1996 CHRYSLER VOYAGER wheel bolt torque

NS vehicles can be tied to a flat bed device using
the reinforced loops located under the front and rear
bumpers on the drivers side of the vehicle. There are
also four reinforced elongated holes for T or R-hooks
located on the bottom of the front frame rail torque
boxes behind the front wheels and forward of the
rear wheels inboard of the rocker panel weld seam.
TOWINGÐFRONT WHEEL LIFT
Chrysler International recommends that a vehicle
be towed with the front end lifted, whenever possible.
A 90 cm (36 in.) length of 4x4 wood beam can be
placed between the wheel lift device and the bottom
of the fascia to prevent damage to vehicle during the
lifting operation. The beam can removed after lifting
the front of the vehicle.
TOWINGÐREAR 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.
²4-speed electronic automatic transaxle vehicles
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.
TOWINGÐTOW HOOKS
WARNING: Do not use the tow hook to lift the vehi-
cle off the ground.
A tow-hook bolt, located in the rear interior trim
storage compartment (with jack), is provided with
your vehicle. The tow hook is used for towing the
vehicle with all four wheels on the ground only. It
can be attached to the vehicle through an opening in
the lower front fascia. The tow hook must be fully
seated to the attach bracket through the lower front
fascia as shown. If the tow hook is not fully seated to
the attach bracket the vehicle should not be towed.
NOTE: The tow hook bolt protective plug must be
removed from the tow hook bracket prior to bolt
attachment. The tow hook is used ONLY for towing
the vehicle with all four wheels on the ground.
Fig. 2
0 - 6 LUBRICATION AND MAINTENANCENS/GS
SERVICE PROCEDURES (Continued)

DIAGNOSIS AND TESTING
SUSPENSION AND STEERING DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
Front End Whine On Turns 1. Defective wheel bearing 1. Replace wheel bearing
2. Incorrect wheel alignment 2. Check and reset wheel alignment
3. Worn tires 3. Replace tires
Front End Growl Or Grinding On
Turns1. Defective wheel bearing 1. Replace wheel bearing
2. Engine mount grounding 2. Check for motor mount hitting
frame rail and reposition engine as
required
3. Worn or broken C/V joint 3. Replace C/V joint
4. Loose wheel lug nuts 4. Verify wheel lug nut torque
5. Incorrect wheel alignment 5. Check and reset wheel alignment
6. Worn tires 6. Replace tires
7. Front strut pin in upper strut mount 7. Replace the front strut upper mount
and bearing
Front End Clunk Or Snap On Turns 1. Loose lug nuts 1. Verify wheel lug nut torque
2. Worn or broken C/V joint 2. Replace C/V joint
3. Worn or loose tie rod 3. Tighten or replace tie rod end
4. Worn or loose ball joint 4. Tighten or replace ball joint
5. Worn/loose control arm bushing 5. Replace control arm bushing
6. Loose stabilizer bar. 6. Tighten stabilizer bar to specified
torque
7. Loose strut mount to body
attachment7. Tighten strut attachment to
specified torque
8. Loose crossmember bolts 8. Tighten crossmember bolts to
specified torque
Front End Whine With Vehicle
Going Straight At A Constant Speed1. Defective wheel bearing 1. Replace wheel bearing
2. Incorrect wheel alignment 2. Check and reset wheel alignment
3. Worn tires 3. Replace tires
4. Worn or defective transaxle gears
or bearings4. Replace transaxle gears or
bearings
Front End Growl Or Grinding With
Vehicle Going Straight At A
Constant Speed1. Engine mount grounding 1. Reposition engine as required
2. Worn or broken C/V joint 2. Replace C/V joint
Front End Whine When
Accelerating Or Decelerating1. Worn or defective transaxle gears
or bearings1. Replace transaxle gears or
bearings
Front End Clunk When Accelerating
Or Decelerating1. Worn or broken engine mount 1. Replace engine mount
2. Worn or defective transaxle gears
or bearings2. Replace transaxle gears or
bearings
3. Loose lug nuts 3. Verify wheel lug nut torque
4. Worn or broken C/V joint 4. Replace C/V joint
5. Worn or loose ball joint 5. Tighten or replace ball joint
6. Worn or loose control arm bushing 6. Replace control arm bushing
7. Loose crossmember bolts 7. Tighten crossmember bolts to
specified torque
8. Worn tie rod end 8. Replace tie rod end
NSSUSPENSION 2 - 3

CONDITION POSSIBLE CAUSES CORRECTION
Road Wander 1. Incorrect tire pressure 1. Inflate tires to recommended
pressure
2. Incorrect front or rear wheel toe 2. Check and reset wheel toe
3. Worn wheel bearings 3. Replace wheel bearing
4. Worn control arm bushings 4. Replace control arm bushing
5. Excessive friction in steering gear 5. Replace steering gear
6. Excessive friction in steering shaft
coupling6. Replace steering coupler
7. Excessive friction in strut upper
bearing7. Replace strut bearing
Lateral Pull 1. Unequal tire pressure 1. Inflate all tires to recommended
pressure
2. Radial tire lead 2. Perform lead correction procedure
3. Incorrect front wheel camber 3. Check and reset front wheel
camber
4. Power steering gear imbalance 4. Replace power steering gear
5. Wheel braking 5. Correct braking condition causing
lateral pull
Excessive Steering Free Play 1. Incorrect Steering Gear Adjustment 1. Adjust Or Replace Steering Gear
2. Worn or loose tie rod ends 2. Replace or tighten tie rod ends
3. Loose steering gear mounting bolts 3. Tighten steering gear bolts to
specified torque
4. Loose or worn steering shaft
coupler4. Replace steering shaft coupler
Excessive Steering Effort 1. Low tire pressure 1. Inflate all tires to recommended
pressure
2. Lack of lubricant in steering gear 2. Replace steering gear
3. Low power steering fluid level 3. Fill power steering fluid reservoir to
correct level
4. Loose power steering pump drive
belt4. Correctly adjust power steering
pump drive belt
5. Lack of lubricant in ball joints 5. Lubricate or replace ball joints
6. Steering gear malfunction 6. Replace steering gear
7. Lack of lubricant in steering
coupler7. Replace steering coupler
PRE-WHEEL ALIGNMENT INSPECTION
Before any attempt is made to change or correct
the wheel alignment factors. The following part
inspection and the necessary corrections should be
made to those parts which influence the steering of
the vehicle.
(1) Check and inflate all tires to recommended
pressure. All tires should be the same size and in
good condition and have approximately the same
wear. Note the type of tread wear which will aid in
diagnosing, see Wheels and Tires, Group 22.
(2) Check front wheel and tire assembly for radial
runout.
(3) Inspect lower ball joints and all steering link-
age for looseness.
(4) Check for broken or sagged front and rear
springs.(5) Check vehicle ride height to verify it is within
specifications.
(6) AlignmentMUSTonly be checked after the
vehicle has the following areas inspected and or
adjusted. Recommended tire pressures, full tank of
fuel, no passenger or luggage compartment load and
is on a level floor or a properly calibrated alignment
rack.
SERVICE PROCEDURES
WHEEL ALIGNMENT CHECK AND ADJUSTMENT
PROCEDURE
CASTER AND CAMBER
Front suspension Caster and Camber settings on
this vehicle are determined at the time the vehicle is
designed. This is done by determining the precise
2 - 4 SUSPENSIONNS
DIAGNOSIS AND TESTING (Continued)

(11) When vehicle is at correct camber setting
torque both front strut to steering knuckle attaching
bolts to 90 N´m (65 ft. lbs.) plus an additional 1/4
turn after required torque is met.
(12) If Toe readings obtained are not within the
required specification range, adjust Toe to meet the
preferred specification setting. Toe is adjustable
using the following Toe setting procedure.
FRONT TOE SETTING PROCEDURE
(1) Prepare vehicle as described in the Pre-Align-
ment Vehicle Inspection procedure.
(2) Center steering wheel and lock in place using a
steering wheel clamp.
CAUTION: Do not twist front inner tie rod to steer-
ing gear rubber boots during front wheel Toe
adjustment.(3) Loosen front inner to outer tie rod end jam
nuts (Fig. 7). Grasp inner tie rods at serrations and
rotate inner tie rods of steering gear (Fig. 7) to set
front Toe to the preferred Toe specification. See
Alignment Specifications in this group of the service
manual for preferred specification.
(4) Tighten tie rod jam nuts (Fig. 7) to 75 N´m (55
ft.lbs.) torque.
(5) Adjust steering gear to tie rod boots at tie rod.
(6) Remove steering wheel clamp.
SPECIFICATIONS
ALIGNMENT SPECIFICATIONS
All alignment specifications are to be checked and
adjusted with the vehicle at its correct ride height.
Refer to the ride height specifications listed in the
following alignment specifications chart.
Fig. 6 Camber Adjustment Cam Bolt
Fig. 7 Front Wheel Toe Adjustment
NSSUSPENSION 2 - 7
SERVICE PROCEDURES (Continued)

FRONT SUSPENSION
INDEX
page page
DESCRIPTION AND OPERATION
BALL JOINT............................ 11
COIL SPRING........................... 11
FRONT SUSPENSION DESCRIPTION......... 9
HUB AND BEARING ASSEMBLY............ 10
LOWER CONTROL ARM.................. 10
Mc PHERSON STRUT ASSEMBLY........... 10
STABILIZER BAR ATTACHING LINK.......... 10
STABILIZER BAR........................ 10
STEERING KNUCKLE.................... 10
SUSPENSION CRADLE (CROSSMEMBER)..... 9
WHEEL MOUNTING STUDS................ 11
DIAGNOSIS AND TESTING
BALL JOINT (LOWER).................... 12
HUB AND BEARING ASSEMBLY............ 12
LOWER CONTROL ARM.................. 12
Mc PHERSON STRUT.................... 11
STABILIZER BAR........................ 12
STEERING KNUCKLE.................... 12SERVICE PROCEDURES
SUSPENSION CRADLE THREAD REPAIR
PROCEDURE......................... 12
REMOVAL AND INSTALLATION
BALL JOINT............................ 22
FRONT WHEEL MOUNTING STUDS......... 28
HUB AND BEARING ASSEMBLY............ 25
LOWER CONTROL ARM.................. 19
Mc PHERSON STRUT.................... 13
REAR WHEEL MOUNTING STUDS.......... 29
STABILIZER BAR........................ 23
STEERING KNUCKLE.................... 14
DISASSEMBLY AND ASSEMBLY
BALL JOINT SEAL BOOT.................. 33
LOWER CONTROL ARM FRONT BUSHING.... 34
LOWER CONTROL ARM REAR BUSHING..... 35
Mc PHERSON STRUT.................... 30
STABILIZER BAR BUSHING................ 35
SPECIFICATIONS
FRONT SUSPENSION FASTENER TORQUES . . 36
SPECIAL TOOLS
FRONT SUSPENSION.................... 37
DESCRIPTION AND OPERATION
FRONT SUSPENSION DESCRIPTION
An independent Mc Pherson Strut type front sus-
pension is used on these vehicles. Vertical shock
absorbing Mc Pherson Struts attach to the top of the
steering knuckle and to the front strut tower. This
interconnection between the steering knuckle and the
body of the vehicle, provides for the correct steering
knuckle position. This steering knuckle position pro-
vides for the correct front Caster and Camber set-
tings for the vehicle, at the time the vehicle is
designed.
Lower control arms are attached inboard to the
cast aluminum front suspension cradle and outboard
to the bottom of the steering knuckle. Attachment of
the lower control arm to the steering knuckle is done
through a ball joint in the lower control arm.
During steering maneuvers, the strut and the
steering knuckle (through the ball joint and a pivot
bearing in the strut's upper retainer) turn as an
assembly.
SUSPENSION CRADLE (CROSSMEMBER)
This vehicle uses a one piece cast aluminum cradle
for the front suspension. The cradle is used as theattaching points for the lower control arms, stabilizer
bar and steering gear. The cradle also has the power
steering hoses and the chassis brake tubes attached
to it.
The cradle is mounted to the front frame rails at
four points, two on each side of the vehicle. The cra-
dle is isolated from the body of the vehicle using four
isolators, one located at each mounting bolt location.
WARNING: If a threaded hole in the suspension
cradle needs to be repaired, only use the type of
thread insert and installation procedure specified
for this application.
The threaded holes in the cradle that are
used for attachment of the lower control arm
rear bushing retainer, power steering hose and
chassis brake tubes can be repaired. The repair
is done by the installation of a Heli-Coilt
thread insert which has been specifically devel-
oped for this application. Refer to the Mopar
Parts Catalog for the specified Heli-Coil thread
insert to be used for this application. The pro-
cedure for installing the Heli-Coiltthread
insert is detailed in the Service Procedures sec-
tion in this group of the service manual.
NSSUSPENSION 2 - 9

instructions included with the thread insert for the
detailed procedure used for the installation of the
thread insert.
NOTE: The thread inserts for this application are
for the repair of M8x1.25 and M10x1.5 threads. Be
sure the correct tools are used for the required
thread insert size.
TOOL REQUIREMENT FOR M8x1.25 Thread
²8.3mm (5/16 in.) Drill Bit
²120É Countersink
²Heli-CoiltTap #4863-8
²Heli-CoiltGage #4624-8
²Heli-CoiltHand Inserting Tool 7751-8
²Needle Nose Pliers ± For Removal Of Thread
Insert Driving Tang
TOOL REQUIREMENT FOR M10x1.5 Thread
²10.5mm (25/64 in.) Drill Bit
²120É Countersink
²Heli-CoiltTap #4863-10
²Heli-CoiltGage #4624-10
²Heli-CoiltHand Inserting Tool 7751-10
²Needle Nose Pliers ± For Removal Of Thread
Insert Driving Tang
REMOVAL AND INSTALLATION
Mc PHERSON STRUT
REMOVAL
WARNING: DO NOT REMOVE THE NUT FROM THE
STRUT ROD WHILE STRUT ASSEMBLY IS
INSTALLED IN VEHICLE, OR BEFORE STRUT
ASSEMBLY SPRING IS COMPRESSED.
(1) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this service man-
ual, for the required lifting procedure to be used for
this vehicle.
(2) Remove the wheel and tire assembly from loca-
tion on front of vehicle requiring strut removal.
(3) If both strut assemblies are to be removed,
mark the strut assemblies right or left according to
which side of the vehicle they were removed from.
(4) Remove the hydraulic brake hose routing
bracket and the speed sensor cable routing bracket
from the strut damper brackets (Fig. 6).
NOTE: When removing nut from stud of stabilizer
bar attaching link, do not allow stud to rotate. Hold
stud from rotating by inserting a Torx Plus 40IP bit
in the end of the stud as shown in (Fig. 7).(5) Remove the stabilizer bar attaching link (Fig.
7) from the bracket on the strut assembly.
CAUTION: The steering knuckle to strut assembly
attaching bolts are serrated and must not be turned
during removal. Remove nuts while holding bolts
stationary in the steering knuckles.
(6) Remove the 2 strut assembly clevis bracket to
steering knuckle attaching bolts (Fig. 8).
(7) Remove the 3 nuts attaching the strut assem-
bly upper mount to the strut tower (Fig. 9).
INSTALLATION
(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.
9). Then using a crow foot. tighten the 3 attaching
nuts to a torque of 28 N´m (250 in. lbs.).
Fig. 6 Brake Hose And Speed Sensor Cable Routing
Fig. 7 Stabilizer Bar Link To Strut Attachment
NSSUSPENSION 2 - 13
SERVICE PROCEDURES (Continued)

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.
(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. 8).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. Also,
attaching bolts should be installed with the
nuts facing the front of the vehicle (Fig. 8).
Tighten the strut assembly to steering knuckle
attaching bolts to a torque of 88 N´m (65 ft. lbs.)
plus an additional 1/4 turn after specified
torque is met.(3) Install stabilizer bar attaching link (Fig. 7) on
bracket of strut assembly. Install stabilizer bar
attaching link to strut bracket attaching nut.
NOTE: When torquing nut on stud of stabilizer bar
attaching link, do not allow stud to rotate. Hold stud
from rotating by inserting a Torx Plus 40IP bit in the
end of the stud as shown in (Fig. 10).
(4) Tighten the stabilizer bar link to strut attach-
ing nut using a Torx Plus 40IP bit and crowfoot as
shown in (Fig. 10) to a torque of 88 N´m (65 ft. lbs.).
(5) Install hydraulic brake hose and speed sensor
cable routing brackets on the strut assembly brackets
(Fig. 6). 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.).
STEERING KNUCKLE
REMOVE
(1) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation And Maintenance Section of this manual for
the required lifting procedure to be used for this
vehicle.
(2) Remove the cotter pin and nut lock (Fig. 11)
from the end of the stub axle.
(3) Remove the wheel and tire assembly from the
vehicle.
(4) Remove the wave washer (Fig. 12) from the
end of the stub axle
Fig. 8 Strut Damper Attachment To Steering
Knuckle
Fig. 9 Strut Assembly To Strut Tower Attaching
Nuts
Fig. 10 Torquing Stabilizer Bar Link To Strut
Attaching Nut
2 - 14 SUSPENSIONNS
REMOVAL AND INSTALLATION (Continued)

CAUTION: If the vehicle being serviced is
equipped with eccentric strut assembly attaching
bolts, the eccentric bolt must be installed in the
bottom (slotted) hole on the strut clevis bracket
(Fig. 25).
(2) Install steering knuckle back in clevis bracket
of strut damper assembly (Fig. 24). Install the strut
damper to steering knuckle attaching bolts. Tighten
both attaching bolts to a torque of 90 N´m (65 ft. lbs.)
plus an additional 1/4 turn.
(3) Slide drive shaft back into front hub and bear-
ing assembly. Then install steering knuckle onto the
stud of the ball joint assembly (Fig. 23).
(4) Install aNEWsteering knuckle to ball joint
stud, clamping bolt and nut (Fig. 21). Tighten the
clamping bolt and nut to a torque of 145 N´m (105 ft.
lbs.).
(5) Install tie rod end into steering knuckle. Start
attaching nut onto stud of tie rod end. While holding
stud of tie rod end stationary using a 11/32 socket,
(Fig. 17) tighten tie rod end to steering knuckle
attaching nut. Then using a crowfoot and 11/32
socket (Fig. 26), tighten the tie rod end attaching nut
to a torque of 54 N´m (40 ft. lbs.).
(6) Install braking disc on hub and bearing assem-
bly (Fig. 16).
(7) Install disc brake caliper assembly on steering
knuckle. Caliper is installed by first sliding bottom of
caliper under abutment on steering knuckle, and
then rotating top of caliper against top abutment
(Fig. 14).
(8) Install disc brake caliper assembly to steering
knuckle attaching bolts (Fig. 13). Tighten the disc
brake caliper assembly attaching bolts to a torque of
35 N´m (30 ft. lbs.).
(9) Clean all foreign matter from the threads of
the outer C/V joint stub axle. Install the washer and
stub axle to hub/bearing assembly nut on stub axle
and securely tighten nut.(10) Install wheel speed sensor and mounting bolt
(Fig. 19) on steering knuckle. Tighten the speed sen-
sor attaching bolt to a torque of 7 N´m (60 in. lbs.).
(11)
Install front wheel and tire assembly. Install
and tighten the wheel mounting stud nuts in proper
sequence until all nuts are torqued to half the required
specification. Then repeat the tightening sequence to
the full specified torque of 135 N´m (100 ft. lbs.).
(12) Lower vehicle.
(13) With the vehicle's brakes applied to keep hub
from turning, tighten the hub nut to a torque of 203
N´m (150 ft. lbs.) (Fig. 27).
(14) Install the spring wave washer on the end of
the stub axle.
(15) Install the hub nut lock, and anewcotter pin
(Fig. 11). Wrap cotter pin prongs tightly around the
hub nut lock as shown in (Fig. 11).
(16) Set front Toe on vehicle to required specifica-
tion. Use procedure listed under Wheel Alignment, in
the Front Suspension Service Procedures section of
this service manual.
Fig. 25 Correctly Installed Eccentric Attaching Bolt
Fig. 26 Torquing Tie Rod End Attaching Nut
Fig. 27 Torquing Front Stub Axle To Hub Nut
2 - 18 SUSPENSIONNS
REMOVAL AND INSTALLATION (Continued)