support.

Clip
ABS sensor
harness support

• Take the ABS sensor harness loose from
support on the other side of strut (not shown).
• Remove the lower strut bolts.
¾ Discard the nuts, use new ones for
reassembly.

Lower strut
nuts/bolts

NOTE: Do not remove the nuts from the
stabilizer connecting rod.

Do not remove
Figure SR2

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3. Carefully separate the knuckle from the strut.
NOTE: Do not let the knuckle fall away from
the strut. This will cause the weight of the
knuckle assembly
to pull on the brake line and the driveshaft
boot (if equipped).

Elastic
strap

4. Use an elastic strap or other suitable tool to
secure the knuckle to the stabilizer bar as shown.
NOTE: Make sure the knuckle assembly is
secure. Its weight must be supported during
the entire repair process.

Knuckle

Figure SR3

ABS
sensor
connector
cover

5. Remove the 2 bolts for the ABS sensor
connector cover.

Bolts

Figure SR4
ABS sensor
connector

6. Disconnect the ABS sensor connector.
•

ABS sensor connector is on the back side of
the cover.

Figure SR5

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7. Pull the ABS sensor harness from behind the
strut.

ABS
sensor
harness

8. Let the ABS sensor harness hang out of the way
as shown.

9. Raise the vehicle enough so the lower control arm
is not touching the jack stand.

Figure SR6

10. Remove the 3 upper strut mounting nuts.
•

Discard the nuts, use new ones for
reassembly.

Nuts

Figure SR7

11. Maneuver the strut so it is hanging upside down
as shown.
NOTE: The weight of strut is supported by the
stabilizer connecting rod.
Stabilizer
connecting
rod

Figure SR8
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Repair Bracket Installation for Driver Side AND Passenger Side Strut Housing
(Level 2 repair continued)
NOTE: The repair bracket installation procedure is the same on both sides, unless stated otherwise.
WARNING: Perform repairs in a well ventilated area.
NOTE: For 4WD vehicles: If the driveshaft boot is ripped, it should be covered to prevent debris from
entering the driveshaft joint.

1. Inspect the ABS sensor harness for damage. If
damaged, repair as necessary.
2. Push the ABS harness and connector through the
panel.
• The harness/connector will now be out of the
working area.

ABS
sensor
harness
Figure RB1

3. Use a scraper bar to scrape off loose flaking rust
and corrosion.

Figure RB2

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4. Clean all the loose rust from the strut housing and wheel house areas (see Figure RB3).
• Use an abrasive pad or other suitable tool.
CAUTION: Avoid contacting the brake line(s) with your abrasive tool.
NOTE: If the brake line is in the way of an area that needs cleaning, move it out of the way by first
removing the clip from the mount.

Remove the
clip if
needing to
move the
brake line

Figure RB3
Brake lines
and junction
block

4a. Passenger side: work around the
2 brake lines and junction block best
as possible (see Figure RB4).

Figure RB4
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NOTE: Steps 5 and 6 apply to Driver side only.
5. From under the hood, remove the air filter box and the air intake duct between the filter box and the
engine.

Check E-coat
for rub through

6. Inspect the steering column upper joint (steering
shaft) in the area circled in Figure RB5.
Check for rubbing/contact with the strut housing
panel.
Contact may have occurred if the strut housing
separated from the wheel house.
• ONLY if the E-coat has been rubbed
through to bare metal, the steering shaft will
need to be replaced.
• If the steering shaft needs replacement, you
will be instructed to replace it later in this
procedure.

Steering
shaft
Figure RB5

7. Passenger side – as needed: Remove the battery, Relay Box-2, etc, to access the strut tower for inspection
of separation.

7a. Only if the strut housing panel is separated as
shown in Figure RB6:
Use a wire brush to clean any loose rust, paint,
or other debris from the area shown with dashed
line.

Figure RB6

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8. Use low pressure compressed air to blow off dust and debris:
• From the under hood side of the strut housing panel and the surrounding area, and
• From the wheel house area.

9. Use isopropyl alcohol to clean/wipe down the area:
• If the strut housing panel was separated, clean/wipe down the under hood side of the strut housing
panel and the surrounding area.
• Clean/wipe down the wheel house area.

10. Only if the strut housing panel is separated:

Two coats of
self etching
primer

Completely and liberally coat the strut housing
panel (in the area shown with dashed line) with
self etching primer.
• Use DuPont Etch Primer (P/N
A-4119S™) or equivalent.
• Follow all product instructions.
• A second coat may be needed for heavy rust
spots.

Figure RB7

• Let each coat dry for 5 minutes.
NOTE: Refer to the Parts Information for
additional product details.

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11. Completely and liberally coat the strut housing and wheel house area with self etching primer.
• Use DuPont Etch Primer (P/N A-4119S™) or equivalent.
• Follow all product instructions.
• Coat all of the exposed metal areas on the strut housing and wheel house panels.
• A second coat may be needed for heavy rust spots.
• Let each coat dry for 5 minutes.
NOTE: Refer to the Parts Information for additional product details.

Up to 2 coats of self
etching primer applied

Driver side

Figure RB8

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Passenger side

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12. Driver side: Locate the 2 existing holes at the upper area of the strut housing panel (see Figure RB8a).
•

With a drill bit, enlarge the 2 existing holes to 10 mm (3/8 in).

13. Passenger side: Locate the one existing hole at the upper area of the strut housing panel (see
Figure RB8a).
•

With a drill bit, enlarge the one existing hole to 10 mm (3/8 in).
Existing holes,
enlarge to
10 mm (3/8 in)

Note the location of the
existing threaded holes.
They will be used to
align the repair bracket
in the following steps.

Driver side

Figure RB8a

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Passenger side

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14. Attach the repair bracket using the existing holes that you enlarged (see RB9).
• The repair bracket is part of the Repair Kit listed in the Parts Information.
• Use bolts and hex nuts from the Repair Kit.
• Also use the existing bolt(s) where shown in RB9.
• Tighten the bolts/nuts finger tight.
Attach bolts at
enlarged holes

Attach smaller
bolt at smaller
existing hole

Slide
bracket
behind
brake
lines

Repair Bracket

Attach existing bolts in
their existing threaded
holes

Driver side

Figure RB9

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Passenger side

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15. Only if the strut housing panel is separated:
a. Attach the ratchet strap as shown in Figure RB10.
b. Use the ratchet strap to pull the strut housing panel down until the existing threaded hole(s) is aligned
with the matching hole in the repair bracket (see Figure RB10).
16. Install all bolts as shown in Figure RB10, and make them finger tight.
17. Align the bottom edge of the repair bracket with the edge of the body frame.
• The bracket will have some movement in all directions. Move it (align it) the best possible.
18. Once the bottom edge is aligned, securely tighten all bolts (see Figure RB10).
• At this time, a pair of locking pliers or equivalent tool may be used to further support the repair bracket
(see Figure RB10).
• Bolts need to be tight enough to hold the bracket in place while center punching and drilling holes in the
next step.
Hook here
Ratchet strap
Route strap
under
brake line

Attach all bolts

Hook
here

Hook
here

If needed: Position
locking pliers here
Align edge of
bracket with
body frame

Driver side

Figure RB10

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Passenger side

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NOTE: Photos for installation of the repair bracket show the ratchet strap being used. In most cases,
the strut housing panel will not be separated and the ratchet strap will not be needed.
19. Drill the holes shown by white arrows in Figure RB11 to 10 mm (3/8 in):
a. Center punch the holes.
b. Pilot drill with a 1/8 drill bit.
c. Drill holes to 10 mm (3/8 in).
20. Passenger side: Draw a white line as shown in RB11.

White arrows:
Drill holes to
10 mm (3/8 in)

Driver side

Figure RB11

Draw line on
strut housing

Passenger side

21. When drilling is done, remove the repair bracket.

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22. For the 4 holes that will have Rivet Nuts installed, drill final hole size to 13.1 mm
(33/64 in). See Figure RB12.
NOTE: Each dealer was shipped, at no charge, one 33/64 drill bit (J-50878).
23. Install Rivet Nuts in the 13.1 mm (33/64 in) holes.
• Refer to Rivet Nut Installation Instructions on the next page.
CAUTION: DO NOT use power tools or impact tools with the Rivet Tool – use hand tools only.
IMPORTANT:
• Lower holes - Required: Rivet Nuts are required in the lower holes (indicated with dashed line in
Figure RB12).
If the metal in the area of the lower holes will not support the rivet nuts, then the vehicle is “not
repairable”: Retain the vehicle at the dealer, supply the customer with a rental car, and Fax a
completed Non-Repairable Report to Morley (see page 54).
NOTE: Upper holes – not required: If the metal in the area of the upper holes will not support rivet nuts,
continue with the repair. Rivet nuts are preferred but not required in the upper holes.

Drill these holes to final
size of 13.1 mm (33/64 in)

Upper holes for
rivet nuts - see
NOTE above

Lower holes for
rivet nuts
Driver side

Figure RB12

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Passenger side

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Rivet Nut Installation Instructions
CAUTION: DO NOT use power tools or impact tools with the Rivet Tool – use hand tools only.
NOTE: Rivet Tool J-50835 comes with extreme pressure lubricant. Apply to the threads and
contact points of part #2 and part #3 for approximately every 60 rivet nuts installed (enough for
15 brackets).
#2

Part #1

#3

Rivet nut

RB13 – Rivet Tool
1. Thread no more than finger tight part #2 into part #3 until it bottoms out (see Figure RB14).
•

This is a left handed thread.

2. Insert part #1 through part #2 and part #3 (see Figure RB15).

Figure RB14

Figure RB15

3. Thread a rivet nut onto part #1 until it bottoms out no more than finger tight (see Figure RB16).

Figure RB16

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4. Insert the rivet nut into the 13.1 mm (33/64 in) hole until it bottoms out on its collar.
Rivet nut collar
bottomed out in hole

Body panel

Figure RB17
5. Install the rivet nut by performing the following:
a. Hold the rivet nut and tool against the body panel with moderate pressure.
b. Hold stationary part #3 while turning part #2 clockwise.
c. Turn part #2 approximately 2 turns or until turning resistance increases.
• At this point, the rivet nut is installed.
Part #2: Turn
with wrench

Part #3: Hold