suspension CHRYSLER VOYAGER 1996 Workshop Manual

the Nut, Special Tool 6908±3 (Fig. 84). This will pull
the front bushing into the lower control arm.
(5) Continue pulling the bushing into the lower
control arm until bushing is seated squarely against
the lower control arm and there is no gap between
the bushing and the lower control arm (Fig. 85).
(6) Install the lower control arm on the front sus-
pension cradle. Refer to Lower Control Arm in the
Removal And Installation Section in this group of the
service manual for the required procedure.
LOWER CONTROL ARM REAR BUSHING
REMOVE
(1) Remove the lower control arm from the front
suspension cradle. Refer to Lower Control Arm in the
Removal And Installation Section in this group of the
service manual for the required procedure.
(2) Mount the lower control arm in a visewithout
using excessive clamping force.
(3) Using a sharp knife, (such as a razor) slit the
bushing lengthwise (Fig. 86) to allow its removal
from the lower control arm (Fig. 86).
(4) Remove the bushing from the lower control
arm.
INSTALL
CAUTION: Do not apply grease or any other type of
lubricant other than the silicone lubricant specified
below to the control arm bushing.
(1) Apply Mopar Silicone Spray Lube or an equiv-
alent, to the hole in lower control arm rear bushing.
This will aid in the installation of the bushing on the
lower control arm.
(2) With the lower control arm held securely in a
vise, install bushing on lower control arm. Installbushing by pushing and rocking the bushing until it
is fully installed on lower control arm. Be sure when
bushing is installed it is past the upset on the end of
the lower control arm (Fig. 87).
(3) The rear bushing of the lower control arm,
when correctly installed, is to be positioned on the
lower control arm as shown in (Fig. 87).
STABILIZER BAR BUSHING
Disassembly/Assembly
(1) If stabilizer bar to front suspension cradle
bushings require replacement at time of inspection,
install new bushings before installing stabilizer bar.
Stabilizer bar bushings are replaced by opening the
slit on the bushings and peeling them off the stabi-
lizer bar. Install new bushings on stabilizer bar, by
spreading bushing at slit and forcing them on stabi-
lizer bar.
Fig. 85 Correctly Installed Lower Control Arm
Bushing
Fig. 86 Slit Lower Control Arm Rear Bushing
Fig. 87 Correctly Installed Lower Control Arm
Bushing
NSSUSPENSION 2 - 35
DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: Bushings must be installed on stabilizer bar
so the square corner of the bushing will be down
and slit in bushing will be facing the rear of the
vehicle when the stabilizer is installed (Fig. 88).SPECIFICATIONS
FRONT SUSPENSION FASTENER TORQUES
DESCRIPTION TORQUE
McPHERSON STRUT:
To Strut Tower
Attaching Nuts............28N´m(250 in. lbs.)
Clevis Bracket To Steering
Knuckle..................88N´m(65ft.lbs.)
Plus 1/4 Additional Turn
Strut Shaft Nut.............100 N´m (75 ft. lbs.)
STEERING KNUCKLE:
Ball Joint Stud To Steering
Knuckle Nut/Bolt.........136 N´m (100 ft. lbs.)
Disc Brake Caliper Bolts.......22N´m(16ft.lbs.)
Wheel Stop..................95N´m(70ft.lbs.)
STEERING GEAR:
To Suspension Cradle
Attaching Bolts...........183 N´m (135 ft. lbs.)
Tie Rod End Adjusting
Sleeve Nut................75N´m(55ft.lbs.)
Tie Rod End To Steering
Knuckle Nut...............61N´m(45ft.lbs.)
FRONT SUSPENSION CRADLE:
To Body Attaching Bolts......163 N´m (120 ft. lbs.)
Lower Control Arm
Pivot Bolt...............185 N´m (137 ft. lbs.)
Lower Control Arm Rear
Bushing Retainer Bolt.......68N´m(50ft.lbs.)
Reinforcement Plate
Attaching Bolts M-12.......108 N´m (80 ft. lbs.)
Reinforcement Plate
Attaching Bolts M-14......166 N´m (123 ft. lbs.)
STABILIZER BAR:
Bushing Retainer ToSuspension
Cradle Attaching Bolts.......70N´m(50ft.lbs.)
Attaching Link Nuts...........88N´m(65ft.lbs.)
HUB AND BEARING:
To Steering Knuckle Bolts......110N´m(80ft.lbs.)
Front Stub Axle To Hub
Bearing Nut.............183 N´m (135 ft. lbs.)
Wheel Mounting
LugNut...........110-135 N´m (85-115 ft. lbs.)
Fig. 88 Correctly Installed Stabilizer Bar To Cradle
Bushing
2 - 36 SUSPENSIONNS
DISASSEMBLY AND ASSEMBLY (Continued)

SPECIAL TOOLS
FRONT SUSPENSION
Installer Ball Joint 6758
Wrench Strut Rod Nut 6864
Remover Ball Joint 6919
Remover/Installer Control Arm Bushing 6908
Remover Tie Rod End MB±991113
NSSUSPENSION 2 - 37

REAR SUSPENSION
INDEX
page page
GENERAL INFORMATION
REAR SUSPENSION..................... 38
DESCRIPTION AND OPERATION
REAR TRACK BAR....................... 39
REAR WHEEL ALIGNMENT................ 39
SHOCK ABSORBERS (REAR LOAD LEVELING) . 40
STABILIZER BAR........................ 39
REMOVAL AND INSTALLATION
JOUNCE BUMPER....................... 46
LEAF SPRING FRONT MOUNT............. 47LEAF SPRING REAR MOUNT.............. 47
REAR SPRINGS (AWD)................... 43
REAR SPRINGS (FWD)................... 40
REAR TRACK BAR....................... 45
SHOCK ABSORBER...................... 45
STABILIZER BAR........................ 46
TRACK BAR MOUNT..................... 45
SPECIFICATIONS
REAR SUSPENSION FASTENER TORQUES . . . 48
GENERAL INFORMATION
REAR SUSPENSION
The rear suspension design on this vehicle uses
leaf springs and a tube and casting axle (Fig. 1) and
(Fig. 2). It is designed to handle the various load
requirements of the vehicle. The leaf springs used on
the rear suspension of this vehicle are of either a
mono-leaf or multi-leaf design.The rear axle used on front wheel drive applica-
tions of this vehicle is mounted to the rear leaf
springs using isolator bushings at the axle mounting
brackets.
The rear axle used on all wheel drive applications
of this vehicle is also mounted to the rear leaf
springs but does not use isolator bushings between
the rear axle and the leaf springs.
Fig. 1 Front Wheel Drive Rear Suspension
2 - 38 SUSPENSIONNS

The rear suspension used on the front wheel drive
commercial version of this vehicle is unique to this
application. The rear axle is mounted to the rear leaf
springs as on the non-commercial application of this
vehicle but does not use any isolators between the
spring and the axle. The leaf spring used on the com-
mercial version of this vehicle is a multi-leaf spring
but is a unique design for the commercial applica-
tion.
The rear leaf spring shackle angles provide
increasing suspension rates as the vehicle is loaded.
This provides a comfortable unloaded ride and also
ample rear suspension travel when the vehicle is
loaded.
A new type of load-leveling shock is available. The
self leveling shock absorbers are a self-contained
vehicle leveling system and shock absorber combined.
The shock absorbers are mounted at an angle, paral-
lel to the springs and forward at the top. This design
provides greater stability in addition to controlling
ride motion.
The rear wheel bearings used are similar to the
bearings used in the front wheels. The bearings are
permanently sealed and require no maintenance. The
bearing and hub are serviced as an assembly. For
service procedures, refer to Group 5, Brakes.DESCRIPTION AND OPERATION
REAR WHEEL ALIGNMENT
Alignment adjustment is not required. The rear
axle alignment settings are preset at the factory and
therefore no alignment is necessary.
REAR TRACK BAR
On front wheel drive applications of this vehicle
that are equipped with single leaf rear springs a
track bar (Fig. 3) is used on the rear axle.
The track bar connects the rear axle to the frame/
body of the vehicle. The track bar is isolated from the
body of the vehicle by an isloator bushing located in
each end of the track bar.
The track bar (Fig. 3) prevents excessive side to
side movement of the rear axle. The track bar is used
to keep the location of the axle in the correct position
for optimum handling and control of the vehicle.
STABILIZER BAR
The stabilizer bar (Fig. 4) interconnects both sides
of the rear axle and attaches to the rear frame rails
using 2 rubber isolated link arms.
Jounce and rebound movements affecting one
wheel are partially transmitted to the opposite wheel
to reduce body roll.
Fig. 2 All Wheel Drive Rear Suspension
NSSUSPENSION 2 - 39
GENERAL INFORMATION (Continued)

Attachment to the rear axle tube, and rear frame
rails is through rubber-isolated bushings. All parts
are serviceable, and the stabilizer bar to axle bush-
ings are split for easy removal and installation. The
split in the bushing should be positioned up when
the stabilizer bar is installed on the vehicle.
The 2 rubber isolated link arms are connected to
the rear frame rails by brackets. These brackets are
bolted to the bottom of the frame rails.
SHOCK ABSORBERS (REAR LOAD LEVELING)
A new type of load-leveling shock is available. The
self leveling shock absorbers are a self-contained
vehicle leveling system and shock absorber combined.
It does not require an external compressor, hoses,height leveling sensors, etc. It uses road inputs
(bumps, stops, starts, turns, acceleration, decelera-
tion, etc.) to activate pumping, which is just the
extension and compression of the shock absorber. On
the outside, it looks like a larger than normal shock
absorber. Internally, it consists of a hydraulic pump
and gas-spring cushion for leveling, as well as the
normal shock absorbing mechanism. All the height
leveling sensors, pump, etc., are contained inside the
shocks. The shocks are mounted at an angle, parallel
to the springs and forward at the top. This design
provides greater stability in addition to controlling
ride motion. These new load-leveling shock absorbers
use longer fasteners than the standard shock absorb-
ers, although the fasteners are longer, the torque
specifications are the same.
REMOVAL AND INSTALLATION
REAR SPRINGS (FWD)
REMOVAL
(1) Raise vehicle on frame contact hoist to a com-
fortable working position.
(2) Support axle with a jack stand. Pad should just
contact axle.
(3) Begin removal of the shock absorber lower
mounting bolt (Fig. 5).
Fig. 4 Stabilizer Bar
Fig. 3 Rear Track Bar
2 - 40 SUSPENSIONNS
DESCRIPTION AND OPERATION (Continued)

NOTE: If shock absorber bolt deflects upward dur-
ing removal, raise axle by adjusting support jack. If
shock absorber bolt deflects downward during
removal, lower axle by adjusting support jack (or by
pulling on axle).
(4) Using 2 jack stands positioned under the outer
ends of the axle, raise the axle enough to remove the
weight of the axle from the rear springs.
(5) Loosen and remove the axle plate bolts from
the rear axle (Fig. 6).
(6) Remove the axle plate from the rear axle and
the leaf spring (Fig. 7).
(7) Using the jack standsslowlylower the rear
axle, permitting the rear springs to hang free.
(8) Loosen and remove the 4 bolts (Fig. 8) from the
front mount of the leaf spring.
(9) Loosen and remove the nuts from the spring
hanger (Fig. 9) for the rear leaf spring. Then remove
the hanger plate from the hanger and remove the
spring from the spring hanger (Fig. 9).
Fig. 5 Rear Shock Mounting Bolt
Fig. 6 Axle Plate Bolts
Fig. 7 Axle Plate
Fig. 8 Leaf Spring Front Mount
Fig. 9 Rear Spring Hanger
NSSUSPENSION 2 - 41
REMOVAL AND INSTALLATION (Continued)

(10) Remove the leaf spring from the vehicle (Fig.
10).
(11) Loosen and remove the pivot bolt from the
front mount of the rear leaf spring. (Fig. 11).
FRONT BUSHING REPLACEMENT
(1) Install leaf spring in a proper holding fixture.
(2) Install leaf spring press Special Tool C-4212±F.
(3) Install adapter Special Tool C-4212±3.
(4) Tighten leaf spring press until bushing is
extracted from leaf spring.
(5) Remove leaf spring press from leaf spring.
(6) Insert replacement bushing into the leaf spring
eye.Verify that the bushing flange is on the left
side of the leaf spring when leaf spring is in the
in vehicle installed position.
(7) Install leaf spring press Special Tool C-4212±F.
(8) Install adapter Special Tool C-4212±4.
(9) Tighten leaf spring press until bushing flange
bottoms solidly against leaf spring eye.
(10) Remove leaf spring press and adapter.(11) Bend the bushing tabs so that they are con-
tacting the leaf spring.
INSTALLATION
(1) Assemble front spring mount to front of spring
eye and install pivot bolt and nut. Do not tighten.
CAUTION: Pivot bolt must face inboard to prevent
structural damage during installation of spring.
(2) Raise front of spring and install four hanger
bolts, tighten to 61 N´m (45 ft. lbs.) torque.
(3) Install rear of spring onto rear spring shackle.
Install shackle plate. Do not tighten.
(4) Verify lower leaf spring isolator is in position.
(5) Raise axle into correct position on leaf spring
with axle centered under spring locator post (Fig.
12).
(6) Verify that the leaf spring isolator is correctly
positioned in the axle plate.
(7) Install axle plate on the spring.
(8) Install axle plate bolts. Tighten bolts to 108
N´m (80 ft. lbs.) torque.
(9) Install shock absorber bolts. Do not tighten.
(10) Lower vehicle to floor so that the full weight
of vehicle is supported by the tires.
(11) Tighten component fasteners as follows:
²Front pivot boltÐ156 N´m (115 ft. lbs.)
²Shackle nutsÐ61 N´m (45 ft. lbs.)
²Shock absorber boltsÐ101 N´m (75 ft. lbs.)
(12) If the vehicle is not equipped with antilock
brakes, raise vehicle and the connect the actuator for
the height sensing proportioning valve on the rear
leaf spring. Adjust the height sensing proportioning
valve. Refer to the Adjustment Section in this group
of the service manual for the required adjustment
procedure.
Fig. 10 Leaf Spring Remove/Install
Fig. 11 Leaf Spring Front Mount
Fig. 12 Leaf Spring Locator Post
2 - 42 SUSPENSIONNS
REMOVAL AND INSTALLATION (Continued)

REAR SPRINGS (AWD)
REMOVE
(1) Raise vehicle on frame contact hoist to a com-
fortable working position.
(2) Remove the driveshaft from the side of the
vehicle that requires the removal of the leaf spring.
Refer to Group 3 Driveline in this service manual for
the procedure covering the removal of the rear drive-
shafts.
(3) Support axle with a jack stand. Pad should just
contact axle.
NOTE: If shock absorber bolt deflects upward dur-
ing removal, raise axle by adjusting support jack. If
shock absorber bolt deflects downward during
removal, lower axle by adjusting support jack (or by
pulling on axle).
(4) Begin removal of the shock absorber lower
mounting bolt (Fig. 13).
(5) Using 2 jack stands positioned under the outer
ends of the axle, raise the axle enough to remove the
weight of the axle from the rear springs.
(6) Loosen and remove the axle plate bolts from
the rear axle (Fig. 14).
(7) Using the jack standsslowlylower the rear
axle, permitting the rear springs to hang free.
(8) Loosen and remove the 4 bolts (Fig. 15) at the
front mount of the rear leaf spring.
(9) Loosen and remove the 2 bolts and the 2 nuts
from the spring hanger (Fig. 16) for the rear leaf
spring. Then remove the inner half of the spring
hanger from the outer half hanger of the spring
hanger and the spring. (Fig. 16).
(10) Remove the rear leaf spring from the outer
half of the spring hanger
Fig. 13 Rear Shock Absorber Mounting Bolt
Fig. 14 Axle Plate Bolts
Fig. 15 Leaf Spring Front Mount
Fig. 16 Rear Spring Hanger
NSSUSPENSION 2 - 43
REMOVAL AND INSTALLATION (Continued)

(11) Remove the leaf spring from the vehicle (Fig.
17).
(12) Loosen and remove the pivot bolt from the
front mount of the rear leaf spring. (Fig. 18).
FRONT BUSHING REPLACEMENT
(1) Install leaf spring in a proper holding fixture.
(2) Install leaf spring press Special Tool C-4212±F.
(3) Install adapter Special Tool C-4212±3.
(4) Tighten leaf spring press until bushing is
extracted from leaf spring.
(5) Remove leaf spring press from leaf spring.
(6) Insert replacement bushing into the leaf spring
eye. Verify that the bushing flange is on the outboard
side of the leaf spring.
(7) Install leaf spring press Special Tool C-4212±F.
(8) Install adapter Special Tool C-4212±4.
(9) Tighten leaf spring press until bushing flange
bottoms solidly against leaf spring eye.
(10) Remove leaf spring press and adapter.(11) Bend the tabs on the bushing until they are
contacting the leaf spring.
INSTALL
CAUTION: Pivot bolt must face inboard to prevent
structural damage during installation of spring.
(1) Install the front of the rear leaf spring into the
spring mount (Fig. 18). Install the pivot bolt and nut.
Do not tighten the pivot bolt at this time.
(2) Position the front spring mount for the rear
leaf spring against the floor pan of the vehicle.
Install the 4 mounting bolts for the spring mount.
Tighten the 4 mounting bolts to a torque of 61 N´m
(45 ft. lbs.).
(3) Install the rear of the leaf spring onto the outer
half of the rear hanger. Install the inner half of the
rear hanger. Install the nut and bolts on the rear
hangerbut do not tighten at this time.
(4) Raise axle assembly into correct position with
axle centered under spring locator post.
(5) Install axle plate bolts. Tighten bolts to 108
N´m (80 ft. lbs.) torque.
(6) Install shock absorber bolts. Do not tighten.
(7) Lower vehicle to floor and with full weight of
vehicle on wheels. Tighten component fasteners as
follows:
CAUTION: The following sequence must be fol-
lowed when tightening the pin nuts on the rear
hanger for the rear leaf spring. First the hanger pin
nuts must be tightened to the specified torque
shown below. Then tighten the retaining bolts for
the inner to outer half of the spring hanger to the
torque specification listed below. This sequence
must be followed to properly seat the bushings into
the springs and to avoid bending the spring hanger.
²Front pivot bolt-156 N´m (115 ft. lbs.)
²Rear spring hanger pin nuts-61 N´m (45 ft. lbs.)
²Rear spring hanger inner to outer half retaining
bolts-61 N´m (45 ft. lbs.)
²Shock absorber upper mounting bolt-115 N´m
(85 ft. lbs.)
²Shock absorber lower mounting bolt-108 N´m (80
ft. lbs.)
(8) If the vehicle is not equipped with antilock
brakes, raise vehicle and connect the actuator for the
height sensing proportioning valve on the rear leaf
spring. Adjust the height sensing proportioning
valve. Refer to the Adjustment Section in this group
of the service manual for the required adjustment
procedure.
Fig. 17 Leaf Spring Remove/Install
Fig. 18 Leaf Spring Front Mount
2 - 44 SUSPENSIONNS
REMOVAL AND INSTALLATION (Continued)