suspension CHRYSLER VOYAGER 1996 Owner's Manual

CAUTION: Wheel bearing damage will result if after
loosening hub nut, vehicle is rolled on the ground
or the weight of the vehicle is allowed to be sup-
ported by the tires.
(5) With the vehicle's brakes applied to keep hub
from turning,loosen and removethe stub axle to
hub nut.
(6) Remove the 2 front disc brake caliper to steer-
ing knuckle attaching bolts (Fig. 13).
(7) Remove the disc brake caliper from the steer-
ing knuckle. Caliper is removed by first rotating top
of caliper away from steering knuckle and then
removing bottom of caliper out from under machined
abutment on steering knuckle (Fig. 14).
(8) Support disc brake caliper assembly by using a
wire hook and suspending it from the strut assembly
(Fig. 15).Do not allow the brake caliper assem-
bly to hang by the brake flex hose.
Fig. 11 Hub/Bearing To Stub Axle Retaining Nut
Fig. 12 Wave Washer
Fig. 13 Front Disc Brake Caliper Attaching Bolts
Fig. 14 Brake Caliper Mounting To Steering Knuckle
Fig. 15 Correctly Supported Disc Brake Caliper
NSSUSPENSION 2 - 15
REMOVAL AND INSTALLATION (Continued)

(9) Remove the brake rotor from the hub and bear-
ing assembly (Fig. 16).
(10) Remove nut attaching outer tie rod end to
steering knuckle (Fig. 17).Nut is to be removed
from tie rod end using the following procedure,
hold tie rod end stud with a 11/32 socket while
loosening and removing nut with a wrench.
(11) Remove tie rod end from steering knuckle
using Remover, Special Tool MB-991113 (Fig. 18).
(12) Remove the front wheel speed sensor (Fig. 19)
from the steering knuckle.
(13) If equipped, remove the wheel stop (Fig. 20)
from the steering knuckle.When installing the
pinch bolt when assembling the steering
knuckle to the ball joint, the pinch bolt must beinstalled from the rear facing the front on the
vehicle.
Fig. 16 Remove/Install Brake Rotor
Fig. 17 Removing Tie Rod End Attaching Nut
Fig. 18 Tie Rod End Removal From Steering
Knuckle Arm
Fig. 19 Front Wheel Speed Sensor
Fig. 20 Wheel Stop Location On Steering Knuckle
2 - 16 SUSPENSIONNS
REMOVAL AND INSTALLATION (Continued)

(14) Remove the steering knuckle to ball joint
stud, clamping nut and bolt (Fig. 21) from the steer-
ing knuckle.
(15) Using a pry bar, separate steering knuckle
from ball joint stud (Fig. 22).Note: Use caution
when separating ball joint stud from steering
knuckle, so ball joint seal does not get cut.
NOTE: Care must be taken not to separate the
inner C/V joint during this operation. Do not allow
driveshaft to hang by inner C/V joint after removing
outer C/V Joint from the hub/bearing assembly in
steering knuckle, end of driveshaft must be sup-
ported.
(16) Pull steering knuckle assembly out and away
from the outer C/V joint of the driveshaft assembly
(Fig. 23).CAUTION: The steering knuckle to strut assembly
attaching bolts are serrated and must not be turned
during removal. Remove nuts while holding bolts
stationary in the steering knuckles.
(17) Remove the 2 steering knuckle to strut
damper clevis bracket attaching bolts (Fig. 24).
(18) Remove the steering knuckle from the strut.
INSTALL
(1) Transfer, or install if necessary, a new hub/
bearing assembly into the steering knuckle. Refer to
Hub And Bearing Assembly Service in this section of
the service manual for the required removal and
installation procedure for the front hub/bearing
assembly.
CAUTION: The steering knuckle to strut assembly
attaching bolts are serrated and must not be turned
during installation. Install nuts while holding bolts
stationary in the steering knuckles.
Fig. 21 Control Arm To Steering Knuckle
Attachment
Fig. 22 Separating Ball Joint Stud From Steering
Knuckle
Fig. 23 Steering Knuckle Separation From
Driveshaft
Fig. 24 Strut To Steering Knuckle Attaching Bolts
NSSUSPENSION 2 - 17
REMOVAL AND INSTALLATION (Continued)

CAUTION: If the vehicle being serviced is
equipped with eccentric strut assembly attaching
bolts, the eccentric bolt must be installed in the
bottom (slotted) hole on the strut clevis bracket
(Fig. 25).
(2) Install steering knuckle back in clevis bracket
of strut damper assembly (Fig. 24). Install the strut
damper to steering knuckle attaching bolts. Tighten
both attaching bolts to a torque of 90 N´m (65 ft. lbs.)
plus an additional 1/4 turn.
(3) Slide drive shaft back into front hub and bear-
ing assembly. Then install steering knuckle onto the
stud of the ball joint assembly (Fig. 23).
(4) Install aNEWsteering knuckle to ball joint
stud, clamping bolt and nut (Fig. 21). Tighten the
clamping bolt and nut to a torque of 145 N´m (105 ft.
lbs.).
(5) Install tie rod end into steering knuckle. Start
attaching nut onto stud of tie rod end. While holding
stud of tie rod end stationary using a 11/32 socket,
(Fig. 17) tighten tie rod end to steering knuckle
attaching nut. Then using a crowfoot and 11/32
socket (Fig. 26), tighten the tie rod end attaching nut
to a torque of 54 N´m (40 ft. lbs.).
(6) Install braking disc on hub and bearing assem-
bly (Fig. 16).
(7) Install disc brake caliper assembly on steering
knuckle. Caliper is installed by first sliding bottom of
caliper under abutment on steering knuckle, and
then rotating top of caliper against top abutment
(Fig. 14).
(8) Install disc brake caliper assembly to steering
knuckle attaching bolts (Fig. 13). Tighten the disc
brake caliper assembly attaching bolts to a torque of
35 N´m (30 ft. lbs.).
(9) Clean all foreign matter from the threads of
the outer C/V joint stub axle. Install the washer and
stub axle to hub/bearing assembly nut on stub axle
and securely tighten nut.(10) Install wheel speed sensor and mounting bolt
(Fig. 19) on steering knuckle. Tighten the speed sen-
sor attaching bolt to a torque of 7 N´m (60 in. lbs.).
(11)
Install front wheel and tire assembly. Install
and tighten the wheel mounting stud nuts in proper
sequence until all nuts are torqued to half the required
specification. Then repeat the tightening sequence to
the full specified torque of 135 N´m (100 ft. lbs.).
(12) Lower vehicle.
(13) With the vehicle's brakes applied to keep hub
from turning, tighten the hub nut to a torque of 203
N´m (150 ft. lbs.) (Fig. 27).
(14) Install the spring wave washer on the end of
the stub axle.
(15) Install the hub nut lock, and anewcotter pin
(Fig. 11). Wrap cotter pin prongs tightly around the
hub nut lock as shown in (Fig. 11).
(16) Set front Toe on vehicle to required specifica-
tion. Use procedure listed under Wheel Alignment, in
the Front Suspension Service Procedures section of
this service manual.
Fig. 25 Correctly Installed Eccentric Attaching Bolt
Fig. 26 Torquing Tie Rod End Attaching Nut
Fig. 27 Torquing Front Stub Axle To Hub Nut
2 - 18 SUSPENSIONNS
REMOVAL AND INSTALLATION (Continued)

LOWER CONTROL ARM
REMOVE
(1) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this manual, for
the required lifting procedure to be used for this
vehicle.
(2) Remove wheel and tire assembly from the side
of vehicle requiring service to the lower control arm.
(3) Remove the wheel stop (Fig. 28) from the steer-
ing knuckle.When installing the pinch bolt when
assembling the steering knuckle to the ball
joint, the pinch bolt must be installed from the
rear facing the front on the vehicle (Fig. 28).
(4) Remove the nut and bolt clamping the steering
knuckle to the ball joint stud. (Fig. 29)NOTE: The attaching bolts for the cradle plate are
of two different thread sizes. Nine of the bolts are a
M-14 thread and one of the bolts is a M-12 thread.
Refer to (Fig. 30) for the cradle plate attaching bolt
locations.
(5) Remove the 10 bolts (Fig. 30) attaching the cra-
dle plate to the front suspension cradle. Then remove
the cradle plate from the cradle.
CAUTION: Pulling steering knuckle out from vehi-
cle after releasing from ball joint can separate inner
C/V joint. See Driveshafts.
(6) Using a pry bar, separate steering knuckle
from ball joint stud (Fig. 31).Use caution when
separating ball joint stud from steering
knuckle, so ball joint seal does not get cut.
Fig. 28 Wheel Stop Location On Steering Knuckle
Fig. 29 Control Arm To Steering Knuckle
Attachment
Fig. 30 Front Suspension Cradle Plate And
Mounting Bolts
Fig. 31 Separating Ball Joint Stud From Steering
Knuckle
NSSUSPENSION 2 - 19
REMOVAL AND INSTALLATION (Continued)

(7) Loosen but do not remove the pivot bolt (Fig.
32) attaching the front bushing of the lower control
arm to the front suspension cradle.
(8) Remove retainer (Fig. 33) attaching rear bush-
ing of lower control arm to front suspension cradle.
CAUTION: Make location reference marks where
the front suspension cradle is mounted against the
front frame rails before loosening and lowering the
cradle. This is required so the cradle can be re-in-
stalled in the design location to achieve proper
front suspension alignment.
(9) Loosen but not fully removing the 2 left side
suspension cradle to frame rail attaching bolts (Fig.
34).
NOTE: When removing the left lower control arm
from the vehicle, the front suspension cradle needsto be lowered for the pivot bolt to clear the tran-
saxle.
(10) Lower the left front corner of the suspension
cradle until pivot bolt will clear end of transaxle (Fig.
35). Remove the pivot bolt and the lower control arm
from the cradle.
INSTALL
NOTE: If the left lower control arm is being
installed on the vehicle the front suspension cradle
needs to be lowered for the pivot bolt to clear the
transaxle.
(1) Position lower control arm assembly into front
suspension cradle.If installing the left lower con-
trol arm, pry down on the left front corner of
the suspension cradle until the pivot bolt clears
the end of the transaxle (Fig. 35).Install pivot
bolt attaching front bushing of lower control arm to
front
Fig. 32 Lower Control Arm Bushing To Cradle Pivot
Bolt
Fig. 33 Control Arm Bushing To Suspension Cradle
Retainer
Fig. 34 Suspension Cradle To Frame Rail Mounting
Bolts
Fig. 35 Lowering Front Suspension Cradle
2 - 20 SUSPENSIONNS
REMOVAL AND INSTALLATION (Continued)

suspension cradle (Fig. 36).Do not tighten or
torque pivot bolt at this time.
(2) Install retainer (Fig. 37) attaching rear bush-
ing of lower control arm to front suspension cradle.
When installing retainer, be sure raised rib on
rear bushing (Fig. 37) is positioned in the
groove on the retainer. Do not torque attaching
bolts at this time.
NOTE: If reference marks were not put on the
frame rails prior to lowering the suspension cradle,
Refer to group 13 Frame And Bumpers for the cra-
dle positioning procedure.
(3) Raise the front suspension cradle against the
front frame rails. Align the cradle with the reference
marks on the frame rails.
(4) Tighten the 4 mounting bolts for the front sus-
pension cradle to a torque of 163 N´m (120 ft. lbs.).(5) Install lower control arm ball joint stud into
steering knuckle. Then install the bolt and nut,
clamping the steering knuckle to the ball joint stud
(Fig. 29). Tighten the clamping bolt to a torque of
145 N´m (105 ft. lbs.).
(6) Install the cradle plate on front suspension cra-
dle and then install the 10 cradle plate to cradle
attaching bolts (Fig. 30). Tighten the 9 M-14 attach-
ing bolts (Fig. 30) to a torque of 165 N´m (123 ft.
lbs.). Tighten the 1 M-12 attaching bolt (Fig. 30) to a
torque of 108 N´m (80 ft. lbs.).
CAUTION: When locating jack stands under lower
control arm, do not place the jack stands under the
ball joints (Fig. 38).
(7) Position jack stands under the lower control
arms as close to the ball joints as possible (Fig. 38).
Lower the vehicle onto the jack stands, until the jack
stands are supporting the total weight of the vehicle
(Fig. 38).
(8) Tighten front lower control arm pivot bolt (Fig.
36) to a torque of 183 N´m (135 ft. lbs.) first, then
tighten rear lower control arm bushing retainer
attaching bolts (Fig. 33) to a torque of 68 N´m (50 ft.
lbs.).
(9) Install the wheel/tire assembly on the vehicle.
(10) Install and tighten the wheel mounting stud
nuts in proper sequence until all nuts are torqued to
half specification. Then repeat the tightening
sequence to the full specified torque of 135 N´m (100
ft. lbs.).
(11) Remove jack stands and lower vehicle to the
ground.
Fig. 36 Lower Control Arm Bushing Pivot Bolt
Correctly Installed
Fig. 37 Installing Lower Control Arm Rear Bushing
Retainer
Fig. 38 Jack Stands Supporting Vehicle Weight
NSSUSPENSION 2 - 21
REMOVAL AND INSTALLATION (Continued)

BALL JOINT
REMOVE
(1) Using a screw driver or other suitable tool, pry
the seal boot off of the ball joint assembly (Fig. 39)
(2) Position receiving cup, Special Tool 6758 to
support lower control arm when removing ball joint
assembly (Fig. 40). Install Remover, Special Tool
6919 on top of the ball joint assembly (Fig. 40).
(3) Using the arbor press, press the ball joint
assembly completely out of the lower control arm.
INSTALL
NOTE: When installing ball joint in lower control
arm, position the ball joint in control arm so notch
in ball joint stud is in the direction shown (Fig. 41).
This will ease assembly of the ball joint to the
steering when installing pinch bolt.(1) By hand, position ball joint into ball joint bore
of lower control arm.Be sure ball joint is not
cocked in the bore of the control arm, this will
cause the ball joint to bind when being pressed
into control arm.
(2) Position control arm with installed ball joint, in
an arbor press with Receiving Cup, Special Tool 6758
supporting the lower control arm (Fig. 42). Then cen-
ter Installer, Special Tool 6908±4 on the bottom of
the ball joint (Fig. 42)
(3) Carefully align all pieces. Then press the ball
joint into the lower control arm until it is completely
seated against surface of lower control arm. The ball
joint is correctly installed when there is no gap
between the ball joint and the lower control arm (Fig.
43).Do not apply excessive force against the
ball joint or the lower control arm.
Fig. 39 Ball Joint Seal Boot Removal
Fig. 40 Ball Joint Removal From Lower Control Arm
Fig. 41 Installation Position Of Ball Joint In Control
Arm
Fig. 42 Installing Ball Joint In Control Arm
2 - 22 SUSPENSIONNS
REMOVAL AND INSTALLATION (Continued)

CAUTION: When installing the ball joint seal on the
ball joint/lower control arm, the shield (Fig. 44) on
the ball joint seal must be positioned as shown.
(4) Install aNEWseal boot by hand as far as pos-
sible on the ball joint. Installation of the seal boot is
to be with the shield positioned as shown (Fig. 44).
CAUTION: Do not use an arbor press to install the
sealing boot on the ball joint. Damage to the seal-
ing boot will occur if excessive pressure is applied
to the sealing boot when it is being installed.
(5) Place Installer, Special Tool 6758 over seal boot
and squarely align it with bottom edge of seal boot
(Fig. 45). Apply hand pressure to Special Tool 6758
until seal boot is pressed squarely against top surface
of lower control arm.
CAUTION: A replacement ball joint is not prelubri-
cated. Properly lubricate the replacement ball joint
using Mopar Multi±Mile grease or an equivalent.
Lubricate ball joint after seal boot is installed butprior to top of seal boot being pushed down below
notch in ball joint stud (Fig. 41). Air must vent out
of the seal boot at notch when grease is pumped
into ball joint, failure to do so will balloon and dam-
age seal boot. Do not over grease the ball joint, this
will prevent the seal boot from pushing down on
the stud of the ball joint.
CAUTION: After the ball joint is properly greased,
clip the end of the grease fitting off below the hex.
The ball joint seal boot is non-purgeable and further
greasing is not required and can result in damage
to the seal boot.
STABILIZER BAR
REMOVE
(1) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this manual, for
the required lifting procedure to be used for this
vehicle.
NOTE: The attaching bolts for the cradle plate are
of two different thread sizes. Nine of the bolts are a
M-14 thread and one of the bolts is a M-12 thread.
Refer to (Fig. 46) for the cradle plate attaching bolt
locations.
(2) Remove the 10 bolts (Fig. 46) attaching the cra-
dle plate to the front suspension cradle. Then remove
the cradle plate from the cradle.
NOTE: When removing nut from stud of stabilizer
bar attaching link, do not allow the stud to rotate.
Hold stud from rotating by inserting a Torx Plus 40
IP bit in the end of the stud (Fig. 47).
Fig. 43 Correctly Installed Lower Ball Joint
Fig. 44 Ball Joint Seal Boot Installed Position
Fig. 45 Installing Ball Joint Seal Boot
NSSUSPENSION 2 - 23
REMOVAL AND INSTALLATION (Continued)

(3) Remove the nuts (Fig. 47) attaching the stabi-
lizer bar attaching links to the stabilizer bar. Then
remove the attaching links from the stabilizer bar.
(4) Remove the stabilizer bar bushing retainers
from the front suspension cradle (Fig. 48).
(5) Remove the stabilizer bar and bushings as an
assembly from the front suspension cradle.
INSTALL
(1) If the stabilizer bar to front suspension cradle
bushings require replacement at time of inspection,
install new bushings before installing stabilizer bar.
Bushings are replaced by opening slit on bushings
and peeling them off stabilizer bar. Install new bush-
ings on stabilizer bar by spreading bushing at slit
and forcing them on the stabilizer bar.Bushings
must be installed on stabilizer bar so slit in
bushing will be facing toward the rear of vehi-
cle with the square corner toward the ground,when the stabilizer bar is installed on the vehi-
cle (Fig. 49).
(2) Position stabilizer bar into front suspension
cradle so stabilizer bar bushings are aligned with
depressions in cradle. Install stabilizer bar bushing
retainers onto crossmember aligning raised bead on
retainer with cutouts in bushings (Fig. 50).Do not
tighten Stabilizer bar bushing retainers at this
time.
(3) Check position of the stabilizer bar in the front
suspension cradle. The center of the curved section of
the stabilizer bar must be aligned with the raised
line in the center of the front suspension cradle (Fig.
51).
(4) Align holes in stabilizer bar with attaching link
assemblies. Install the stabilizer bar attaching links
into the stabilizer bar and install the attaching nuts
(Fig. 47).
Fig. 46 Cradle Plate And Mounting Bolts
Fig. 47 Stabilizer Bar Link Attachment To Stabilizer
Bar
Fig. 48 Front Stabilizer Bar Bushing Retainers
Fig. 49 Correctly Installed Stabilizer Bar To Cradle
Bushing
2 - 24 SUSPENSIONNS
REMOVAL AND INSTALLATION (Continued)