Brake line CHRYSLER VOYAGER 2002 Service Manual
[x] Cancel search | Manufacturer: CHRYSLER, Model Year: 2002, Model line: VOYAGER, Model: CHRYSLER VOYAGER 2002Pages: 2399, PDF Size: 57.96 MB
Page 1 of 2399
GROUP TAB LOCATOR
INIntroduction
0Lubrication & Maintenance
2Suspension
3Differential & Driveline
5Brakes
6Clutch
7Cooling
7aCooling - 2.5L Turbo Diesel
8AAudio
8BChime/Buzzer
8EElectronic Control Modules
8EaElectronic Control Modules
8FEngine Systems
8FaEngine Systems
8GHeated Systems
8HHorn
8IIgnition Control
8IaIgnition Control
8JInstrument Cluster
8LLamps
8MMessage Systems
8NPower Systems
8ORestraints
8PSpeed Control
8QVehicle Theft Security
8RWipers/Washers
8WWiring
9Engine
9aEngine
11Exhaust System
11aExhaust System and Turbocharger
13Frame & Bumpers
14Fuel System
14aFuel System
19Steering
21Transmission
22Tires/Wheels
23Body
24Heating & Air Conditioning
25Emissions Control
25aEmissions Control 2.5L Turbo Diesel
Service Manual Comment Forms
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(2) When using another vehicle as a booster
source, park the booster vehicle within cable reach.
Turn off all accessories, set the parking brake, place
the automatic transmission in PARK or the manual
transmission in NEUTRAL and turn the ignition
OFF.
(3) On disabled vehicle, place gear selector in park
or neutral and set park brake. Turn off all accesso-
ries.
(4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to neg-
ative terminal (-). DO NOT allow clamps at opposite
end of cables to touch, electrical arc will result.
Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the
ground cable attaching point as possible (Fig. 6).
(Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BAT-
TERY - STANDARD PROCEDURE).
(6) Start the engine in the vehicle which has the
booster battery, let the engine idle a few minutes,
then start the engine in the vehicle with the dis-
charged battery.
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter may over-
heat and could fail.
(7) If engine does not start within 15 seconds, stop
cranking engine and allow starter to cool (15 min-
utes), before cranking again.DISCONNECT CABLE CLAMPS AS FOLLOWS:
²Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
²When using a Booster vehicle, disconnect
BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive
terminal.
²Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle.
TOWING
STANDARD PROCEDURE - TOWING
WARNINGS AND CAUTIONS
WARNING: DO NOT ALLOW TOWING ATTACHMENT
DEVICES TO CONTACT THE FUEL TANK OR LINES,
FUEL LEAK CAN RESULT.
DO NOT LIFT OR TOW VEHICLE BY FRONT OR
REAR BUMPER.
DO NOT GO UNDER A LIFTED VEHICLE IF NOT
SUPPORTED PROPERLY ON SAFETY STANDS.
DO NOT ALLOW PASSENGERS TO RIDE IN A
TOWED VEHICLE.
USE A SAFETY CHAIN THAT IS INDEPENDENT
FROM THE TOWING ATTACHMENT DEVICE.
CAUTION: Do not damage brake lines, exhaust sys-
tem, shock absorbers, sway bars, or any other
under vehicle components when attaching towing
device to vehicle.
Do not secure vehicle to towing device by the use
of front or rear suspension or steering components.
Remove or secure loose or protruding objects from
a damaged vehicle before towing.
Refer to state and local rules and regulations before
towing a vehicle.
Do not allow weight of towed vehicle to bear on
lower fascia, air dams, or spoilers.
RECOMMENDED TOWING EQUIPMENT
To avoid damage to bumper fascia and air dams
use:
²FWD vehicles, use of a flat bed towing device or
a wheel lift is recommended (Fig. 7).
²AWD vehicles, a flat bed towing device or a
wheel lift and towing dolly is recommended (Fig. 7).
When using a wheel lift towing device, be sure the
disabled vehicle has at least 100 mm (4 in.) ground
clearance. If minimum ground clearance cannot be
reached, use a towing dolly. If a flat bed device is
used, the approach angle should not exceed 15
degrees.
Fig. 6 JUMPER CABLE CLAMP CONNECTIONS
1 - BATTERY NEGATIVE TERMINAL
2 - POSITIVE JUMPER CABLE
3 - TEST INDICATOR (IF EQUIPPED)
4 - BATTERY POSITIVE TERMINAL
5 - BATTERY
6 - NEGATIVE JUMPER CABLE
0 - 8 LUBRICATION & MAINTENANCERS
JUMP STARTING (Continued)
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GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels removed,
install lug nuts to retain brake drums or rotors.
A towed vehicle should be raised until the lifted
wheels are a minimum 100 mm (4 in.) from the
ground. Be sure there is at least 100 mm (4 in.)
clearance between the tail pipe and the ground. If
necessary, remove the wheels from the front end of
the vehicle and lower the front end closer to the
ground, to increase the ground clearance at the rear
of the vehicle. Install lug nuts on wheel attaching
studs to retain brake drums or rotors.
LOCKED VEHICLE TOWING
When a locked vehicle must be towed with the
front wheels on the ground, use a towing dolly or flat
bed hauler.
FLAT TOWING WITH TOW BAR
²Three speed automatic transaxle vehicles can be
flat towed at speeds not to exceed 40 km/h (25 mph)
for not more than 25 km (15 miles). The steering col-
umn must be unlocked and gear selector in neutral.
²Four speed electronic automatic transaxle vehi-
cles can be flat towed at speeds not to exceed 72
km/h (44 mph) for not more than 160 km (100 miles).
The steering column must be unlocked and gear
selector in neutral.
²AWD models should not be flat towed. For addi-
tional information, refer toRECOMMENDED TOW-
ING EQUIPMENTin this section.
FLAT BED TOWING TIE DOWNS
CAUTION: Do not tie vehicle down by attaching
chains or cables to suspension components or
engine mounts, damage to vehicle can result.
The vehicle can be tied to a flat bed device using
the two pair of front slots on the bottom surface of
the rails, behind the front wheels. The two pair of
rear slots on the bottom of the rail between the
bumper extension bolts and on the bottom of the rail
just rearward of the jounce bumper. Vehicles
equipped with a rear sway bar have brackets at this
location.
TOWING ± FRONT WHEEL LIFT
If the vehicle is being towed from the front, when-
ever possible ensure at least 10 inches road clearance
to the tires.
TOWING ± REAR WHEEL LIFT
If a vehicle cannot be towed with the front wheels
lifted, the rear wheels can be lifted provided the fol-
lowing guide lines are observed.
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
²On AWD vehicles, all four wheels must be free to
rotate. Use towing dollies at unlifted end of vehicle.
²Unlock steering column and secure steering
wheel in straight ahead position with a clamp device
designed for towing.
²Three speed automatic transaxle vehicles can be
flat towed at speeds not to exceed 40 km/h (25 mph)
for not more than 25 km (15 miles). The steering col-
umn must be unlocked and gear selector in neutral.
²Four speed electronic automatic transaxle vehi-
cles can be flat towed at speeds not to exceed 72
km/h (44 mph) for not more than 160 km (100 miles).
The steering column must be unlocked and gear
selector in neutral.
Fig. 7 RECOMMENDED TOWING
1 - WHEEL LIFT
2 - FLAT BED
RSLUBRICATION & MAINTENANCE0-9
TOWING (Continued)
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DIAGNOSIS AND TESTING - HUB AND
BEARING
The condition of the front hub and bearing assem-
bly is diagnosed using the inspection and testing pro-
cedure detailed below.
The bearing contained in the Unit III front hub/
bearing assembly will produce noise and vibration
when worn or damaged. The noise will generally
change when the bearings are loaded. A road test of
the vehicle is normally required to determine the
location of a worn or damaged bearing.
Find a smooth level road surface and bring the
vehicle up to a constant speed. When vehicle is at a
constant speed, swerve the vehicle back and forth
from the left and to the right. This will load and
unload the bearings and change the noise level.
When bearing damage is slight, the noise is some-
times noticeable at lower speeds and at other times
is more noticeable at speeds above 105 km/h (65
mph).
REMOVAL
NOTE: Replacement of the Unit III front hub/bearing
assembly can be normally done without having to
remove the steering knuckle from the vehicle. In the
event that the hub/bearing is frozen in the steering
knuckle and cannot be removed by hand, it will
have to be pressed out of the steering knuckle. The
steering knuckle will require removal from the vehi-
cle to allow the hub/bearing assembly to be
pressed out of the steering knuckle. (Refer to 2 -
SUSPENSION/FRONT/KNUCKLE - REMOVAL)
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) Remove wheel lug nuts, and front tire and
wheel assembly.
(3) Remove the cotter pin, nut lock and spring
washer from the stub axle (Fig. 4).
(4) With aid of a helper applying the brakes to
keep the front hub from turning, remove the hub nut
(Fig. 4).
(5) Remove disc brake caliper and adapter as an
assembly from knuckle as shown (Fig. 5). Hang
assembly out of the way using a bungee cord or wire.
Do not allow caliper hang by brake hose.
(6) Remove brake rotor from hub and bearing (Fig.
5).
(7) Push in on end of driveshaft stub shaft, push-
ing its splines out of the hub splines.(8) Remove the four hub and bearing mounting
bolts from the rear of steering knuckle (Fig. 6).Use
care not to come in contact with and damage
the ABS tone wheel on the driveshaft stub shaft
upon bolt removal.
(9) Remove the hub and bearing assembly from
the steering knuckle.
Fig. 4 Hub Nut
1 - HUB NUT
2 - NUT LOCK
3 - COTTER PIN
4 - SPRING WASHER
Fig. 5 Front Brake Mounting
1 - BRAKE ROTOR
2 - HUB AND BEARING
3 - STEERING KNUCKLE
4 - ADAPTER MOUNTING BOLTS
5 - BRAKE CALIPER
6 - ADAPTER
7 - CLIP
RSFRONT SUSPENSION2-5
HUB / BEARING (Continued)
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INSTALLATION
CAUTION: Hub and bearing assembly mounting
surfaces on the steering knuckle and stub axle (Fig.
7) must be smooth and completely free of foreign
material or nicks prior to installing hub and bearing
assembly.
CAUTION: When installing hub and bearing into
steering knuckle, be careful not to damage the
bearing seal (Fig. 7) on the outer C/V joint.(1) Install hub and bearing onto stub axle and into
steering knuckle until squarely seated on the face of
the steering knuckle.
(2) Install the 4 hub and bearing mounting bolts
from the rear of the knuckle. Equally tighten all 4
mounting bolts in a criss-cross pattern until hub/
bearing assembly is squarely seated against front of
steering knuckle. Tighten mounting bolts to a torque
of 65 N´m (45 ft. lbs.)
(3) Install the brake rotor on the hub and bearing
(Fig. 5).
(4) Install brake caliper and adapter assembly
back over brake rotor and align with mounting holes
on steering knuckle (Fig. 5). Install the mounting
bolts and tighten to 169 N´m (125 ft. lbs.) torque.
(5) Install the hub nut on the end of the stub axle
(Fig. 4). With aid of a helper applying the brakes to
keep the front hub from turning, tighten the hub nut
to Install the mounting bolts and tighten to 244 N´m
(180 ft. lbs.) torque.
(6) 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.).
(7) Lower vehicle to the ground.
(8) Check the front wheel alignment toe setting
and reset if not within specifications. (Refer to 2 -
SUSPENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE)
KNUCKLE
DESCRIPTION
The steering knuckle is a singlealuminumcast-
ing with legs machined for attachment of the strut
assembly, steering linkage, disc brake caliper
adapter, lower control arm ball joint and steering
linkage (Fig. 1). The hub and bearing assembly is
mounted in the center of the steering knuckle using
4 bolts. The driveshaft's constant velocity (C/V) stub
axle is splined through the center of the hub and
bearing and is held in place using a nut, nut lock and
cotter pin.
Service replacement of the front hub and bearing
assembly can be done with the steering knuckle
remaining on the vehicle.
OPERATION
The steering knuckle pivots with the strut assem-
bly between the lower ball joint and the pivot bearing
in the strut assembly. The steering gear outer tie rod
end connects to the trailing end of each knuckle,
allowing the vehicle to be steered.
Fig. 6 Hub And Bearing Mounting Bolts
1 - HUB
2 - STEERING KNUCKLE
3 - MOUNTING BOLTS (4)
4 - DRIVESHAFT
Fig. 7 Mounting Surfaces (Typical)
1 - BEARING SEAL
2 - STUB AXLE
3 - THESE SURFACES MUST BE CLEAN AND FREE OF NICKS
BEFORE INSTALLING BEARING ASSEMBLY
4 - STEERING KNUCKLE
2 - 6 FRONT SUSPENSIONRS
HUB / BEARING (Continued)
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(4) Wipe any grease off the ball joint stem using a
clean shop towel with MopartBrake Parts Cleaner
applied to it.
CAUTION: Do not attempt to install a normal grease
zirc in the ball joint an lubricate the joint through
the zirc fitting.
(5) Reinstall steering knuckle on vehicle. (Refer to
2 - SUSPENSION/FRONT/KNUCKLE - INSTALLA-
TION)
INSTALLATION - EXPORT
(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. 20). 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.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)
LOWER CONTROL ARM
DESCRIPTION
The lower control arm is mounted to the front sus-
pension crossmember using a pivot bolt through the
center of the front pivot bushing, and the front sus-
pension cradle crossmember reinforcement traps the
rear bushing in the crossmember (Fig. 1).
The lower control arm is an iron casting with two
rubber bushings and a ball joint. The lower control
arm front bushing is the spool type and is pressed
into the lower control arm. The standard (Low-line)
lower control arm rear bushing is a push-on bushing
that is pushed over a stem on the rear of the lower
control arm. The optional (High-line, Premium,
Sport) lower control arm rear bushing is a hydro-
bushing that is pressed on. It has liquid filled voids
that provide more effective dampening than the stan-
dard bushing. Vehicles with rear hydro-bushings uti-
lize a different lower control arm than vehicles with
standard bushings. They have a straight slightly
tapered round stem where the hydro-bushing is
mounted whereas the standard arm has a straight
stem with a squared knob on the end to retain the
bushing.
The lower control arm ball joint is pressed into the
outer end of the arm. The ball joint has a tapered
stud and retainer nut for fastening it to the steering
knuckle.
OPERATION
The lower control arm supports the lower end of
the steering knuckle and allows for the up and down
movement of the suspension during the jounce and
rebound travel. The lower control arm ball joint con-
nects the arm to the steering knuckle.
REMOVAL - LOWER CONTROL ARM
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) Remove wheel and tire assembly.
(3) Remove the steering knuckle. (Refer to 2 -
SUSPENSION/FRONT/KNUCKLE - REMOVAL)
(4) Remove the bolts fastening the power steering
cooler to the front suspension cradle crossmember
reinforcement (Fig. 21).
Fig. 20 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
2 - 12 FRONT SUSPENSIONRS
LOWER BALL JOINT SEAL BOOT (Continued)
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Page 48 of 2399
(12) Slowly release the tension from the coil spring
by backing off the compressor drive fully. As the ten-
sion is relieved, make sure the upper mount, pivot
bearing and upper seat are align properly. Remove
the clamp from the lower end of the coil spring and
strut. Push back the spring compressor upper and
lower hooks, then remove the strut assembly from
the spring compressor.
(13) Install strut assembly on the vehicle. (Refer to
2 - SUSPENSION/FRONT/STRUT - INSTALLA-
TION)
INSTALLATION - STRUT ASSEMBLY
CAUTION: Front strut coil springs are side-oriented.
When installing a strut assembly, make sure the
strut being installed has the correct coil spring for
that side of the vehicle. Springs on the left side of
the vehicle have a left-hand wind top-to-bottom
while springs on the right side have a right-hand
wind top-to-bottom (Fig. 49). Do not interchange the
two sides.
(1) Install strut assembly into strut tower, aligning
and installing the 3 studs on the upper strut mount
into the holes in shock tower. Install the 3 upper
strut mount attaching nut/washer assemblies (Fig.43). Then using a crow foot. tighten the 3 attaching
nuts to a torque of 28 N´m (250 in. lbs.).
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.
NOTE: The strut clevis-to-steering knuckle bolts are
installed differently on each side of the vehicle. Left
hand side bolts are to be installed from vehicle rear
to front. Right side bolts are to be installed from
vehicle front to rear.
(2) Align strut assembly with steering knuckle.
Position arm of steering knuckle into strut assembly
clevis bracket. Align the strut assembly clevis
bracket mounting holes with the steering knuckle
mounting holes. Install the 2 strut assembly to steer-
ing knuckle attaching bolts (Fig. 42).If strut assem-
bly is attached to steering knuckle using a cam
bolt, the cam bolt must be installed in the lower
slotted hole on strut clevis bracket.Tighten the
strut clevis-to-steering knuckle attaching bolts to a
torque of 81 N´m (60 ft. lbs.) plus an additional 1/4
(90É) turn after specified torque is met.
(3) Install the stabilizer bar link mounting stud
through the bracket on the strut assembly (Fig. 41).
CAUTION: When installing the nut on the mounting
stud of the stabilizer bar link, do not allow the stud
to rotate in it's socket. Hold the stud from rotating
by placing an open-end wrench on the flat
machined into the stud (Fig. 41).
(4) Hand thread the nut on the end of the stabi-
lizer bar link stud. Hold the stud from turning by
placing an open-end wrench on the flat machined
into the link's mounting stud, then tighten the nut
while holding the wrench in place (Fig. 41). Tighten
the nut to a torque of 88 N´m (65 ft. lbs.).
(5) Install the hydraulic brake hose and speed sen-
sor cable routing brackets on the strut assembly
brackets (Fig. 40). Tighten the routing bracket
attaching bolts to a torque of 13 N´m (10 ft. lbs.).
(6) Install the wheel/tire assembly on the vehicle.
(7) 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.).
Fig. 50 Components Lined Up
1 - IMAGINARY VERTICAL LINE
2 - CLEVIS BRACKET
3 - END OF COIL SPRING
4 - NOTCH IN UPPER SPRING SEAT
RSFRONT SUSPENSION2-25
STRUT (Continued)
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Page 53 of 2399
(6) Position spring mounting bracket over spring
eye and install pivot bolt through center of bushing
from theoutboardside.
NOTE: The pivot bolt must be installed from the
outboard side to allow proper bracket to body
mounting.
(7) Install the nut on the pivot bolt and lightly
tighten. Do not fully tighten bolt at this time.
(8) Raise the under-hoist utility jack or transmis-
sion jack, guiding the forward mounting bracket into
place against the body. It may help to use a drift
punch placed through the hole centered between the
mounting bolt holes in the bracket and the pilot hole
in the body of the vehicle as a guide. When the four
mounting bolt holes line up with their threads in the
body, Install the mounting bolts (Fig. 3). Tighten the
four mounting bolts to 61 N´m (45 ft. lbs.) torque.
(9) Raise or lower the jack until shock absorber
lower eye aligns with threads in axle housing. Install
shock absorber lower mounting bolt. Do not fully
tighten bolt at this time.
(10) Lower the vehicle and remove hoist arms and
block of wood from under vehicle.
(11) Tighten the spring front pivot bolt to 156 N´m
(115 ft. lbs.) torque.(12) Tighten the lower shock absorber mounting
bolt to 88 N´m (65 ft. lbs.) torque.
HUB / BEARING
DESCRIPTION
The rear wheel bearing and rear wheel hub of this
vehicle are a one-piece sealed unit, or hub and bear-
ing unit type assembly (Unit III). The hub and bear-
ing is mounted to the center of the rear axle using 4
mounting bolts. It has five wheel mounting studs on
the hub flange.
All-Wheel-Drive vehicles have a hub and bearing
unit with a splined hole in the center of the hub for
rear driveshaft stub axle acceptance.
Front-Wheel-Drive vehicles with antilock brakes
have an internally mounted wheel speed sensor and
tone wheel. This hub and bearing can be identified
by the rounded cap and molded in connector on the
rear of the assembly (Fig. 7). The sensor and tone
wheel cannot be serviced separately from the hub
and bearing.
Fig. 5 TOOL 8459 MOUNTED FOR BUSHING
REMOVAL
1 - BUSHING
2 - BEARING
3 - WASHER
4 - NUT
5 - BODY (8459-1)
6 - PIN
7 - REMOVER PLATE (8459-2)
8 - SET SCREW
Fig. 6 TOOL 8459 MOUNTED FOR BUSHING
INSTALLATION
1 - NUT
2 - WASHER
3 - BEARING
4 - LEAF SPRING EYE
5 - BUSHING
6 - INSTALLER PLATE (8459-3)
7 - PIN
8 - BODY (8459-1)
2 - 30 REAR SUSPENSIONRS
BUSHINGS (Continued)
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OPERATION
The hub and bearing has internal bearings that
allow the hub to rotate with the tire and wheel
assembly (and driveshaft on All-Wheel-Drive vehi-
cles). The five wheel mounting studs mount the tire
and wheel assembly, and disc brake rotor or brake
drum to the vehicle.
On All-Wheel-Drive vehicles, the splined mating of
the driveshaft stub axle and hub allows the drive-
shaft to rotate with the hub and wheel.
Front-Wheel-Drive vehicles equipped with antilock
brakes have a wheel speed sensor and tone wheel
mounted to the rear of the hub and bearing. The tone
wheel rotates with the hub which is sensed by the
wheel speed sensor.
DIAGNOSIS AND TESTING - HUB AND
BEARING
The bearing contained in the hub and bearing
assembly will produce noise and vibration when worn
or damaged. The noise will generally change when
the bearings are loaded. A road test of the vehicle is
normally required to determine the location of a
worn or damaged bearing.
Find a smooth level road surface and bring the
vehicle up to a constant speed. When vehicle is at a
constant speed, swerve the vehicle back and forth
from the left and to the right. This will load and
unload the bearings and change the noise level.
When bearing damage is slight, the noise is some-
times noticeable at lower speeds and at other times
is more noticeable at speeds above 105 km/h (65
mph).
REMOVAL
FRONT-WHEEL-DRIVE VEHICLES
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) Remove wheel and tire. (Refer to 22 - TIRES/
WHEELS - REMOVAL)
(3) Remove brake drum or disc brake caliper and
rotor from hub and bearing. (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/DRUM - REMOVAL-
)(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
ROTOR - REMOVAL)
(4) If equipped with antilock brakes, perform the
following:
(a) Remove secondary (yellow) retaining clip at
rear of wheel speed sensor head (Fig. 8).
(b) Push up on metal retaining clip (Fig. 8) until
it bottoms. This will release wheel speed sensor
head from hub and bearing.
(c) While holding metal clip up, pull back on
wheel speed sensor head removing it from hub and
bearing.
(5) Remove the 4 bolts attaching the hub and bear-
ing to the rear axle.
CAUTION: Corrosion may occur between the hub
and bearing, and the axle. If this occurs the hub
and bearing will be difficult to remove from the
axle. If the hub and bearing will not come out of the
axle by pulling on it by hand, do not pound on the
hub and bearing to remove it from the axle. Damage
will occur. Use the following procedure.
Fig. 7 Hub And Bearing - FWD With ABS
Fig. 8 Sensor Connector At Hub And Bearing
1 - SECONDARY SENSOR RETAINING CLIP
2 - METAL SENSOR RETAINING CLIP
3 - HUB AND BEARING
RSREAR SUSPENSION2-31
HUB / BEARING (Continued)
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Page 55 of 2399
(6) If hub and bearing cannot be removed from the
axle by hand, use Remover, Special Tool 8458 (Fig. 9)
and following procedure to press the hub and bearing
out of the axle.
(a) Thread Threaded Guide Pins into hub and
bearing mounting bolt holes.
(b) Remove the two outboard spring plate bolts.
(c) Using the spring plate bolts, install the
Screw Mount, Special Tool 8458±2, as shown (Fig.
9).
(d) Place Push Plate, Special Tool 8458±1, on
ends of Threaded Guide Pins
(e) Place a dab of grease in dimple of Push
Plate.
(f) Tighten the Forcing Screw, Special Tool
8458±3, up against dimple in Push Plate and press
hub and bearing out of axle by continuing to
tighten screw.
(g) Remove the tool.
(h) Reinstall the two outboard spring plate bolts.
Tighten the bolts to 102 N´m (75 ft. lbs.) torque.
(7) Remove the hub/bearing from the rear axle and
brake support plate.
ALL-WHEEL-DRIVE VEHICLES
(1) Set the parking brake.The parking brake is
set to keep the hub and bearing, and axle shaft
from rotating when loosening the hub nut.(2) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(3) Remove the wheel/tire assembly. (Refer to 22 -
TIRES/WHEELS - REMOVAL)
(4) Remove the cotter pin and nut retainer (Fig.
18) from the stub shaft of the outer C/V joint.
(5) Remove the spring washer (Fig. 17) from the
stub shaft of the outer C/V joint.
(6) Remove the hub nut and washer (Fig. 16) from
the stub shaft of the outer C/V joint.
(7) Remove the 6 bolts mounting the driveshaft
inner joint to the output shaft of the rear drive line
module.
(8) Remove the rear wheel speed sensor (Fig. 19)
from the rear hub/bearing.
(9) Release the parking brake.
(10) Remove the disc brake caliper to adapter
guide pin bolts (Fig. 15).
(11) Remove rear caliper from adapter using the
following procedure. First rotate front of caliper up
from the adapter. Then pull the rear of the caliper
and the outboard brake shoe anti-rattle clip out from
under the rear abutment on the adapter (Fig. 14).
(12) Support caliper to prevent the weight of the
caliper from damaging the flexible brake hose (Fig.
10).
(13) Remove the rotor from the hub/bearing.
(14) Remove driveshaft from rear drive line mod-
ule and hub/bearing. Driveshaft is removed by first
compressing the inner joint on the driveshaft and
removing it from the drive line module. Then, slide
Fig. 9 Removal Using Special Tool 8458
1 - THREADED GUIDE PINS 8458-4
2 - HUB AND BEARING
3 - LEAF SPRING PLATE
4 - FORCING SCREW 8458-3
5 - SCREW MOUNT 8458-2
6 - PUSH PLATE 8458-1
Fig. 10 Correctly Supported Caliper
1 - WIRE
2 - CALIPER
3 - ADAPTER
4 - ROTOR
5 - INNER FENDER
2 - 32 REAR SUSPENSIONRS
HUB / BEARING (Continued)
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