tow CHRYSLER VOYAGER 2004 Owner's Manual

(3) Position the upper hooks on top of the coil
spring upper seat so the upper hooks span approxi-
mately 1 inch past outside diameter of upper seat
(Fig. 47). This will allow proper clearance for upper
mount installation without pinching the hooks in-be-
tween the two pieces.Do not allow hooks to be
placed closer to edge.
(4) Compress the coil spring far enough to allow
strut installation.
(5) If the pivot bearing has been removed from the
upper seat, install the pivot bearing on the top of the
upper spring seat (Fig. 48). The bearing must be
installed on upper seat with the smaller diameter
side of the pivot bearing toward the spring seat. Be
sure the pivot bearing is sitting flat on the spring
seat once mounted.(6) Install the spring isolator on the lower spring
seat of the strut (Fig. 38).
(7) Install the jounce bumper on the strut shaft
(Fig. 38). The jounce bumper is to be installed with
the small end pointing downward.
(8) Install the dust shield on the strut. Collapse
and stretch the dust shield down over the top of the
jounce bumper until the dust shield snaps into the
slot on the jounce bumper. The jounce bumper will be
at the top of the inner dust boot. Return the dust
shield to its fully extended length.
(9) Install the strut through the bottom of the coil
spring until the lower spring seat contacts the lower
end of the coil spring. The clevis bracket on the strut
should point straight outward away from the com-
pressor (to the 6 o'clock position). If necessary, repo-
sition the strut or coil spring in the compressor so
the strut clevis bracket lines up with the lower coil
spring end as indicated in the figure (Fig. 49). Install
the clamp to hold the strut and coil spring together.
(10) Install the strut mount over the strut shaft
and onto the top of the pivot bearing and upper seat
as shown (Fig. 44). Loosely install the retaining nut
on the strut shaft.
(11) Install Strut Nut Socket (on the end of a
torque wrench), Special Tool 6864, on the strut shaft
retaining nut (Fig. 45). Next, install a 10 mm socket
on the hex on the end of the strut shaft. While hold-
ing the strut shaft from turning, tighten the strut
shaft retaining nut to a torque of 100 N´m (75 ft.
lbs.).
Fig. 47 Hook Placement On Upper Seat
1 - HOOKS POSITIONED 1 INCH FROM EDGE
2 - PIVOT BEARING AND UPPER SEAT
Fig. 48 Pivot Bearing Installation
1 - PIVOT BEARING
2 - UPPER SEAT
Fig. 49 Coil Spring Positioning
1 - END OF LEFT COIL SPRING AT STRUT LOWER SEAT
2 - END OF RIGHT COIL SPRING AT STRUT LOWER SEAT
3 - LOWER SEATS OF STRUTS
4 - RIGHT STRUT CLEVIS BRACKET
5 - LEFT STRUT CLEVIS BRACKET
2 - 24 FRONT SUSPENSIONRS
STRUT (Continued)

NOTE: Before releasing the tension the compressor
has on the spring, using the following figure as ref-
erence (Fig. 50), make sure the upper spring seat,
coil spring and strut clevis bracket are all lined up
properly (within 5É of one another).
(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 (RIGHT SIDE ONLY)
4 - NOTCH IN UPPER SPRING SEAT
RSFRONT SUSPENSION2-25
STRUT (Continued)

BUSHINGS
REMOVAL - LEAF SPRING FRONT BUSHING
(1) Raise vehicle on frame-contact hoist as follows:
(a) Position the hoist arm supporting the corner
of the vehicle to be serviced against a block of wood
placed on the body sill as shown (Fig. 3).
(b) Position the remaining hoist arms at each
corner of the vehicle in the normal fashion. (Refer
to LUBRICATION & MAINTENANCE/HOISTING
- STANDARD PROCEDURE)
(c) Raise the vehicle to a comfortable working
level.
(2)
Position an under-hoist utility jack or transmis-
sion jack under rear axle toward the side needing bush-
ing replacement. Jack pad should just contact axle.
(3) Remove shock absorber lower mounting bolt.
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) Remove four bolts securing leaf spring front
mounting bracket to the body (Fig. 3).
(5) Using jack,slowlylower rear axle, permitting
the forward end of rear spring to hang down. Lower
it enough to allow access to spring pivot bolt. It may
be necessary to place a wooden block between the
spring and vehicle to hold forward end of the spring
in place.(6) Remove leaf spring forward pivot bolt, then
remove mounting bracket.
(7) Straighten the retainer tabs on the bushing
(Fig. 4).
(8) Place Remover/Installer, Special Tool 8459 on
leaf spring and bushing as shown (Fig. 5) and tighten
Set Screw securing Remover Plate to tool threaded
shaft.
Fig. 3 LIFTING POINT AND SPRING MOUNT
1 - BODY SILL AREA
2 - MOUNTING BOLTS
3 - SPRING MOUNTING BRACKET
4 - LEAF SPRING
5 - HOIST LIFT ARM
6 - WOODEN BLOCK
Fig. 4 STRAIGHTENED RETAINING TABS
1 - SPRING EYE
2 - RETAINING TABS
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
RSREAR SUSPENSION2-29

ASSEMBLY - SHOCK ABSORBER (UPPER
BUSHING)
NOTE: This procedure applies to load-leveling
shock absorbers only.
(1) Install the Receiver, Special Tool 8526-1, into
the cup of the Ball Joint Press, Special Tool C-4212F,
and tighten the set screw. Install the Driver, Special
Tool 8526-2, on the tip of the Ball Joint Press screw
drive as shown (Fig. 24). Position the Driver this way
to seat the bushing to its correct depth.
(2) Place the shock absorber upper mounting eye
in the Receiver so the notch in the Receiver clears
the shock absorber body (Fig. 25).(3) Position the bushing between the shock
absorber eye and the Driver (Fig. 25). Tighten the
screw drive until the Driver, bushing, and shock
absorber eye are touching and squarely aligned.
(4) Press the bushing into the shock absorber eye
until the Driver bottoms against the face of the eye.
(5) Back off the Ball Joint Press screw drive and
remove the shock absorber from the press.
(6) Install the shock absorber on the vehicle. Refer
to REMOVAL AND INSTALLATION in this section
for the procedure.
INSTALLATION - SHOCK ABSORBER
(1) While holding shock absorber in position
against the frame rail, install the shock absorber
upper mounting bolt.
(2) Install the shock absorber lower mounting bolt
securing the lower end of the shock absorber to the
axle.
(3) Remove the support jack.
(4) Lower the vehicle to the ground so the full curb
weight of the vehicle is supported by the suspension.
(5) Tighten the upper and lower shock absorber
mounting bolt to a torque of 88 N´m (65 ft. lbs.).
SPRING - AWD
REMOVAL
(1) Raise vehicle on frame-contact hoist as follows:
(a) Position the hoist arm supporting the corner
of the vehicle to be serviced against a block of wood
placed on the body sill as shown (Fig. 26).
(b) Position the remaining hoist arms at each
corner of the vehicle in the normal fashion. (Refer
to LUBRICATION & MAINTENANCE/HOISTING
- STANDARD PROCEDURE)
(c) Raise the vehicle to a comfortable working
level.
(2) Position an under-hoist utility jack or transmis-
sion jack under rear axle toward the side needing
spring replacement. Jack 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).
(3) Begin removal of the shock absorber lower
mounting bolt (Fig. 27).
(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. 28).
Fig. 24 Special Tools Positioned For Installation
1 - SCREW DRIVE
Fig. 25 Installing Bushing In Shock Absorber
1 - BUSHING
2 - SCREW DRIVE
3 - SHOCK ABSORBER
4 - NOTCH
2 - 38 REAR SUSPENSIONRS
SHOCK ABSORBER (Continued)

mount (Fig. 26). 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 shackle. Install the inner half of the
rear hanger. Install the pin nuts and bolts on the
rear shackle,but 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 (Fig. 28). Tighten bolts
to 95 N´m (70 ft. lbs.) torque.
(6) Install shock absorber bolts.Do not tighten
at this time.
(7) Lower the vehicle and remove hoist arms and
block of wood from under vehicle.
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.
(8) Tighten the spring front pivot bolt to 156 N´m
(115 ft. lbs.) torque.
(9) Tighten rear spring shackle pin nuts to 61 N´m
(45 ft. lbs.) torque.
(10) Tighten rear spring shackle inner to outer
half retaining bolts to 61 N´m (45 ft. lbs.) torque.
(11) Tighten the lower shock absorber mounting
bolt to 102 N´m (75 ft. lbs.) torque.
SPRING - CARGO
REMOVAL
(1) Raise vehicle on frame-contact hoist as follows:
(a) Position the hoist arm supporting the corner
of the vehicle to be serviced against a block of wood
placed on the body sill as shown (Fig. 26).
(b) Position the remaining hoist arms at each
corner of the vehicle in the normal fashion. (Refer
to LUBRICATION & MAINTENANCE/HOISTING
- STANDARD PROCEDURE)
(c) Raise the vehicle to a comfortable working
level.
(2) Position an under-hoist utility jack or transmis-
sion jack under rear axle toward the side needing
spring replacement. Jack 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).
(3) Begin removal of the shock absorber lower
mounting bolt (Fig. 27).
(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. 28).
(6) Using the jack standsslowlylower the rear
axle, permitting the rear springs to hang free.
(7) Loosen and remove the 4 bolts at the front
mount of the rear leaf spring (Fig. 26).
(8) Loosen and remove the nuts from the spring
hanger for the rear leaf spring (Fig. 35).
(9) Remove the hanger plate from the hanger and
remove the spring from the spring hanger (Fig. 35).
(10) Remove the leaf spring from the vehicle.
(11) Loosen and remove the pivot bolt from the
front mount of the rear leaf spring. (Fig. 30).
INSTALLATION
CAUTION: Pivot bolt must face inboard to prevent
structural damage during installation of spring.
(1) Install the front eyelet of the rear leaf spring
into the spring mount. 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 front spring
mount (Fig. 26). Tighten the 4 mounting bolts to a
torque of 61 N´m (45 ft. lbs.).
Fig. 30 Leaf Spring Front Mount (Typical)
1 - LEAF SPRING
2 - SPRING MOUNT
2 - 40 REAR SUSPENSIONRS
SPRING - AWD (Continued)

(3) Install rear of spring onto rear spring shackle.
Install shackle plate and nuts (Fig. 35).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 (Fig. 28). Tighten bolts
to 95 N´m (70 ft. lbs.) torque.
(6) Install shock absorber bolts.Do not tighten
at this time.
(7) Lower the vehicle and remove hoist arms and
block of wood from under vehicle.
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.
(8) Tighten the spring front pivot bolt to 156 N´m
(115 ft. lbs.) torque.
(9) Tighten rear spring shackle pin nuts to 61 N´m
(45 ft. lbs.) torque.
(10) Tighten the lower shock absorber mounting
bolt to 102 N´m (75 ft. lbs.) torque.
SPRING - FWD
REMOVAL
(1) Raise vehicle on frame-contact hoist as follows:
(a) Position the hoist arm supporting the corner
of the vehicle to be serviced against a block of wood
placed on the body sill as shown (Fig. 31).
(b) Position the remaining hoist arms at each
corner of the vehicle in the normal fashion. (Refer
to LUBRICATION & MAINTENANCE/HOISTING
- STANDARD PROCEDURE)
(c) Raise the vehicle to a comfortable working
level.
(2) Position an under-hoist utility jack or transmis-
sion jack under rear axle toward the side needing
spring replacement. Jack pad should just contact
axle.
(3) Remove the shock absorber lower mounting
bolt (Fig. 32).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).
Fig. 31 LIFTING POINT AND SPRING MOUNT
1 - BODY SILL AREA
2 - MOUNTING BOLTS
3 - SPRING MOUNTING BRACKET
4 - LEAF SPRING
5 - HOIST LIFT ARM
6 - WOODEN BLOCK
Fig. 32 Rear Shock Mounting Bolt
1 - SHOCK BOLT
RSREAR SUSPENSION2-41
SPRING - CARGO (Continued)

(5) Raise axle into correct position on leaf spring
with axle centered under spring locator post (Fig.
36).
(6) Verify that the leaf spring isolator is correctly
positioned in the spring plate.
(7) Install spring plate in position on the spring
(Fig. 33).
(8) Install spring plate bolts (Fig. 33). Tighten
bolts to 95 N´m (70 ft. lbs.) torque.
(9) Install lower shock absorber bolt.Do not
tighten at this time.
(10) Remove jack under axle.
(11) Lower the vehicle and remove hoist arms and
block of wood from under vehicle.
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.
(12) Tighten the spring front pivot bolt to 156 N´m
(115 ft. lbs.) torque.
(13) Tighten rear spring shackle pin nuts to 61
N´m (45 ft. lbs.) torque.
(14) Tighten the lower shock absorber mounting
bolt to 102 N´m (75 ft. lbs.) torque.SPRING MOUNTS - FRONT
REMOVAL
(1) Raise vehicle on frame-contact hoist as follows:
(a) Position the hoist arm supporting the corner
of the vehicle to be serviced against a block of wood
placed on the body sill as shown (Fig. 37).
(b) Position the remaining hoist arms at each
corner of the vehicle in the normal fashion. (Refer
to LUBRICATION & MAINTENANCE/HOISTING
- STANDARD PROCEDURE)
(c) Raise the vehicle to a comfortable working
level.
(2) Position an under-hoist utility jack or transmis-
sion jack under rear axle toward the side needing
bushing replacement. Jack pad should just contact
axle.
(3) Remove shock absorber lower mounting bolt.
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) Remove four bolts securing leaf spring front
mounting bracket to the body (Fig. 37).
(5) Using jack,slowlylower rear axle, permitting
the forward end of rear spring to hang down. Lower
it enough to allow access to spring pivot bolt. It may
Fig. 36 Leaf Spring Locator Post
1 - LEAF SPRING ISOLATOR
2 - LEAF SPRING
3 - LOCATOR POST
Fig. 37 LIFTING POINT AND SPRING MOUNT
1 - BODY SILL AREA
2 - MOUNTING BOLTS
3 - SPRING MOUNTING BRACKET
4 - LEAF SPRING
5 - HOIST LIFT ARM
6 - WOODEN BLOCK
RSREAR SUSPENSION2-43
SPRING - FWD (Continued)

(3) Lower the vehicle so that the full weight of the
vehicle is on all four tires. With the vehicle at its
curb height, tighten the following bolts to the torques
listed:
²Stabilizer bar bushing retainer-to-axle bracket
bolts Ð 61 N´m (45 ft. lbs.)
²Stabilizer bar-to-link Ð 61 N´m (45 ft. lbs.)
TRACK BAR
DESCRIPTION
On front-wheel-drive applications of this vehicle
that are equipped with single leaf rear springs, a
track bar is used on the rear axle (Fig. 1).
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 isolator bushing located in
each end of the track bar.
OPERATION
The track bar prevents excessive side-to-side move-
ment 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.
REMOVAL
(1) Remove the nut and bolt mounting the track
bar to the rear axle (Fig. 41).
(2) Remove the nut and bolt attaching the track
bar to the track bar mount on the body of the vehicle.
Remove the track bar from the track bar mount.
INSTALLATION
(1) Install the track bar first into the body mount
for the track bar (Fig. 42). Install the track bar bolt
with the head of the bolt facing toward the rear of
the vehicle (Fig. 43). Do not tighten.
(2) Install the track bar into its mounting bracket
on the rear axle (Fig. 41). Install the track bar bolt
with the head of the bolt facing toward the rear of
the vehicle. Do not tighten.
(3) Lower the vehicle to the ground until the full
weight of the vehicle is supported by the wheels.
Tighten both track bar attaching bolts to a torque of
95 N´m (70 ft. lbs.).
Fig. 41 Track Bar Mounting To Axle (Typical)
1 - LOWER TRACK BAR BOLT INSTALLATION
Fig. 42 Track Bar Installation (Typical)
1 - TRACK BAR REPLACEMENT
Fig. 43 Track Bar Bolt Installation
1 - TRACK BAR BOLT
2 - 46 REAR SUSPENSIONRS
STABILIZER BAR (Continued)

now rotate around the pinion mate shaft in opposite
directions. This allows the side gear and axle shaft
attached to the outside wheel to rotate at a faster
speed.
FLUID - DIFFERENTIAL
ASSEMBLY
STANDARD PROCEDURE - DIFFERENTIAL
ASSEMBLY FLUID CHANGE
The drain plug (Fig. 40) for the differential assem-
bly is located in the bottom of the differential assem-
bly case, toward the rear of the unit.
The fill plug (Fig. 41) for the differential assembly
is located on the rear of the assembly case.The correct fill level is to the bottom of the fill plug
hole. Be sure the vehicle is on a level surface, or is
hoisted in a level manner, in order to obtain the cor-
rect fill level.
(1) Raise the vehicle on a hoist.
(2) Position a drain pan under the differential
drain plug (Fig. 40).
(3) Remove the drain plug and allow the fluid to
drain into the pan.
(4) Install the drain plug and torque to 35 N´m (26
ft. lbs.).
Fig. 38 Differential OperationÐStraight Ahead
Driving
1 - IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT
100% OF CASE SPEED
2 - PINION GEAR
3 - SIDE GEAR
4 - PINION GEARS ROTATE WITH CASE
Fig. 39 Differential OperationÐOn Turns
1 - PINION GEARS ROTATE ON PINION SHAFT
Fig. 40 Differential Drain Plug
1 - DIFFERENTIAL DRAIN PLUG
Fig. 41 Differential Fill Plug
1 - DIFFERENTIAL FILL PLUG
3 - 40 REAR DRIVELINE MODULERS
DIFFERENTIAL ASSEMBLY (Continued)

WARNING
WARNING: DUST AND DIRT ACCUMULATING ON
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN ASBESTOS FIBERS FROM PRODUCTION OR
AFTERMARKET BRAKE LININGS. BREATHING
EXCESSIVE CONCENTRATIONS OF ASBESTOS
FIBERS CAN CAUSE SERIOUS BODILY HARM.
EXERCISE CARE WHEN SERVICING BRAKE
PARTS. DO NOT SAND OR GRIND BRAKE LINING
UNLESS EQUIPMENT USED IS DESIGNED TO CON-
TAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE
PARTS WITH COMPRESSED AIR OR BY DRY
BRUSHING. CLEANING SHOULD BE DONE BY
DAMPENING THE BRAKE COMPONENTS WITH A
FINE MIST OF WATER, THEN WIPING THE BRAKE
COMPONENTS CLEAN WITH A DAMPENED CLOTH.
DISPOSE OF CLOTH AND ALL RESIDUE CONTAIN-
ING ASBESTOS FIBERS IN AN IMPERMEABLE
CONTAINER WITH THE APPROPRIATE LABEL. FOL-
LOW PRACTICES PRESCRIBED BY THE OCCUPA-
TIONAL SAFETY AND HEALTH ADMINISTRATION
(OSHA) AND THE ENVIRONMENTAL PROTECTION
AGENCY (EPA) FOR THE HANDLING, PROCESSING,
AND DISPOSING OF DUST OR DEBRIS THAT MAY
CONTAIN ASBESTOS FIBERS.
CAUTION
CAUTION: During service procedures, grease or
any other foreign material must be kept off brake
shoe assemblies, and braking surfaces of brake
rotor or drum, and external surfaces of hub and
bearing assembly.
CAUTION: Handling of brake rotors and calipers
must be done in such a way as to avoid damage to
the rotor and scratching or nicking of brake lining
on the brake shoes.
CAUTION: At no time when servicing a vehicle, can
a sheet metal screw, bolt or other metal fastener be
installed in the shock tower to take the place of an
original plastic clip. Also, NO holes can be drilled
into the front shock tower in the area shown in (Fig.
1), for the installation of any metal fasteners into
the shock tower. Because of the minimum clear-ance in this area (Fig. 1), installation of metal fas-
teners could damage the coil spring coating and
lead to a corrosion failure of the spring. If a plastic
clip is missing, or is lost or broken during servicing
a vehicle, replace only with the equivalent part
listed in the Mopar parts catalog.
CAUTION: Only the recommended jacking or hoist-
ing positions for this vehicle are to be used when-
ever it is necessary to lift a vehicle. Failure to raise
a vehicle from the recommended locations could
result in lifting a vehicle by the hydraulic control
unit mounting bracket. Lifting a vehicle by the
hydraulic control unit mounting bracket will result
in damage to the mounting bracket and the hydrau-
lic control unit.
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM
NOTE: There are three diagnosis charts following
that cover the RED BRAKE WARNING INDICATOR
LAMP, BRAKE NOISE and OTHER BRAKE CONDI-
TIONS.
Fig. 1 Shock Tower To Spring Minimum Clearance
Area
1 - SHOCK TOWER
2 - COIL SPRING
3 - NO SHEET METAL SCREWS, BOLTS, OR ANY OTHER METAL
FASTENERS ARE TO BE INSTALLED INTO SHOCK TOWER IN
THIS AREA. ALSO, NO HOLES ARE TO BE DRILLED INTO
SHOCK TOWER IN THIS SAME AREA.
5 - 4 BRAKES - BASERS
BRAKES - BASE (Continued)