CHRYSLER VOYAGER 2001 Service Manual

SPECIFICATIONS
WHEEL ALIGNMENT
NOTE: All specifications are given in degrees.NOTE: All wheel alignments are to be set at curb
height. (Refer to 2 - SUSPENSION/WHEEL ALIGN-
MENT - STANDARD PROCEDURE)
FRONT WHEEL ALIGNMENT PREFERRED SETTING ACCEPTABLE RANGE
CAMBER +0.10É -0.30É to +0.50É
Cross-Camber (Maximum side-to-side
difference)0.0É 0.50É
CASTER* +2.31É +1.31É to +3.31É
Cross-Caster (Maximum side-to-side difference) 0.0É 1.00É
TOTAL TOE** +0.10É þ0.10É to +0.30É
Maximum side-to-side difference 0.0É 0.06É
REAR WHEEL ALIGNMENT PREFERRED SETTING ACCEPTABLE RANGE
CAMBER* 0.0É -0.25É to +0.25É
TOTAL TOE* ** 0.0É þ0.20É to +0.20É
THRUST ANGLE* 0.0É -0.30É to +0.30É
Notes:
* For reference only. These are non-adjustable angles.
** TOTAL TOE is the sum of both left and right wheel toe settings. TOTAL TOE must be equally split between
each front wheel to ensure the steering wheel is centered after setting toe. Positive toe is toe-in and negative toe
is toe-out
RSWHEEL ALIGNMENT2-55
WHEEL ALIGNMENT (Continued)

SUSPENSION
TABLE OF CONTENTS
page page
FRONT SUSPENSION......................1WHEEL ALIGNMENT.......................3
FRONT SUSPENSION
TABLE OF CONTENTS
page page
LOWER BALL JOINT SEAL BOOT
DESCRIPTION............................1REMOVAL...............................1
INSTALLATION............................1
LOWER BALL JOINT SEAL
BOOT
DESCRIPTION
The lower ball joint seal boot is a two piece unit. It
consists of a seal boot and a separate shield that is
located in a groove at the top of the seal boot.
NOTE: The seal boot should only be replaced if
damaged during vehicle service. The entire lower
control arm should be replaced if the joint has been
contaminated.
REMOVAL
(1)Remove steering knuckle from vehicle. (Refer to 2
- SUSPENSION/FRONT/KNUCKLE - REMOVAL)
(2) Remove shield from seal boot by gently pulling
on it.
(3) Using a screw driver or other suitable tool, pry
seal boot off of the lower ball joint.
INSTALLATION
(1) Place a liberal dab of MopartWheel Bearing
Grease around the base of the ball joint stem at the
socket.
(2) Install aNEWseal boot by hand as far as pos-
sible on the ball joint.
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.(3) Place Installer, Special Tool 6758, over seal
boot and squarely align it with bottom edge of seal
boot (Fig. 1). Apply hand pressure to Special Tool
6758 until seal boot is pressed squarely against top
surface of lower control arm.
(4) Wipe any grease off the ball joint stem.
(5) Place the shield over the top of the seal boot
and stretch it into the groove at the top of the seal
boot.
Fig. 1 Installing Ball Joint Seal Boot (Typical)
1 - SHIELD (NOT ON RG VEHICLE)
2 - SPECIAL TOOL 6758
3 - LOWER CONTROL ARM
4 - BALL JOINT SEAL BOOT
RGSUSPENSION2a-1

CAUTION: Do not attempt to install a normal grease
zirc in the ball joint and lubricate the joint through
the zirc fitting.
(6) Reinstall steering knuckle on vehicle. (Refer to
2 - SUSPENSION/FRONT/KNUCKLE - INSTALLA-
TION)
2a - 2 FRONT SUSPENSIONRG
LOWER BALL JOINT SEAL BOOT (Continued)

WHEEL ALIGNMENT
TABLE OF CONTENTS
page page
WHEEL ALIGNMENT
STANDARD PROCEDURE...................3CURB HEIGHT MEASUREMENT............3
WHEEL ALIGNMENT
STANDARD PROCEDURE - CURB HEIGHT
MEASUREMENT
The wheel alignment is to be checked and all align-
ment adjustments made with the vehicle at its
required curb height specification.
Vehicle height is to be checked with the vehicle on
a flat, level surface, preferably a vehicle alignment
rack. The tires are to be inflated to the recommended
pressure. All tires are to be the same size as stan-
dard equipment. Vehicle height is checked with the
fuel tank full of fuel, and no passenger or luggage
compartment load.
Vehicle height is not adjustable. If the measure-
ment is not within specifications, inspect the vehiclefor bent or weak suspension components. Compare
the parts tag on the suspect coil spring(s) to the
parts book and the vehicle sales code, checking for a
match. Once removed from the vehicle, compare the
coil spring height to a correct new or known good coil
spring. The heights should vary if the suspect spring
is weak.
(1) Measure from the inboard edge of the wheel
opening fender lip directly above the wheel center
(spindle), to the floor or alignment rack surface.
(2) When measuring, the maximum left-to-right
differential is not to exceed 12.5 mm (0.5 in.).
(3) Compare the measurements to the specifica-
tions listed in the following Curb Height Specifica-
tions charts.
CURB HEIGHT SPECIFICATIONS - LONG WHEEL BASE VEHICLES WITH SDF SUSPENSION
TIRE SALES CODE/TIRE SIZE FRONT REAR
TMM / 215/65 R 16756mm 10mm
29.76 in.   0.39 in.772mm 10mm
30.39 in.   0.39 in.
CURB HEIGHT SPECIFICATIONS - LONG WHEEL BASE VEHICLES WITH SDF + SER
SUSPENSION
TIRE SALES CODE/TIRE SIZE FRONT REAR
TMM / 215/65 R 16756mm 10mm
29.76 in.   0.39 in.771mm 10mm
30.35 in.   0.39 in.
CURB HEIGHT SPECIFICATIONS - SHORT WHEEL BASE VEHICLES
TIRE SALES CODE/TIRE SIZE FRONT REAR
TMM / 215/65 R 16755mm 10mm
29.72 in.   0.39 in.770mm 10mm
30.31 in.   0.39 in.
RGWHEEL ALIGNMENT2a-3

DIFFERENTIAL & DRIVELINE
TABLE OF CONTENTS
page page
HALF SHAFT - FRONT.....................1
HALF SHAFT - REAR.....................16PROPELLER SHAFT......................24
REAR DRIVELINE MODULE................26
HALF SHAFT - FRONT
TABLE OF CONTENTS
page page
HALF SHAFT - FRONT
DESCRIPTION............................1
DIAGNOSIS AND TESTING..................1
HALF SHAFT...........................1
REMOVAL...............................2
INSTALLATION............................5
SPECIFICATIONS.........................7
CV BOOT - INNER
REMOVAL...............................7INSTALLATION............................8
CV BOOT - OUTER
REMOVAL..............................11
INSTALLATION...........................12
OUTER CV JOINT BEARING SHIELD
REMOVAL..............................14
INSTALLATION...........................14
HALF SHAFT - FRONT
DESCRIPTION
All vehicles use an unequal length half shaft sys-
tem (Fig. 1).
The left half shaft uses a tuned rubber damper
weight. When replacing the left half shaft, be sure
the replacement half shaft has the same damper
weight as the original.
All half shaft assemblies use the same type of
inner and outer joints. The inner joint of both half
shaft assemblies is a tripod joint, and the outer joint
of both half shaft assemblies is a Rzeppa joint. Both
tripod joints and Rzeppa joints are true constant
velocity (CV) joint assemblies. The inner tripod joint
allows for the changes in half shaft length through
the jounce and rebound travel of the front suspen-
sion.
On vehicles equipped with ABS brakes, the outer
CV joint is equipped with a tone wheel used to deter-
mine vehicle speed for ABS brake operation.
The inner tripod joint of both half shafts is splined
into the transaxle side gears. The inner tripod joints
are retained in the side gears of the transaxle usinga snap ring located in the stub shaft of the tripod
joint. The outer CV joint has a stub shaft that is
splined into the wheel hub and retained by a steel
hub nut.
DIAGNOSIS AND TESTING - HALF SHAFT
VEHICLE INSPECTION
(1) Check for grease in the vicinity of the inboard
tripod joint and outboard CV joint; this is a sign of
inner or outer joint seal boot or seal boot clamp dam-
age.
(2) A light film of grease may appear on the right
inner tripod joint seal boot; this is considered normal
and should not require replacement of the seal boot.
NOISE AND/OR VIBRATION IN TURNS
A clicking noise and/or a vibration in turns could
be caused by one of the following conditions:
²Damaged outer CV or inner tripod joint seal
boot or seal boot clamps. This will result in the loss
and/or contamination of the joint grease, resulting in
inadequate lubrication of the joint.
RSDIFFERENTIAL & DRIVELINE3-1

²Noise may also be caused by another component
of the vehicle coming in contact with the half shafts.
CLUNKING NOISE DURING ACCELERATION
This noise may be a result of one of the following
conditions:
²A torn seal boot on the inner or outer joint of the
half shaft assembly.
²A loose or missing clamp on the inner or outer
joint of the half shaft assembly.
²A damaged or worn half shaft CV joint.
SHUDDER OR VIBRATION DURING ACCELERATION
This problem could be a result of:
²A worn or damaged half shaft inner tripod joint.
²A sticking tripod joint spider assembly (inner tri-
pod joint only).
²Improper wheel alignment. (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE)
VIBRATION AT HIGHWAY SPEEDS
This problem could be a result of:
²Foreign material (mud, etc.) packed on the back-
side of the wheel(s).
²Out of balance tires or wheels. (Refer to 22 -
TIRES/WHEELS - STANDARD PROCEDURE)
²Improper tire and/or wheel runout. (Refer to 22 -
TIRES/WHEELS - DIAGNOSIS AND TESTING)
REMOVAL
(1) Raise vehicle on jack stands or centered on a
frame contact type hoist.
(2) Remove the cotter pin and nut lock (Fig. 2)
from the end of the half shaft.
(3) Remove the wave washer (Fig. 3) from the end
of the half shaft.
(4) Remove the wheel and tire assembly from the
vehicle. (Refer to 22 - TIRES/WHEELS - REMOVAL)
(5) With the vehicle's brakes applied to keep hub
from turning,loosen and removethe half shaft
nut.
(6) Remove the two front disc brake caliper
adapter to steering knuckle attaching bolts (Fig. 4).
Fig. 1 Unequal Length Half Shaft System
1 - STUB AXLE
2 - OUTER C/V JOINT
3 - OUTER C/V JOINT BOOT
4 - TUNED RUBBER DAMPER WEIGHT
5 - INTERCONNECTING SHAFT
6 - OUTER C/V JOINT BOOT
7 - STUB AXLE
8 - OUTER C/V JOINT9 - RIGHT HALFSHAFT
10 - INNER TRIPOD JOINT BOOT
11 - INNER TRIPOD JOINT
12 - INNER TRIPOD JOINT
13 - INNER TRIPOD JOINT BOOT
14 - INTERCONNECTING SHAFT & LEFT HALFSHAFT
3 - 2 HALF SHAFT - FRONTRS
HALF SHAFT - FRONT (Continued)

(7) Remove the disc brake caliper assembly from
the steering knuckle. Caliper assembly is removed by
first rotating top of caliper assembly away from
steering knuckle and then removing bottom of assem-
bly out from under machined abutment on steering
knuckle.
(8) Support disc brake caliper assembly by using a
wire hook and suspending it from the strut assembly
(Fig. 5).Do not allow the brake caliper assembly
to hang by the brake flex hose.
(9) Remove the brake rotor from the hub and bear-
ing assembly.(10) Remove nut attaching outer tie rod end to
steering knuckle (Fig. 6).Nut is to be removed
from tie rod end using the following procedure,
hold tie rod end stud with a socket while loos-
ening and removing nut with a wrench.
(11) Remove tie rod end from steering knuckle
using Remover, Special Tool MB-991113 (Fig. 7).
Fig. 2 Half Shaft Retaining Nut
1 - HUB/BEARING
2 - NUT LOCK
3 - COTTER PIN
4 - HALF SHAFT
Fig. 3 Wave Washer
1 - HUB/BEARING ASSEMBLY
2 - WAVE WASHER
3 - HALF SHAFT
Fig. 4 Front Brake Mounting
1 - BRAKE ROTOR
2 - HUB AND BEARING
3 - STEERING KNUCKLE
4 - ADAPTER MOUNTING BOLTS
5 - BRAKE CALIPER
6 - ADAPTER
7 - CLIP
Fig. 5 Correctly Supported Disc Brake Caliper -
Typical
1 - STEERING KNUCKLE
2 - BRAKE FLEX HOSE
3 - CALIPER ASSEMBLY
4 - WIRE HANGER
5 - STRUT ASSEMBLY
RSHALF SHAFT - FRONT3-3
HALF SHAFT - FRONT (Continued)

(12) Remove the steering knuckle to strut attach-
ment bolts (Fig. 8) from the steering knuckle.
(13) Pull the steering knuckle from the strut clevis
bracket.
NOTE: Care must be taken not to separate the inner
C/V joint during this operation. Do not allow half
shaft to hang by inner C/V joint after removing
outer C/V Joint from the hub/bearing assembly insteering knuckle, end of half shaft must be sup-
ported.
(14) Pull steering knuckle assembly down and
away from the outer C/V joint of the half shaft
assembly while pulling the joint out of the hub bear-
ing.
(15) Support the outer end of the half shaft assem-
bly. Insert a pry bar between inner tripod joint and
transaxle case (Fig. 9). Pry against inner tripod joint,
until tripod joint retaining snap-ring is disengaged
from transaxle side gear.
Fig. 6 Removing Tie Rod End Attaching Nut
1 - TIE ROD END
2 - STEERING KNUCKLE
3 - WRENCH
4 - SOCKET
5 - TIE ROD END STUD
Fig. 7 Tie Rod End Removal From Steering Knuckle
Arm
1 - TIE ROD END
2 - SPECIAL TOOL MB-991113
3 - STUD
4 - STEERING KNUCKLE ARM
Fig. 8 Strut To Steering Knuckle Attaching Bolts
1 - STRUT CLEVIS BRACKET
2 - NUTS AND BOLTS
3 - STEERING KNUCKLE
Fig. 9 Disengaging Inner Tripod Joint From
Transaxle
1 - INNER TRIPOD JOINT
2 - TRANSAXLE CASE
3-PRYBAR
3 - 4 HALF SHAFT - FRONTRS
HALF SHAFT - FRONT (Continued)