wheel CHRYSLER VOYAGER 2001 Service Manual

DIAGNOSIS AND TESTING - TIRE WEAR
PATTERNS
Under inflation will cause wear on the shoulders of
tire. Over inflation will cause wear at the center of
tire.
Excessive camber causes the tire to run at an
angle to the road. One side of tread is then worn
more than the other (Fig. 18).
Excessive toe-in or toe-out causes wear on the
tread edges and a feathered effect across the tread
(Fig. 18).
DIAGNOSIS AND TESTING - TREAD WEAR
INDICATORS
Tread wear indicators are molded into the bottom
of the tread grooves. When tread depth is 1.6 mm
(1/16 in.), the tread wear indicators will appear as a
13 mm (1/2 in.) band (Fig. 19).
Tire replacement is necessary when indicators
appear in two or more grooves or if localized balding
occurs.
STANDARD PROCEDURE - TIRE INFLATION
PRESSURES
The specified tire pressures have been chosen to
provide safe operation, vehicle stability, and a smooth
ride. The proper tire pressure specification can be
found on the Tire Inflation Pressure Label provided
with the vehicle (usually on the rear face inside the
glove box).
A quality air pressure gauge is recommended to
check tire air pressure. Tire pressure should be
checked cold once per month. Check tire pressure
more frequently when the weather temperature var-
ies widely. Tire pressure will decrease when the out-door temperature drops. After checking the air
pressure, replace valve cap finger tight.
Inflation pressures specified on the Tire Inflation
Pressure Label are always the cold inflation pressure
of the tire. Cold inflation pressure is obtained after
the vehicle has not been operated for at least 3
hours, or the vehicle is driven less than one mile
after being inoperative for 3 hours. Tire inflation
pressures may increase from 2 to 6 pounds per
square inch (psi) during operation. Do not reduce this
normal pressure buildup.
Fig. 18 Tire Wear Patterns
Fig. 19 Tread Wear Indicators
1 - TREAD ACCEPTABLE
2 - TREAD UNACCEPTABLE
3 - WEAR INDICATOR
RSTIRES/WHEELS22-11
TIRES (Continued)

Improper inflation can cause:
²Uneven wear patterns
²Reduced tread life
²Reduced fuel economy
²Unsatisfactory ride
²The vehicle to drift.
WARNING: OVER OR UNDER INFLATED TIRES CAN
AFFECT VEHICLE HANDLING. THE TIRE CAN FAIL
SUDDENLY, RESULTING IN LOSS OF VEHICLE
CONTROL.
Under inflation causes rapid shoulder wear, tire
flexing, and can result in tire failure (Fig. 20).
Over inflation causes rapid center wear and loss of
the tire's ability to cushion shocks (Fig. 21).STANDARD PROCEDURE - TIRE PRESSURE
FOR HIGH SPEED OPERATION
DaimlerChrysler Corporation advocates driving at
safe speeds within posted speed limits. Where speed
limits allow the vehicle to be driven at high speeds,
correct tire inflation pressure is very important.
Vehicles loaded to maximum capacity should not be
driven at continuous speeds over 120 km/h (75 mph).
Never exceed the maximum speed capacity of the
tire. For information on tire identification and speed
ratings, (Refer to 22 - TIRES/WHEELS/TIRES -
DESCRIPTION).
STANDARD PROCEDURE - TIRE LEAK
REPAIRING
For proper repairing, a radial tire must be removed
from the wheel. Repairs should only be made if the
defect, or puncture, is in the tread area (Fig. 22). The
tire should be replaced if the puncture is located in
the sidewall.
Deflate tire completely before attempting to dis-
mount the tire from the wheel.Use a lubricant
such as a mild soap solution when dismounting
or mounting tire.Use tools free of burrs or sharp
edges which could damage the tire or wheel rim.
Before mounting tire on wheel, make sure all rust
is removed from the rim bead and repaint if neces-
sary.
Install wheel on vehicle, and progressively tighten
the 5 wheel nuts to a torque of 135 N´m (100 ft. lbs.).
Fig. 20 Under Inflation Wear
1 - THIN TIRE TREAD AREAS
Fig. 21 Over Inflation Wear
1 - THIN TIRE TREAD AREA
Fig. 22 Tire Repair Area
1 - REPAIRABLE AREA
22 - 12 TIRES/WHEELSRS
TIRES (Continued)

CLEANING - TIRES
Before delivery of a vehicle, remove the protective
coating on the tires with white sidewalls or raised
white letters. To remove the protective coating, apply
warm water and let it soak for a few minutes. After-
wards, scrub the coating away with a soft bristle
brush. Steam cleaning may also be used to remove
the coating.
CAUTION: DO NOT use gasoline, mineral oil, oil-
based solvent or a wire brush for cleaning.
WHEELS
DESCRIPTION - WHEEL
Original equipment wheels are designed for proper
operation at all loads up to the specified maximum
vehicle capacity.
All models use either steel or aluminum drop-cen-
ter wheels. Every wheel has raised sections between
the rim flanges and rim drop well called safety
humps (Fig. 23). Initial inflation of the tires forces
the bead over these raised sections. In case of air
loss, the safety humps hold the tire in position on the
wheel until the vehicle can be brought to a safe stop.
Cast aluminum wheels require special balance
weights to fit on the flange of the rim (Fig. 24).
When wheel alignment is necessary on a vehicle
with cast aluminum wheels, special wheel clamps are
required to avoid damage to the wheel's finish.The wheel studs and nuts are designed for specific
wheel applications and must be replaced with equiv-
alent parts.
All aluminum wheels have wheel mounting (lug)
nuts with an enlarged nose. This enlarged nose is
necessary to ensure proper retention of the wheels.
DIAGNOSIS AND TESTING - WHEEL
INSPECTION
Inspect wheels for:
²Excessive runout
²Dents, cracks or irregular bends
²Damaged wheel stud (lug) holes
²Air Leaks
NOTE: Do not attempt to repair a wheel by hammer-
ing, heating or welding.
If a wheel is damaged, an original equipment
replacement wheel should be used. When obtaining
replacement wheels, they should be equivalent in
load carrying capacity. The diameter, width, offset,
pilot hole and bolt circle of the wheel should be the
same as the original wheel.
WARNING: FAILURE TO USE EQUIVALENT
REPLACEMENT WHEELS MAY ADVERSELY
AFFECT THE SAFETY AND HANDLING OF THE
VEHICLE.
WARNING: REPLACEMENT WITH USED WHEELS IS
NOT RECOMMENDED. THE SERVICE HISTORY OF
THE WHEEL MAY HAVE INCLUDED SEVERE TREAT-
MENT OR VERY HIGH MILEAGE. THE RIM COULD
FAIL WITHOUT WARNING.
Fig. 23 Safety Rim
1 - TIRE
2 - WELL
3 - SAFETY HUMPS
4 - FLANGE
Fig. 24 Styled Aluminum Wheel Weight
1 - TIRE
2 - WHEEL
3 - STYLED WHEEL WEIGHT
RSTIRES/WHEELS22-13
TIRES (Continued)

CLEANING - ALUMINUM WHEEL CARE
Chrome plated and painted aluminum wheels
should be cleaned regularly using mild soap and
water to maintain their luster and to prevent corro-
sion.
Care must be taken in the selection of tire and
wheel cleaning chemicals and equipment to prevent
damage to the wheels. Any of the ªDO NOT USEº
items listed below WILL damage chrome plated and
painted aluminum wheels.
DO NOT USE:
²any abrasive metal cleaner
²any abrasive cleaning pad or brush
²any cleaner that contains an acid (this will
immediately react with and discolor the chromium
surface)
²chrome polish (unless it is buffed off immedi-
ately after application)
²oven cleaner
²a car wash that uses carbide-tipped wheel clean-
ing brushes
SPECIFICATIONS
WHEEL
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Wheel Mounting (Lug)
Nut Hex Size19 mm
Wheel Mounting Stud
SizeM12 x 1.5 mm
TORQUE SPECIFICATIONS
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Wheel Mounting (Lug ) Nut 135 100 Ð
WHEEL COVER
DESCRIPTION
This vehicle uses a bolt-on type wheel cover (Fig.
25).
This bolt-on wheel cover cannot be removed from
the wheel until three of the five wheel mounting nuts
shown are removed (Fig. 25). The bolt-on wheel cover
can then be removed with the remaining two wheel
nuts tightened in place.
REMOVAL
(1) Noting the location of the valve stem in rela-
tionship to the wheel mounting nuts, remove the
three wheel mounting nuts securing the wheel cover
to the wheel and hub (Fig. 25).
CAUTION: When removing the wheel cover, do not
pry the wheel cover from the wheel. This can result
in damage to the wheel cover. The wheel cover is
removed by pulling it off the wheel by hand.
(2) Grasp the wheel cover at the edges in line with
the remaining installed wheel nuts and pull straight
outward from the wheel. This will pop the wheel
cover retaining tabs over the two remaining wheel
nuts, removing the wheel cover from the wheel.
INSTALLATION
NOTE: Wheel mounting nuts must be installed on
the studs as shown to allow installation of the
wheel cover (Fig. 26).
(1) Place the wheel cover on the wheel in the fol-
lowing fashion:
(a) Align the valve notch in the wheel cover with
the valve stem on the wheel.
(b) At the same time, align the two holes in the
wheel cover having the retaining tabs with the two
installed wheel nuts (Fig. 27).
(c) Press in on center of wheel cover until wheel
cover retaining tabs push past and engage rear of
previously installed wheel mounting nuts (Fig. 27).
This will hold the wheel cover in place.
Fig. 25 Nuts Securing Wheel Cover
1 - VALVE STEM
2 - BOLT-ON WHEEL COVER
3 - NUTS SECURING WHEEL COVER
22 - 14 TIRES/WHEELSRS
WHEELS (Continued)

(2) Install andlightly tightenthe three remain-
ing wheel mounting nuts, securing the wheel cover in
place (Fig. 25).
(3) Tighten all five wheel mounting nuts in the
proper sequence (Fig. 28). Tighten wheel nuts to a
torque of 135 N´m (100 ft. lbs.).
WHEEL MOUNTING STUDS -
FRONT
REMOVAL
CAUTION: If a wheel mounting stud needs to be
replaced in the hub and bearing assembly, the
studs MUST NOT be hammered out of the hub
flange. If a stud is removed by hammering it out of
the bearing flange, damage to the hub and bearing
assembly will occur leading to premature bearing
failure.
(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in Lubrication
and Maintenance.
(2) Remove the front wheel and tire assembly from
the vehicle.
(3) Remove the two adapter mounting bolts secur-
ing both the disc brake caliper adapter to the steer-
ing knuckle (Fig. 29).
(4) Remove the disc brake caliper and adapter as
an assembly from the steering knuckle (Fig. 29).
Hang the assembly out of the way using wire or a
bungee cord. Use care not to overextend the brake
hose when doing this.
(5) Remove brake rotor from hub by pulling it
straight off wheel mounting studs (Fig. 29).
(6) On the wheel mounting stud to be removed,
install a wheel mounting (lug) nut far enough so the
threads on the stud are even with end of nut. Install
Remover, Special Tool C-4150A on hub and bearing
assembly flange and wheel stud (Fig. 30).
(7) Tighten down on special tool, pushing wheel
stud out of the hub flange. When shoulder of wheel
stud is past flange, remove special tool from hub and
bearing. Remove nut from stud and remove stud
from hub flange.
Fig. 26 Two Wheel Mounting Nuts Installed
1 - WHEEL
2 - VALVE STEM
3 - HUB PILOT
4 - NUTS
Fig. 27 Wheel Cover Installation Over Two Nuts
1 - RETAINING TABS
2 - VALVE STEM
3 - BOLT-ON WHEEL COVER
Fig. 28 Nut Tightening Sequence
RSTIRES/WHEELS22-15
WHEEL COVER (Continued)

INSTALLATION
(1) Install replacement wheel stud into flange of
hub and bearing assembly. Install washers on wheel
stud, then install a wheel mounting (lug) nut on stud
with flat side of lug nut against washers as shown
(Fig. 31).
(2) Tighten the nut, pulling the wheel stud into
the flange of the hub and bearing. When the head ofthe stud is fully seated against the rear of the hub
flange, remove nut and washers from stud.
(3) Install the brake rotor back on the hub and
bearing (Fig. 29).
(4) Install brake caliper and adapter back over
brake rotor aligning adapter with mounting holes on
steering knuckle (Fig. 29).
(5) Install the two adapter mounting bolts securing
the adapter to the steering knuckle. Tighten the
mounting bolts to 169 N´m (125 ft. lbs.) torque.
(6) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting lug nuts in proper
sequence until all nuts are torqued to half specifica-
tion, then repeat the tightening sequence to the full
specified torque of 135 N´m (100 ft. lbs.).
(7) Lower vehicle to the ground.
WHEEL MOUNTING STUDS -
REAR
REMOVAL
CAUTION: If a wheel attaching stud needs to be
replaced in the hub and bearing assembly the studs
MUST NOT be hammered out of the hub flange. If a
stud is removed by hammering it out of the bearing
flange, damage to the hub and bearing assembly
will occur leading to premature hub and bearing
failure.
(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in Lubrication
and Maintenance.
Fig. 29 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. 30 Wheel Stud Removal (Typical)
1 - WHEEL MOUNTING (LUG) NUT
2 - HUB AND BEARING ASSEMBLY
3 - SPECIAL TOOL C-4150A
4 - STEERING KNUCKLE
5 - WHEEL STUD
Fig. 31 Installing Wheel Stud (Typical)
1 - WASHERS
2 - HUB AND BEARING ASSEMBLY
3 - WHEEL MOUNTING (LUG) NUT
4 - STEERING KNUCKLE
22 - 16 TIRES/WHEELSRS
WHEEL MOUNTING STUDS - FRONT (Continued)

(2) Remove the rear wheel and tire assembly.
(3) Remove the brake drum or disc brake caliper
and rotor. Refer to Brakes.
(4) Install a lug nut on the wheel stud to be
removed from the hub and bearing assembly (Fig. 32)
so the threads on stud are even with end of lug nut.
Install Remover, Special Tool C-4150A on hub and
bearing assembly flange and wheel stud (Fig. 32).
(5) Tightening down on special tool will push
wheel stud out of the hub and bearing assembly
flange.
(6) Remove lug nut from stud and remove wheel
stud from flange.INSTALLATION
(1) Install replacement wheel stud into flange of
hub and bearing assembly. Install washers on wheel
stud, then install a wheel lug nut on stud with flat
side of lug nut against washers (Fig. 33).
(2) Tighten the wheel lug nut, pulling the wheel
stud into the flange of the hub and bearing assembly.
When the head of the stud is fully seated against the
bearing flange, remove lug nut and washers from
wheel stud.
(3) Install the brake drum or disc brake rotor and
caliper on the hub and bearing assembly.
(4) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting stud nuts in proper
sequence until all nuts are torqued to half specifica-
tion. Then repeat the tightening sequence to the full
specified torque of 135 N´m (100 ft. lbs.).
(5) Lower vehicle to the ground.
Fig. 32 Wheel Stud Removal From Hub And Bearing
1 - HUB AND BEARING ASSEMBLY
2 - WHEEL MOUNTING (LUG) NUT
3 - WHEEL STUD
4 - SPECIAL TOOL C-4150A
Fig. 33 Wheel Stud Installation
1 - WHEEL MOUNTING (LUG) NUT
2 - HUB AND BEARING ASSEMBLY
3 - WASHERS
4 - WHEEL STUD
RSTIRES/WHEELS22-17
WHEEL MOUNTING STUDS - REAR (Continued)

VISUAL INSPECTION
Sheet Molded Compound (SMC) and Resin Trans-
fer Molded (RTM), because they are composites, react
differently to impact that sheet metal does. Compos-
ite materials can mask the severity of an accident.
Adhesive bond lines, interior structure of the doors,
and steel structure need to be inspected carefully to
get a true damage assessment. Close inspection may
require partial removal of interior trim or inner pan-
els.
Identify the type of repair:
Puncture or Crack ± Damage that has penetrated
completely through the panel. Damage is confined to
one general area; a panel section is not required.
However, a backer panel, open fiberglass tape, or
matted material must be bonded from behind (Fig.
7).
PANEL SURFACE PREPARATION
If a body panel has been punctured, cracked, or
crushed, the damaged area must be removed from
the panel to achieve a successful repair. All spider
web cracks leading away from a damaged area must
be stopped or removed. To stop a running crack in a
SMC or RTM panel, drilla6mm(0.250 in.) hole at
the end of the crack farthest away from the damage.
If spider web cracks can not be stopped, the panel
would require replacement. The surfaces around the
damaged area should be stripped of paint and freed
from was and oil. Scuff surfaces around repair area
with 360 grit wet/dry sand paper, or equivalent, to
assure adhesion of epoxy repair materials.
PATCHING PANELS
An RTM or SMC panel that has extensive punc-
ture type damage can be repaired by cutting out the
damaged material (Fig. 8). Use a suitable reciprocat-
ing saw or cut off wheel to remove the section of the
SMC or RTM panel that is damaged. The piece cut
out can be used as a template to shape the new
patch. It is not necessary to have access to the back
of the panel to install a patch. Bevel edges of cutout
at 20 degrees to expose a larger bonding area on the
outer side. This will allow for an increased reinforce-
ment areas.
PANEL PATCH FABRICATIONS
A patch can be fabricated from any rigid fiberglass
panel that has comparable contour with the repair
area. discard SMC or RTM panels. Lift gates and
fenders can be used to supply patch material. If
existing material is not available or compatible, a
patch can be constructed with epoxy and reinforce-
ment mesh (dry wall tape). Perform the following
operation if required:
(1) Cover waxed paper or plastic with adhesive
backed nylon mesh (dry wall tape) larger than the
patch required (Fig. 9).
(2) Tape waxed paper or plastic sheet with mesh to
a surface that has a compatible contour to the repair
area.
(3) Apply a liberal coat of epoxy adhesive over the
reinforcement mesh (Fig. 9). If necessary apply a sec-
ond or third coat of epoxy and mesh after firs coat
has cured. The thickness of the patch should be the
same as the repair area.
(4) After patch has cured, peel waxed paper or
plastic from the back of the patch.
Fig. 7 Damage Component
1 - PUNCTURE
Fig. 8 DAMAGED PANEL CUTOUT AND PATCH
1 - CUTOUT
2 - DAMAGED BODY PANEL
3 - 4MM (0.160 IN.) HOLES
4 - PATCH CUT TO SIZE
23 - 6 BODYRS
BODY (Continued)

LUBRICANT USAGE
COMPONENT SERVICE INTERVAL LUBRICANT
Door Hinges - Hinge Pin and Pivot
Contact AreasAs Required Engine Oil
Hood Hingers - Pivot Points As Required Engine Oil
Lifgate Hinges As Required Engine Oil
Door Check Straps As Required Spray white lube (3)
Door Latches As Required Multi-Purpose Grease (Water
Resistant) (1)
Lifgate Latches As Required Spray white lube (3)
Lifgate Prop Pivots As Required Spray white lube (3)
Ash Receiver As Required Spray white lube (3)
Fuel Filler Door Remote Control
Latch MechanismAs Required Spray white lube (3)
Parking Brake Mechanism As Required Spray white lube (3)
Sliding Seat Tracks As Required Spray white lube (3)
All Other Hood Mechanisms As Required Multipurpose Grease (2)
Door Lock Cylinders As Required Lock Cylinder Lubricant (4)
Lifgate Lock Cylinder As Required Lock Cylinder Lubricant (4)
Sliding Door Upper Track As Required Multi-Purpose Grease NLGI Grade
2 EP (2)
Sliding Door Center Track Leading
EdgeAs Required Multi-Purpose Grease NLGI Grade
2 EP (2)
Sliding Door Lower Track Leading
EdgeAs Required Multi-Purpose Grease NLGI Grade
2 EP (2)
Window System Components
(Regulators, tracks, links, channel
areas Ð except glass run
weatherstrips and felt lubricator, if
equipped.)As Required Spray white lube (3)
1 MOPARž Wheel Bearing Grease (High Temperature)
2 MOPARž Multi-Mileage Lubricant or equivalent
3 MOPARž Spray white lube or equivalent
4 MOPARž Lock Cylinder Lubricant or equivalent
23 - 10 BODYRS
BODY (Continued)

REAR WHEEL HOUSE FLOOR PAN - LEFT AND RIGHT SIDES
REAR WHEELHOUSE TO FLOOR PAN - LEFT AND RIGHT SIDES
23 - 24 BODYRS
BODY (Continued)