Polaris GEM E Series User manual

GEM Service Manual - REV 1 - 4/19/2012 November 2007
1 – INTRODUCTION ............................... 1-1
2 – SUSPENSION AND STEERING ....... 2-1
3 – DRIVETRAIN ..................................... 3-1
4 – BRAKES............................................ 4-1
5 – ELECTRICAL .................................... 5-1
6 – WHEELS AND TIRES ....................... 6-1
7 – BODY................................................. 7-1

INTRODUCTION 1 - 1
GEM Service Manual November 2007
CONTENTS
INTRODUCTION................................................................................................................................................................................1 - 2
GENERAL WARNINGS .....................................................................................................................................................................1 - 2
VEHICLE IDENTIFICATION/SAFETY CERTIFICATION LABEL.......................................................................................................1 - 3
FASTENER USAGE...........................................................................................................................................................................1 - 3
PARTS AND LUBRICANT RECOMMENDATION..............................................................................................................................1 - 5
MAINTENANCE SCHEDULES..........................................................................................................................................................1 - 5
HOISTING AND JACKING.................................................................................................................................................................1 - 6

1 - 2 INTRODUCTION
November 2007 GEM Service Manual
INTRODUCTION
Appropriate service methods and proper repair
procedures are essential for the safe, reliable
operation of your vehicles, as well as the safety of
the individual doing the work. This service manual
provides general directions for accomplishing
service and repair work with recommended
techniques. Following them will help ensure
reliability.
There are numerous variations in procedures,
techniques, tools, and parts for servicing your
vehicle, as well as in the skill levels of the
individuals doing the work. This manual cannot
possibly anticipate all such variations and provide
advice or cautions for each. Accordingly, anyone
who departs from the instructions provided in this
manual must first establish that he/she
compromises neither their personal safety nor
vehicle integrity by their choice of methods, tools,
or parts.
GENERAL WARNINGS
Observe the following safety precautions whenever
you are working on your vehicle:
• Always wear safety glasses for eye protection.
• Use safety stands whenever a procedure
requires you to be under the vehicle.
• Be sure that the ignition switch is always in the
OFF position and that the key is removed.
• Be sure to switch the 72-volt master disconnect
to OFF.
• Set the parking brake and place wood blocks
(4" x 4" or larger) to the front and rear surfaces
of the tires to restrain the vehicle from
movement.
• Do not smoke while working on your vehicle.
Batteries produce hydrogen gas that is
extremely flammable and will explode upon
exposure to any ignition source.
• Remove rings, watches, loose jewelry, and
loose clothing when working on your vehicle to
avoid injury.
NOTE: The terms right-hand (RH) and left-hand
(LH) are relative to one sitting in the driver's
seat. Therefore, right-hand refers to the
passenger side, and left-hand refers to the
driver's side of the vehicle.

INTRODUCTION 1 - 3
GEM Service Manual November 2007
VEHICLE
IDENTIFICATION/SAFETY
CERTIFICATION LABEL
DESCRIPTION
A label, containing the Vehicle Identification
Number (VIN) and safety certification, is located
above the bench seat on the underside of the rear
roof panel on the driver's side.
The information on the label includes:
• Vehicle Identification Number (VIN)
• Month and year of manufacture
• Gross Vehicle Weight Rating (GVWR)
• Gross Front and Rear Axle Ratings (GAWR)
• Wheel size
• Tire size
• Cold tire pressure
Fig. 1 VIN/Certification Label
Fig. 2 VIN/Certification Location
1 - VIN/Certification Label Location (Typical - 2-passenger model
shown)
NOTE: The last six digits of the VIN are also
located on the rear frame support under the
bench seat cushion.
FASTENER USAGE
DESCRIPTION
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR
PERSONAL INJURY.
Fasteners and torque specifications references in
this Service Manual are identified SAE format.
During any maintenance or repair procedure, it is
important to salvage all fasteners (nuts, bolts, etc.)
for reassembly. If the fastener is not salvageable, a
fastener of equivalent specification must be used.
NOTE: Nylon lock nuts must always be
replaced.

1 - 4 INTRODUCTION
November 2007 GEM Service Manual
FASTENER USAGE (CONTINUED)
TORQUE SPECIFICATIONS
Description Thread
Size Use
Loctite®
242
Inch-Pounds Foot-
Pounds
Battery cables to battery post NO 95-105 in/lbs 5/16"
post
120-180 in/lbs 3/8"
post
---
Brake line to wheel/master cylinder NO 37 ---
Brake master cylinder to frame 5/16 - 18 NO 225 ---
Brake pedal assembly to frame 5/16 - 18 NO 225 ---
Brake pedal to push rod 3/8 - 16 NO --- 30
Brake, parking – cable mount to rear
suspension ½” x 13 NO --- 50
Control arm to frt. suspension frame M12 x 1.75 NO --- 30
Differential to frt. suspension frame 5/16 – 18 NO 225 ---
Front suspension frame to frame (lower) M12 x 1.75 YES --- 60
Front suspension frame to frame (upper) 3/8 – 16 YES --- 30
Ball joint pinch bolt M6 – 1 YES --- 30
Motor to differential ¼ - 20 YES 65 ---
Rack & pinion to frt. suspension frame M8 x 1.25 NO 225 ---
Rear suspension frame to frame M12 x 1.75 NO --- 60
Seat belt D-ring to frame NO --- 60
Seat belt end to frame NO --- 60
Seat belt latch assembly to frame NO --- 60
Seat belt latch assembly to bracket – bucket
seat NO --- 60
Seat belt retractor to bracket – bucket seat NO --- 60
Seat belt retractor to frame – bench seat NO --- 60
Shock absorber lower bolt M12 x 1.75 NO --- 60
Shock absorber upper bolt M12 x 1.75 NO --- 60
Steering column pinch bolt 3/8 – 16 NO --- 35
Steering column to dash frame 5/16 – 18 NO 225 ---
Steering wheel to steering shaft NO --- 20
Tie rod stud nut M10 x 1.5 NO --- 35
Wheel lug nuts 12mm NO --- 65

INTRODUCTION 1 - 5
GEM Service Manual November 2007
PARTS AND LUBRICANT
RECOMMENDATION
When service is required, GEM recommends that
only GEM replacement parts be used. GEM
provides the best-engineered products for servicing
GEM vehicles.
DESCRIPTION - LUBRICANTS AND GREASE
Only lubricants bearing designations defined by
The Society for Automotive Engineers (SAE)
should be used to service a GEM vehicle.
The National Lubricating Grease Institute (NLGI)
rates lubricating grease for quality and usage. All
approved products have the NLGI symbol (Fig. 3)
on the label. At the bottom of the symbol is the
usage and quality identification letters. The letter
"G" identifies wheel-bearing lubricant. The letter "L"
identifies chassis lubricant. The letter following the
usage letter indicates the quality of the lubricant.
The following symbols indicate the highest quality.
Fig. 3 NLGI Symbols
1 - Wheel bearing lubrication
2 - Chassis lubrication
3 - Chassis and wheel bearing lubrication
DESCRIPTION - DIFFERENTIAL
Use 30 SAE engine oil – 12.44:1/14.76:1, 16 oz..
DESCRIPTION - BRAKE FLUID
Use only DOT 3 brake fluid from an unopened
container when filling the master cylinder to prevent
contaminants from entering the brake system.
MAINTENANCE SCHEDULES
Perform the following inspections, and corrections
as necessary, on a monthly basis.
Item Description
1. Check all six batteries for proper water
levels (if applicable).
2. Check battery terminals for tight
connections.
3. Check battery terminals for corrosion.
4. Check tires for correct PSI and wear.
5. Check for proper operation of hand brake.
6. Check master cylinder for proper brake
fluid levels.
7. Check brake lines for leaks.
8. Check seat belts for proper operation.
9. Check headlights, horn, turn signals,
windshield wiper and brake lights for
proper operation.
10. Check battery hold-down bar to make
sure batteries are tightly secured.
11. Check for worn insulation and frayed
wires.

1 - 6 INTRODUCTION
November 2007 GEM Service Manual
HOISTING AND JACKING
Fig. 4 Hoisting/Jacking Locations
A vehicle can be lifted with:
• A single-post frame-contact hoist
• A twin-post, chassis hoist
• A ramp-type drive-on hoist
NOTE: When a frame-contact type hoist is
used, verify that the lifting pads are positioned
properly.
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE
VEHICLE. WHEN A CHASSIS OR DRIVETRAIN
COMPONENT IS REMOVED FROM A VEHICLE,
THE CENTER OF GRAVITY IS ALTERED
MAKING SOME HOISTING CONDITIONS
UNSTABLE. PROPERLY SUPPORT OR
SECURE VEHICLE TO HOISTING DEVICE WHEN
THESE CONDITIONS EXIST.
CAUTION: Do not attempt to lift a vehicle with a
floor jack positioned under an axle tube, body
side panel or sill, or front control arm. When
properly positioned, a floor jack can be used to
lift a GEM vehicle. Support the vehicle in the
raised position with jack stands at the locations
indicated.

SUSPENSION & STEERING 2 - 1
November 2007 GEM Service Manual
CONTENTS
WHEEL ALIGNMENT......................................................................................................................................................................2 - 2
ALIGNMENT...................................................................................................................................................................................2 - 4
FRONT SUSPENSION ...................................................................................................................................................................2 - 5
SPRING OVER SHOCK ABSORBER ASSEMBLY ........................................................................................................................2 - 6
CONTROL ARM ASSEMBLY (WITH BUSHINGS).........................................................................................................................2 - 7
REAR SUSPENSION......................................................................................................................................................................2 - 8
REAR SUSPENSION FRAME/AXLE (2-4 PASSENGER ONLY) (e2, e4, eS, eL)........................................................................2 - 8
REAR SUSPENSION FRAME/AXLE (6 PASSENGER & LONG BACK EXTRA DUTY) (e6, e6S, eLXD).....................................2 - 9
REAR HUB AND BEARING/SPINDLE (6 PASSENGER & LONG BACK EXTRA DUTY) (e6, e6S, eLXD)....................................2 - 10
STEERING......................................................................................................................................................................................2 - 11
STEERING WHEEL........................................................................................................................................................................2 - 13
STEERING COLUMN ASSEMBLY.................................................................................................................................................2 - 15
STEERING GEAR...........................................................................................................................................................................2 - 16
OUTER TIE ROD END....................................................................................................................................................................2 - 17
STEERING KNUCKLE....................................................................................................................................................................2 - 18

2 - 2 SUSPENSION AND STEERING
GEM Service Manual November 2007
INSPECTION - PRE-ALIGNMENT
WHEEL ALIGNMENT The steering system should be inspected for wear.
Any worn or damaged components must be
replaced before checking alignment. The pressure
of all four tires should be set to specification with a
high quality tire pressure gauge, not the pencil type,
before checking the alignment or performing a
driving inspection. Customer complaints of poor
handling or excessive front tire wear should be
confirmed by a test drive. The test drive should be
performed on a smooth level surface with plenty of
room to maneuver.
DESCRIPTION
Front wheel alignment is essential for proper
vehicle handling and passenger safety. Front-end
damage or replacement of any steering or front
suspension component will require inspection of the
alignment to determine if it is still within
specifications.
CAUTION: Never attempt to modify suspension
or steering components by heating or bending. Before starting wheel alignment, the following
inspection and necessary corrections must be
completed. Refer to Fig. 1 Tire Wear Chart and the
Suspension and Steering Diagnosis and Testing
Chart below for additional information.
1. Inspect tires for size, air pressure and tread
wear.
2. Inspect front wheel bearings for wear.
3. Inspect ball joints, linkage pivot points and
steering gear for looseness, roughness or
binding.
4. Inspect suspension components for wear and
noise.
5. Road test the vehicle.
Fig. 1 Tire Wear Chart

SUSPENSION AND STEERING 2 - 3
November 2007 GEM Service Manual
SUSPENSION AND STEERING DIAGNOSIS AND TESTING
Condition Possible Causes Correction
Front end noise • Loose or worn wheel bearing
• Loose or worn steering or suspension
components
• Replace front knuckle assembly
• Tighten or replace components as
necessary
Excessive play in
steering
• Loose or worn wheel bearing
• Loose or worn steering or suspension
components
• Loose or worn steering gear
• Replace front knuckle assembly
• Tighten or replace components as
necessary
• Tighten or replace steering gear
Front wheels
shimmy
• Loose or worn wheel bearing
• Loose or worn steering or suspension
components
• Tires worn or out of balance
• Replace front knuckle assembly
• Tighten or replace components as
necessary
• Replace or balance tires
Vehicle instability • Loose or worn wheel bearing
• Loose or worn steering or suspension
components
• Tire pressure
• Alignment
• Replace front knuckle assembly or rear
drum brake assembly
• Tighten or replace components as
necessary.
• Adjust tire pressure
• Align vehicle to specifications
Excessive
steering effort
• Loose or worn steering gear
• Steering column u-joints binding
• Tire pressure
• Alignment
• Replace steering gear
• Replace steering column
• Adjust tire pressure
• Align vehicle to specifications
Vehicle pulls to
one side
• Tire pressure
• Tire
• Worn wheel bearings
• Loose or worn ball joints
• Weak or broken spring/shock absorber
assembly
• Adjust tire pressure
• Rotate front tires side to side
• Replace front knuckle assembly
• Replace ball joints as necessary
• Replace spring/shock/absorber
• Check for proper front end alignment
Vehicle pulls to
one side while
braking
• Brakes worn or out of adjustment
• Air in brake lines
• Loose or worn steering or suspension
components
• Worn wheel bearings
• Wheel cylinder leaking (rear only)
• Adjust or replace brake components
• Bleed brakes
• Tighten or replace components as
necessary
• Replace front knuckle assembly
• Replace wheel cylinder
Excessive tire
wear at center of
tire
• Toe out of specification
• Tires over-inflated
• Reset toe to proper specification
• Release park brake or adjust park brake
cable tension
• Repair or replace brakes
Vehicle cannot
reach top speed • Toe out of specification
• Park brake on or cables tensioned too
tight
• Brakes binding
• Reset toe to proper specification
• Release park brake or adjust park brake
cable tension
• Repair or replace brakes
Vehicle will not
coast • Toe out of specification
• Park brake on or cables tensioned too
tight
• Brakes binding
• Reset toe to proper specification
• Release park brake or adjust park brake
cable tension
• Repair or replace brakes
Vehicle makes
thumping sound
on tight turns
• Toe out of specification.
• CV boot cut or torn. • Reset toe to proper specification • Replace CV boot

2 - 4 SUSPENSION AND STEERING
GEM Service Manual November 2007
ALIGNMENT
DESCRIPTION
TOP VIEW
Fig. 2 Toe-In vs. Toe-Out
Toe is the only available adjustment in the front
wheel alignment. Toe is the difference between the
leading inside edges and trailing inside edges of
the front tires. It should be measured at a point
above the ground equal to one-half the overall
diameter of the wheel/tire assembly. The
specification is + 1/16 inch toe in.
Wheel toe position out of specification causes
unstable steering, uneven tire wear and steering
wheel off-center.
MEASURING TOE
1. Park the vehicle on a level flat surface.
2. Center the front wheels.
3. Roll car forwards 6-8 ft and apply emergency
brake.
4. Measure distance from the inboard edge of the
tread at the rear of the right front tire to the
inboard edge of the tread at the rear of the left
front tire.
5. Measure distance from the inboard edge of the
tread at the front of the right front tire to the
inboard edge of the tread at the front of the left
front tire.
6. Subtract the front measurement from the rear
measurement. If the front measurement is less
than the rear, the vehicle has toe-in, and is
shown with a plus sign (+1/16"). If the front
measurement is greater than the rear, the
vehicle has toe-out, and the difference is shown
with a minus sign (-1/16").
ADJUSTING TOE
1. Center the front wheels.
2. Inspect the position of the pinch bolt that joins
the steering column shaft to the steering gear.
This bolt must be horizontal and under the shaft
(see Figure 3). If necessary, turn the steering
wheel to put the bolt in this orientation.
Remove and re-center the steering wheel if
required.
3. Lash the steering wheel in the centered
position.
4. Loosen the lock nuts on the tie rods.
5. Use locking pliers to hold the clamp that
secures the small end of the boot to the tie rod.
Take care not to damage the boot.
6. Using a 9/16” wrench, rotate the tie rods so that
the front wheels have the specified toe-in (see
Figure 4).
7. Tighten the lock nuts.
Fig. 3 Pinch Bolt Orientation
1 - Steering shaft
2 - Pinch bolt (parallel to steering gear mounting bracket)
3 - Steering gear
Fig. 4 Tie Rod Adjustment

SUSPENSION AND STEERING 2 - 5
November 2007 GEM Service Manual
FRONT SUSPENSION
Fig. 5 Front Suspension System
1 - Front suspension frame
2 - Upper control arm
3 - Spring/shock absorber
4 - Knuckle
5 - Lower control arm
DESCRIPTION
The front suspension is designed to allow each
wheel to adapt to different road surfaces
independently. The wheels are mounted to rotor
assemblies, which in turn are mounted to the
steering components attached to a control arm, that
pivot up and down on bushings. Spring and shock
absorber assemblies at each yoke provide
cushioning.
CAUTION: Suspension components with
rubber/urethane bushings should be tightened
with the vehicle at normal ride height. It is
important to have the springs supporting the
weight of the vehicle when the fasteners are
tightened. This will maintain vehicle ride
comfort and prevent premature bushing wear.
TORQUE SPECIFICATIONS
Description Thread Size Use
Loctite®
242
Inch-
Pounds Foot -
Pounds
Brake line to wheel/master cylinder NO 37 ---
Control arm to frt. Suspension frame M10 x 1.5 NO --- 30
Differential to frt. Suspension frame 5/16” –18 NO 225 ---
Front suspension frame to frame (lower) M12 x 1.75 YES --- 40
Front suspension frame to frame (upper) 3/8 –16 YES --- 30
Halfshaft to knuckle assembly M16 x 1.5 YES --- 65
Ball joint pinch bolt M10 x 1.50 YES --- 30
Rack & Pinion to frt. Suspension frame M8 x 1.25 NO 225 ---
Rear suspension frame to frame M12 x 1.75 NO --- 60
Shock absorber lower bolt M12 x 1.75 NO --- 60
Shock absorber upper bolt M12 x 1.75 NO --- 60
Steering column pinch bolt 3/8 – 16 NO --- 35
Steering column to dash frame 5/16 – 18 NO 225 ---
Steering wheel to steering shaft NO --- 20
Tie rod stud nut M10 x 1.5 NO --- 35
Wheel lug nuts 12mm NO --- 65

2 - 6 SUSPENSION AND STEERING
GEM Service Manual November 2007
SPRING OVER SHOCK
ABSORBER ASSEMBLY
DESCRIPTION
The GEM e-series vehicles combine a spring and
shock absorber into a single unit. They are used on
both the front and rear suspension. They are not
serviceable, but must be replaced.
OPERATION
The shock absorbers dampen bounce and rebound
of the vehicle over various road and terrain
conditions.
DIAGNOSIS AND TESTING
Movement between mounting bushings, metal
brackets and attaching components may cause a
knocking or rattling noise from a shock
absorber/spring unit. Tightening the attaching nuts
can usually stop these noises. If the noise persists,
inspect for damaged and worn bushings and/or
attaching components. Replace if any of these
conditions exist.
A squeaking noise from the shock absorber may be
caused by the hydraulic valving and may be
intermittent. This condition is not repairable and the
shock absorber must be replaced.
The shock absorbers are not refillable or
adjustable. If a malfunction or leak occurs, the
shock absorber/spring unit must be replaced.
To test a shock absorber, hold it in an upright
position and force the piston in and out of the
cylinder four or five times. The action throughout
each stroke should be smooth and even.
CAUTION: The shock absorber bushings do not
require any type of lubrication. Do not attempt
to stop bushing noise by lubricating them.
Grease and mineral oil-based lubricants will
deteriorate the bushing.
REMOVAL - FRONT SHOCKS
1. Raise and support the vehicle on a suitable
hoist.
2. Using a 3/4-inch wrench and socket, remove
mounting bolts and nuts.
3. Remove the shock.
CLEANING AND INSPECTION
Check bolts and nuts for signs of wear and replace
if necessary.
INSTALLATION
1. Install the shock.
2. Install the bolts and nuts. Just tighten snug.
3. Lower the vehicle to the ground.
4. Torque the shock bolts to 60 ft-lb.
REMOVAL - REAR SHOCKS
1. Measure the ride height.
2. Raise and support the vehicle on a suitable
hoist.
3. Using a 3/4-inch wrench and socket, remove
mounting bolts and nuts.
4. Remove the shock.
CLEANING AND INSPECTION
Check bolts and nuts for signs of wear and replace
if necessary.
INSTALLATION
1. Remove the shock.
2. Install the shock.
3. Install the bolts and nuts. Just tighten snug.
4. Use a suitable jack stand; raise the rear
suspension to the measure ride height as
measured in the removal procedure.
5. Torque the shock bolts to 60 ft-lb.
6. Lower the vehicle.
TORQUE SPECIFICATIONS
Description Thread Size Use
Loctite®
242
Inch-
Pounds Foot - Pounds
Shock absorber upper and lower bolt M12 x 1.75 NO --- 60

SUSPENSION AND STEERING 2 - 7
November 2007 GEM Service Manual
CONTROL ARM ASSEMBLY
(WITH BUSHINGS)
DESCRIPTION
The upper and lower control arm connects the front
suspension to the front frame support assembly. It
is connected to the front frame support by bolts
passing through bushings that allow the control arm
to pivot vertically.
NOTE: The bushings are not serviceable. The
control arm and bushings must be replaced as
a unit.
REMOVAL
1. Raise and support the vehicle on a suitable
hoist.
2. Remove the hubcap.
3. Remove the tire and wheel assembly.
4. If removing the upper control arm only, use a
3/4-inch wrench and socket and remove the
spring/shock absorber lower mounting bolt.
5. Support the control arm assembly, then remove
the bolts connecting control arm to front frame
and the steering knuckle.
6. Remove the control arm assembly.
INSTALLATION
1. Install the control arm assembly to the frame
and steering knuckle. Tighten just snug.
2. If installing the upper control arm only, install
the spring/shock absorber lower mounting bolt.
Tighten just snug.
3. Install the tire and wheel assembly. Tighten the
lug nuts to 65 ft-lbs.
4. Install the hubcap.
5. Lower vehicle to ground, then tighten the
control arm mounting bolts to 30 ft-lbs.
6. Tighten spring/shock absorber lower mounting
bolt to 60 ft-lbs.
TORQUE SPECIFICATIONS
Description Thread Size Use
Loctite®
242
Inch-
Pounds Foot-
Pounds
Brake line to wheel/master cylinder NO 37 ---
Control arm to front suspension frame M10 x 1.5 NO --- 30
Halfshaft to steering knuckle assembly M16 x 1.5 YES --- 65
Shock absorber lower bolt M12 x 1.75 NO --- 60
Shock absorber upper bolt M12 x 1.75 NO --- 60
Tie rod stud nut M10 x 1.5 NO --- 35
Wheel lug nuts 12mm NO --- 65

2 - 8 SUSPENSION AND STEERING
GEM Service Manual November 2007
REAR SUSPENSION
DESCRIPTION
The rear suspension is comprised of a frame that
includes the rear axle, and spring/shock absorbers.
Fig. 6 Rear Suspension System
1 - Rear suspension frame/axle
2 - Spring/Shock absorber
OPERATION
The rear suspension frame pivots up and down on
bolts where it is mounted to the rear of the frame.
Rear drum brakes and wheels are mounted on
flanges at each end of the rear axle. Spring/shock
absorber units control the movement, thereby
maintaining contact of the tires on the road.
CAUTION: Suspension components with
rubber/urethane bushings should be tightened
with the vehicle at normal ride height. It is
important to have the springs supporting the
weight of the vehicle when the fasteners are
torqued. This will maintain vehicle ride comfort
and prevent premature bushing wear.
REAR SUSPENSION
FRAME/AXLE
(2-4 PASSENGER ONLY)
(e2, e4, eS, eL)
DESCRIPTION
The rear suspension frame is attached to the rear
of the vehicle frame by bolts in bushings.
OPERATION
The rear suspension frame provides a platform for
the rear shocks, and acts as an axle for the rear
wheels and brakes.
REMOVAL
1. Raise and support the vehicle on a suitable
hoist.
2. Remove rear drum brake assemblies.
3. (Vehicles with spat only) If removing the rear
axle only, remove the spat bracket. See Spat
Bracket in Body section.
4. Make sure to properly support rear frame/axle
assembly.
5. Remove the bolts securing the brake lines to
the axle.
6. Remove the lower spring/shock bolts with a 3/4-
inch wrench and socket.
7. Remove the bolts attaching the frame/axle
assembly to rear trailing arms.
8. Remove the frame/axle assembly.
CLEANING AND INSPECTION
Inspect frame/axle assembly for damage and/or
worn bushings. Bushings are not serviceable.
Replace the frame/axle assembly if worn or
damaged.

SUSPENSION AND STEERING 2 - 9
November 2007 GEM Service Manual
INSTALLATION
1. Move the frame/axle assembly into position on
the rear of vehicle frame.
2. Install the bolts attaching the frame/axle
assembly to rear trailing arms. Tighten just
snug.
3. Install the spring/shock assembly mounting
bolts with 3/4-inch wrench and socket. Tighten
just snug.
4. Install bolts securing brake lines to axle.
5. Remove support from rear axle assembly.
6. (Vehicles with spat only) If installing the rear
axle only, install the spat bracket. See Spat
Bracket in Body section.
7. Attach the rear drum brake assemblies.
8. Install the tire and wheel assembly. Tighten the
lug nuts just snug.
9. Tighten wheel lug nuts to 65 ft-lbs.
10. Install the hubcap.
11. Lower the vehicle to the floor.
12. Tighten rear suspension frame-to-frame bolts to
60 ft-lbs.
13. Tighten spring/shock absorber mounting bolts
to 60 ft-lbs.
REAR SUSPENSION
FRAME/AXLE
(6 PASSENGER & LONG
BACK EXTRA DUTY)
(e6, e6S, eLXD)
REMOVAL
1. Raise and support the vehicle on a suitable
hoist.
2. Remove the hubcap.
3. Remove the tire and wheel assembly.
4. Remove the brake drum.
5. (Vehicles with Spat). If removing the rear axle
only, remove the spat bracket. See Spat
Bracket in Body section.
6. Make sure to properly support the rear
Frame/Axle assembly.
7. Remove the bolts securing the brake lines to
the axle.
8. Remove the rear hub and bearing.
9. Remove the rear spindles.
10. Note: Support the backing plate assemblies to
protect the brake lines and parking brake
cables.
11. Remove the lower spring/shock bolts with a 3/4
inch wrench and socket.
12. Remove the bolts attaching the frame/axle
assembly to the rear trailing arms.
13. Remove the frame/axle assembly.
INSTALLATION
1. Move the frame/axle assembly into position on
the rear of the vehicle frame.
2. Install the bolts attaching the frame/axle
assembly to the rear trailing arms. Tighten just
snug.
3. Install the spring/shock assembly mounting
bolts with a 3/4 inch wrench and socket.
Tighten just snug.
4. Install the rear spindles and position the
backing plate assemblies. Apply thread sealer
to the bolts and torque to 75 ft-lbs.
5. Install the hub and bearing. Torque to
165 ft-lbs.
6. Install the bolts securing the brake lines to the
axle.
7. (Vehicles with Spat). If installing the rear axle
only, install the spat bracket. See Spat Bracket
in Body section.
8. Install the brake drum.
9. Install the tire and wheel assembly. Tighten just
snug.
10. Tighten the lug nuts to 65 ft-lbs.
11. Install the hubcap.
12. Lower the vehicle to the floor.
13. Tighten the rear suspension to frame bolts to
14. 60 ft-lbs.
15. Tighten the spring/shock absorber bolts to
60 ft-lbs.

2 - 10 SUSPENSION AND STEERING
GEM Service Manual November 2007
REMOVAL
REAR HUB AND
BEARING/SPINDLE
(6 PASSENGER & LONG
BACK EXTRA DUTY)
(e6, e6S, eLXD)
1. Raise and support the vehicle on a suitable
hoist.
2. Remove the hubcap.
3. Remove the tire and wheel assembly.
4. Remove the brake drum.
5. Remove the bearing dust cap
6. Remove the hub bearing retainer.
7. Remove the rear hub and bearing.
8. Remove the bolts and rear spindle.
NOTE: Support the backing plate assemblies to
protect the brake lines and parking brake
cables.
INSTALLATION
1. Install bolts for the backing plate and rear
spindle. Note: Apply thread sealer to spindle
bolts. Tighten bolts to 75 ft-lbs.
Fig. 7 Rear Hub and Bearing/Spindle
2. Install the rear hub and bearing. Tighten
1 - Assy. Brake - LH Rear
2 - Assy. Hub - Rear 3. Install the hub and bearing. Torque to
165 ft-lbs.
3 - Spindle - Rear
4 - Drum 5 - Bolt 4. Install the dust cap.
5 - Dust Cover
6 - Hex Nut 5. Install the brake drum.
7 - Hex Bolt 6. Install the tire and wheel assembly. Tighten just
snug.
8 - Lock Washer
7. Tighten the lug nuts to 65 ft-lbs.
8. Install the hubcap.
9. Lower the vehicle to the floor.
10. Tighten the rear suspension to frame bolts to
60 ft-lbs.
11. Tighten the spring/shock absorber bolts to
60 ft-lbs.
TORQUE SPECIFICATIONS
Description Thread Size Use
Loctite®
242
Inch-
Pounds Foot- Pounds
Brake line to wheel/master cylinder NO 37 ---
Brake, drum assembly to rear axle M8 x 1.25 NO --- 19
Brake, parking – cable mount to rear
suspension ½” x 13 NO --- 50
Rear suspension frame to frame M12 x 1.75 NO --- 60
Shock absorber lower bolt M12 x 1.75 NO --- 60
Shock absorber upper bolt M12 x 1.75 NO --- 60
Wheel lug nuts 12mm NO --- 65

SUSPENSION AND STEERING 2 - 11
November 2007 GEM Service Manual
STEERING
Fig. 8 Steering System Description
The steering system is comprised of:
• Steering wheel
• Steering column
• Rack and pinion steering gear with integral tie
rods
• Tie rod ends
• Steering knuckle
• Ball joints
OPERATION
The steering column transmits rotation of the
steering wheel to the pinion in the steering gear.
Rotation of the pinion moves the gear rack in the
steering gear from side to side. This lateral action
of the rack pushes and pulls the tie rods that are
attached to the steering knuckles. Steering
knuckles pivot on ball joints that are mounted on
the control arms. Wheel and brake assemblies are
mounted to the steering knuckles. The pivoting
action of the knuckles change the direction of the
front wheels.

2 - 12 SUSPENSION AND STEERING
GEM Service Manual November 2007
STEERING DIAGNOSIS AND TESTING
Condition Possible Causes Correction
Rattle or clunk • Gear mounting bolts loose
• Loose or damaged suspension
components
• Loose or damaged steering column
• Tighten bolts to specification
• Inspect and repair suspension components
• Replace steering column
Difficult to turn
wheel (wheel
sticks or binds)
• Low tire pressure
• Worn or damaged steering
components (ball joints, tie rod ends)
• Steering column u-joints binding
• Steering gear worn
• Adjust tire pressure
• Inspect and repair/replace as necessary
• Replace steering column
• Replace steering gear
Steering wheel
does not want to
return to center
position
• Incorrect tire pressure
• Lack of lubrication suspension
components
• Worn coil spring/ shock assembly
• Adjust tire pressure
• Inspect and lubricate suspension
components
• Replace steering gear
• Inspect and/or replace coil over shock assy
Excessive play in
steering wheel • Loose or worn steering or
suspension components
• Worn or loose wheel bearings
• Steering gear mounting bolts loose
• Steering gear worn
• Steering column u-joints worn
• Inspect and repair as necessary
• Replace steering knuckle or drum brake
assembly
• Tighten mounting bolts
• Replace steering gear
• Replace steering column
Vehicle pulls or
leads to one side • Incorrect tire pressure
• Redial tire lead
• Brakes dragging
• Improper front end alignment
• Adjust tire pressure
• Rotate tires
• Adjust or repair as necessary
• Check front end alignment