1996 CHRYSLER VOYAGER lock

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)

NOTE: When torquing nut on stud of stabilizer bar
attaching link, do not allow the stud to rotate. Hold
stud from rotating by inserting a Torx Plus 40 IP bit
in the end of the the stud (Fig. 47).
(5) Tighten the stabilizer bar attaching link nuts
(Fig. 47) to a torque of 88 N´m (65 ft. lbs.).
(6) Tighten the stabilizer bar bushing retainer to
cradle attaching bolts (Fig. 48) to 68 N´m (50 ft. lbs.)
torque.
(7) Install the cradle plate on front suspension cra-
dle and then install the 10 cradle plate to cradle
attaching bolts (Fig. 46). Tighten the 9 M-14 attach-
ing bolts (Fig. 46) to a torque of 165 N´m (123 ft.
lbs.). Tighten the 1 M-12 attaching bolt (Fig. 46) to a
torque of 108 N´m (80 ft. lbs.).
(8) Lower vehicle.
HUB AND BEARING ASSEMBLY
REMOVE
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 Front
Steering Knuckle in this section of the service man-
ual for the required removal and installation proce-
dure.
(1) Remove the cotter pin, and nut lock from the
stub axle (Fig. 52).
(2) Remove the spring wave washer (Fig. 53) from
the end of the stub axle.
Fig. 50 Stabilizer Bar Bushing Retainer Installation
Fig. 51 Stabilizer Bar Correctly Positioned In Cradle
Fig. 52 Cotter Pin And Nut Lock
Fig. 53 Nut Lock Wave Washer
NSSUSPENSION 2 - 25
REMOVAL AND INSTALLATION (Continued)

LOWER CONTROL ARM FRONT BUSHING
REMOVE
(1) Remove the lower control arm from the front
suspension cradle. Refer to Lower Control Arm in the
Removal And Installation Section in this section of
the service manual for the required procedure.
(2) Securely mount the lower control arm in a vise.
(3) Assemble for removal of the front bushing, the
Bushing Receiver, Special Tool 6908±2, Bushing
Remover, Special Tool 6908±1, Nut, Special Tool
6908±3 thrust washer, threaded rod and small nut,
as shown in (Fig. 82) on the lower control arm and
front bushing.
(4) To remove front bushing from lower control
arm, hold the threaded rod stationary and tighten
the Nut, Special Tool 6908±3 (Fig. 82). This will force
the front bushing out of the lower control arm and
into Bushing Receiver, Special Tool 6908±2 (Fig. 82).
INSTALL
(1) Securely mount the lower control arm in a vise.
NOTE: The lower control arm front bushing is a
directional bushing. It must be installed in the lower
control arm positioned as shown in (Fig. 83).
(2) Position the front bushing in the lower control
arm so that the 2 rubber blocks on the bushing are
positioned horizontally as shown in (Fig. 83).
(3) Assemble for installation of the front bushing,
the Bushing Receiver, Special Tool 6908±5, Bushing
Installer, Special Tool 6908±4, Nut, Special Tool
6908±3 thrust washer, threaded rod and small nut,
as shown in (Fig. 84) on the lower control arm and
front bushing.
(4) To install the front bushing in lower control
arm, hold the threaded rod stationary and tighten
Fig. 81 Installing Ball Joint Seal Boot
Fig. 82 Tools Assembled For Removal Of Front
Bushing
Fig. 83 Installation Position Of Lower Control Arm
Front Bushing
Fig. 84 Tools Assembled For Installation Of Front
Bushing
2 - 34 SUSPENSIONNS
DISASSEMBLY AND ASSEMBLY (Continued)

(10) Remove the leaf spring from the vehicle (Fig.
10).
(11) Loosen and remove the pivot bolt from the
front mount of the rear leaf spring. (Fig. 11).
FRONT BUSHING REPLACEMENT
(1) Install leaf spring in a proper holding fixture.
(2) Install leaf spring press Special Tool C-4212±F.
(3) Install adapter Special Tool C-4212±3.
(4) Tighten leaf spring press until bushing is
extracted from leaf spring.
(5) Remove leaf spring press from leaf spring.
(6) Insert replacement bushing into the leaf spring
eye.Verify that the bushing flange is on the left
side of the leaf spring when leaf spring is in the
in vehicle installed position.
(7) Install leaf spring press Special Tool C-4212±F.
(8) Install adapter Special Tool C-4212±4.
(9) Tighten leaf spring press until bushing flange
bottoms solidly against leaf spring eye.
(10) Remove leaf spring press and adapter.(11) Bend the bushing tabs so that they are con-
tacting the leaf spring.
INSTALLATION
(1) Assemble front spring mount to front of spring
eye and install pivot bolt and nut. Do not tighten.
CAUTION: Pivot bolt must face inboard to prevent
structural damage during installation of spring.
(2) Raise front of spring and install four hanger
bolts, tighten to 61 N´m (45 ft. lbs.) torque.
(3) Install rear of spring onto rear spring shackle.
Install shackle plate. Do not tighten.
(4) Verify lower leaf spring isolator is in position.
(5) Raise axle into correct position on leaf spring
with axle centered under spring locator post (Fig.
12).
(6) Verify that the leaf spring isolator is correctly
positioned in the axle plate.
(7) Install axle plate on the spring.
(8) Install axle plate bolts. Tighten bolts to 108
N´m (80 ft. lbs.) torque.
(9) Install shock absorber bolts. Do not tighten.
(10) Lower vehicle to floor so that the full weight
of vehicle is supported by the tires.
(11) Tighten component fasteners as follows:
²Front pivot boltÐ156 N´m (115 ft. lbs.)
²Shackle nutsÐ61 N´m (45 ft. lbs.)
²Shock absorber boltsÐ101 N´m (75 ft. lbs.)
(12) If the vehicle is not equipped with antilock
brakes, raise vehicle and the connect the actuator for
the height sensing proportioning valve on the rear
leaf spring. Adjust the height sensing proportioning
valve. Refer to the Adjustment Section in this group
of the service manual for the required adjustment
procedure.
Fig. 10 Leaf Spring Remove/Install
Fig. 11 Leaf Spring Front Mount
Fig. 12 Leaf Spring Locator Post
2 - 42 SUSPENSIONNS
REMOVAL AND INSTALLATION (Continued)

(11) Remove the leaf spring from the vehicle (Fig.
17).
(12) Loosen and remove the pivot bolt from the
front mount of the rear leaf spring. (Fig. 18).
FRONT BUSHING REPLACEMENT
(1) Install leaf spring in a proper holding fixture.
(2) Install leaf spring press Special Tool C-4212±F.
(3) Install adapter Special Tool C-4212±3.
(4) Tighten leaf spring press until bushing is
extracted from leaf spring.
(5) Remove leaf spring press from leaf spring.
(6) Insert replacement bushing into the leaf spring
eye. Verify that the bushing flange is on the outboard
side of the leaf spring.
(7) Install leaf spring press Special Tool C-4212±F.
(8) Install adapter Special Tool C-4212±4.
(9) Tighten leaf spring press until bushing flange
bottoms solidly against leaf spring eye.
(10) Remove leaf spring press and adapter.(11) Bend the tabs on the bushing until they are
contacting the leaf spring.
INSTALL
CAUTION: Pivot bolt must face inboard to prevent
structural damage during installation of spring.
(1) Install the front of the rear leaf spring into the
spring mount (Fig. 18). 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 spring mount.
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 hanger. Install the inner half of the
rear hanger. Install the nut and bolts on the rear
hangerbut 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. Tighten bolts to 108
N´m (80 ft. lbs.) torque.
(6) Install shock absorber bolts. Do not tighten.
(7) Lower vehicle to floor and with full weight of
vehicle on wheels. Tighten component fasteners as
follows:
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.
²Front pivot bolt-156 N´m (115 ft. lbs.)
²Rear spring hanger pin nuts-61 N´m (45 ft. lbs.)
²Rear spring hanger inner to outer half retaining
bolts-61 N´m (45 ft. lbs.)
²Shock absorber upper mounting bolt-115 N´m
(85 ft. lbs.)
²Shock absorber lower mounting bolt-108 N´m (80
ft. lbs.)
(8) If the vehicle is not equipped with antilock
brakes, raise vehicle and connect the actuator for the
height sensing proportioning valve on the rear leaf
spring. Adjust the height sensing proportioning
valve. Refer to the Adjustment Section in this group
of the service manual for the required adjustment
procedure.
Fig. 17 Leaf Spring Remove/Install
Fig. 18 Leaf Spring Front Mount
2 - 44 SUSPENSIONNS
REMOVAL AND INSTALLATION (Continued)

REMOVAL-HEAVY DUTY
The jounce bumpers are serviced as an assembly.
The jounce bumpers screw into a weld nut located in
the frame rail (Fig. 24).
(1) Using slip-joint pliers grasp the base of the
jounce bumper. Turn the base counterclockwise (Fig.
25).
(2) Remove the jounce bumper from the frame rail.
INSTALLATION-HEAVY DUTY
(1) For installation, reverse the removal procedure.
Tighten the jounce bumper to a torque of 33 N´m
(290 in. lbs.).
LEAF SPRING FRONT MOUNT
REMOVE
(1) Loosen the pivot bolt attaching the front of the
leaf spring to the spring mount (Fig. 26).
(2) Install a jackstand under the side of the axle
having the leaf spring mount removed. Using thejackstand support the weight of the axle and leaf
spring.
(3) Remove the lower mounting bolt from the
shock absorber.
(4) Remove the bolts attaching the leaf spring
front mount (Fig. 26) to the body of the vehicle.
(5) Lower the leaf spring and remove the front
mount from the spring.
INSTALLATION
(1) For installation, reverse removal procedure. Do
not tighten front through bolt fully until vehicle is
lowered and the full vehicle weight is applied to the
rear wheels. Tighten leaf spring front mount bolts to
61 N´m (45 ft. lbs.). Tighten leaf spring front through
bolt to 156 N´m (115 ft. lbs.).
LEAF SPRING REAR MOUNT
REMOVE
(1) Remove the attaching nuts and bolts from the
leaf spring rear shackle (Fig. 27) and (Fig. 28).
Fig. 24 Jounce Bumper-Heavy Duty
Fig. 25 Bumper Replacement
Fig. 26 Leaf Spring Front Mount
Fig. 27 Leaf Spring Shackle Nuts (FWD)
NSSUSPENSION 2 - 47
REMOVAL AND INSTALLATION (Continued)

BRAKES
CONTENTS
page page
ANTILOCK BRAKE SYSTEM ±
TEVES MARK-20....................... 85BASE BRAKE SYSTEM..................... 3
GENERAL INFORMATION................... 1
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
BASE BRAKE SYSTEM COMPONENT
DESCRIPTION......................... 1GENERAL VEHICLE SERVICE CAUTIONS...... 1
GENERAL INFORMATION
GENERAL VEHICLE SERVICE CAUTIONS
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 clearance in this area
(Fig. 1), installation of metal fasteners 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 hoisting
positions for this vehicle are to be used whenever 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 mount-
ing bracket and the hydraulic control unit.
BASE BRAKE SYSTEM COMPONENT DESCRIPTION
The standard brake system on this vehicle consists
of the following components:
²Double pin floating caliper disc front brakes.
²Double pin floating caliper rear disc brakes on
all wheel drive applications.²Rear automatic adjusting drum brakes.
²Master cylinder with brake fluid level sensor.
²Vacuum booster.
²Height sensing proportioning valve (non-antilock
brake applications)
²Non-height sensing proportioning valve (antilock
brake applications)
The brakes hydraulic system on both non-antilock
and antilock brake systems is diagonally split (Fig. 2)
(Fig. 3). A diagonally split brake system means the
left front and right rear brakes on one hydraulic sys-
tem and the right front and left rear on the other.
Fig. 1 Shock Tower To Spring Minimum Clearance
Area
NSBRAKES 5 - 1

Fig. 2 Non-Antilock Brakes Hydraulic Brake Tube Routing And Fitting Locations
Fig. 3 Antilock Brakes/Traction Control Hydraulic Brake Tube Routing And Fitting Locations
5 - 2 BRAKESNS
GENERAL INFORMATION (Continued)