1996 CHRYSLER VOYAGER wheel torque

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)

suspension cradle (Fig. 36).Do not tighten or
torque pivot bolt at this time.
(2) Install retainer (Fig. 37) attaching rear bush-
ing of lower control arm to front suspension cradle.
When installing retainer, be sure raised rib on
rear bushing (Fig. 37) is positioned in the
groove on the retainer. Do not torque attaching
bolts at this time.
NOTE: If reference marks were not put on the
frame rails prior to lowering the suspension cradle,
Refer to group 13 Frame And Bumpers for the cra-
dle positioning procedure.
(3) Raise the front suspension cradle against the
front frame rails. Align the cradle with the reference
marks on the frame rails.
(4) Tighten the 4 mounting bolts for the front sus-
pension cradle to a torque of 163 N´m (120 ft. lbs.).(5) Install lower control arm ball joint stud into
steering knuckle. Then install the bolt and nut,
clamping the steering knuckle to the ball joint stud
(Fig. 29). Tighten the clamping bolt to a torque of
145 N´m (105 ft. lbs.).
(6) Install the cradle plate on front suspension cra-
dle and then install the 10 cradle plate to cradle
attaching bolts (Fig. 30). Tighten the 9 M-14 attach-
ing bolts (Fig. 30) to a torque of 165 N´m (123 ft.
lbs.). Tighten the 1 M-12 attaching bolt (Fig. 30) to a
torque of 108 N´m (80 ft. lbs.).
CAUTION: When locating jack stands under lower
control arm, do not place the jack stands under the
ball joints (Fig. 38).
(7) Position jack stands under the lower control
arms as close to the ball joints as possible (Fig. 38).
Lower the vehicle onto the jack stands, until the jack
stands are supporting the total weight of the vehicle
(Fig. 38).
(8) Tighten front lower control arm pivot bolt (Fig.
36) to a torque of 183 N´m (135 ft. lbs.) first, then
tighten rear lower control arm bushing retainer
attaching bolts (Fig. 33) to a torque of 68 N´m (50 ft.
lbs.).
(9) Install the wheel/tire assembly on the vehicle.
(10) 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.).
(11) Remove jack stands and lower vehicle to the
ground.
Fig. 36 Lower Control Arm Bushing Pivot Bolt
Correctly Installed
Fig. 37 Installing Lower Control Arm Rear Bushing
Retainer
Fig. 38 Jack Stands Supporting Vehicle Weight
NSSUSPENSION 2 - 21
REMOVAL AND INSTALLATION (Continued)

INSTALL
CAUTION: Hub and bearing assembly mounting
surfaces on the steering knuckle and halfshaft (Fig.
60) must be smooth and completely free of foreign
material or nicks prior to installing hub and bearing
assembly.
CAUTION: When installing hub and bearing
assembly into steering knuckle, be careful not to
damage the bearing seal (Fig. 60) on the outer C/V
joint.
(1) Install hub/bearing assembly onto stub axle
and into steering knuckle until squarely seated on
the face of the steering knuckle.
(2) Install the 4 hub/bearing assembly to steering
knuckle attaching bolts (Fig. 58). Equally tighten all
4 mounting bolts in a criss-cross pattern until hub/
bearing assembly is squarely seated against front ofsteering knuckle. Then tighten the 4 hub and bearing
assembly mounting bolts to a torque of 65 N´m (45
ft.lbs.)
(3) Install the hub/bearing assembly to stub shaft
washer and retaining nut (Fig. 61).Tighten, but do
not torque the hub nut at this time.
(4) Install the braking disk on the hub and bearing
assembly.
(5) Install front brake caliper back over braking
disc and align with caliper mounting holes on steer-
ing knuckle (Fig. 55). Caliper is installed by first
installing bottom of caliper under machined abut-
ment on bottom of steering knuckle and then rotat-
ing top of caliper toward steering knuckle. Install the
disc brake caliper to steering knuckle attaching bolts
(Fig. 54) and tighten to a torque of 19 N´m (168 in.
lbs.).
(6) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting stud nuts in proper
Fig. 58 Hub/Bearing Assembly Mounting Bolts
Fig. 59 Hub and Bearing Assembly Removal From
Steering Knuckle
Fig. 60 Hub And Bearing Assembly Mounting
Surfaces
Fig. 61 Hub/Bearing To Stub Axle Washer And
Retaining Nut
NSSUSPENSION 2 - 27
REMOVAL AND INSTALLATION (Continued)

sequence until all nuts are torqued to half specifica-
tion. Then repeat the tightening sequence to the full
specified torque of 129 N´m (95 ft. lbs.).
(7) Lower vehicle to the ground.
CAUTION: When tightening hub/bearing assembly
to stub shaft retaining nut, do not exceed the max-
imum torque of 244 N´m (180 ft. lbs.).
(8) With vehicle brakes applied to keep vehicle
from moving, torque stub shaft to hub/bearing assem-
bly retaining nut to 244 N´m (180 ft. lbs.).
(9) Check the Toe setting on the vehicle and reset
if not within specifications.
FRONT WHEEL MOUNTING STUDS
REMOVE
CAUTION: If a wheel attaching stud needs to be
replaced in the hub and bearing assembly the studs
CAN 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.
The following procedure and special tools shown
MUST BEused when replacing wheel attaching
studs.
The hub and bearing assembly does not require
removal from the steering knuckle to replace wheel
attaching studs in the hub and bearing assembly.
(1) Raise vehicle on jackstands 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 front wheel and tire assembly from
the vehicle.
(3) Remove the front caliper assembly from the
front steering knuckle assembly. (Fig. 62) Refer to
Front Disc Brake Service in the Brake Section of this
service manual for caliper removal procedure.
(4) Remove front rotor from hub, by pulling it
straight off wheel mounting studs. (Fig. 63)
(5) Install a lug nut on the wheel stud to be
removed from the hub and bearing assembly, so the
threads on the stud are even with end of lug nut.
Install Remover, Special Tool C-4150A on hub and
bearing assembly flange and wheel stud (Fig. 64).
(6) Tightening down on special tool will push
wheel stud out of the hub and bearing assembly
flange. When shoulder of wheel stud is past flange
remove special tool from hub and bearing assembly.
Remove lug nut from stud and remove wheel stud
from flange.
INSTALL
(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. 65).
(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 braking disk back on the hub and
bearing assembly. (Fig. 63)
Fig. 62 Disc Brake Caliper Mounting
Fig. 63 Removing Braking Disc
2 - 28 SUSPENSIONNS
REMOVAL AND INSTALLATION (Continued)

(4) Install front brake caliper back over braking
disc and align with caliper mounting holes on steer-
ing knuckle (Fig. 62). Refer to Front Disc Brake Ser-
vice in the Brake Section of this service manual for
caliper installation procedure. Install the caliper
adapter to steering knuckle attaching bolts and
torque to 19 N´m (168 in. lbs.).
(5) 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 129 N´m (95 ft. lbs.).
(6) Lower vehicle to the ground.
REAR WHEEL MOUNTING STUDS
REMOVE
CAUTION: If a wheel attaching stud needs to be
replaced in the hub and bearing assembly the studs
CAN NOT be hammered out of the hub flange. If astud 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.
The following procedure and special tools shown
MUSTbe used when replacing wheel attaching
studs.
The hub and bearing assembly does not require
removal from the rear axle for replacement of the
wheel attaching studs.
(1) Raise vehicle on jackstands 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 rear wheel and tire assembly.
(3) Remove the rear brake drum.
(4) Install a lug nut on the wheel stud to be
removed from the hub and bearing assembly (Fig. 66)
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. 66).
(5) Tightening down on special tool will push
wheel stud out of the hub and bearing assembly
flange. Remove lug nut from stud and remove wheel
stud from flange.
INSTALL
(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. 67).
(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.
Fig. 64 Wheel Stud Removal From Hub/Bearing
Assembly
Fig. 65 Installing Wheel Stud Into Hub And Bearing
Fig. 66 Removing Wheel Stud From Hub And
Bearing
NSSUSPENSION 2 - 29
REMOVAL AND INSTALLATION (Continued)

(3) Install the rear brake drum 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 129 N´m (95 ft. lbs.).
(5) Lower vehicle to the ground.
DISASSEMBLY AND ASSEMBLY
Mc PHERSON STRUT
DISASSEMBLY
The Mc Pherson Strut must be remove from the
vehicle for it to be disassembled and assembled.
Refer to Mc Pherson Strut in the Removal And
Installation Section in this group of the service man-
ual for the required procedure to remove and install
the Mc Pherson Strut.
(1) Clamp strut assembly in vise, with strut in a
vertical position.Do not clamp reservoir of strut
assembly in vise, only clamp strut assembly
using strut clevis bracket (Fig. 68).
(2) Mark coil spring and strut assembly right or
left, according to which side of vehicle strut was
removed from, and which strut coil spring was
removed from.
WARNING: DO NOT REMOVE STRUT ROD NUT,
BEFORE STRUT ASSEMBLY COIL SPRING IS COM-
PRESSED, REMOVING SPRING TENSION FROM
UPPER SPRING SEAT AND BEARING ASSEMBLY.
WARNING: WHEN COMPRESSING COIL SPRING
FOR REMOVAL FROM STRUT ASSEMBLY, THE
UPPER SPRING SEAT AND SECOND COIL OF THECOIL SPRING MUST BE CAPTURED BY THE JAWS
OF THE COIL SPRING COMPRESSOR (Fig. 69).
(3) Compress strut coil spring, using Pentastar
Service Equipment Spring Compressor, 7522A (Fig.
69). Be sure the top and bottom attachment shoe
selected, (Fig. 69) properly fit the coil spring.
(4) Install Socket, Strut Nut, Special Tool 6864 on
the strut shaft retaining nut (Fig. 70). Then install a
10 mm socket on the hex of the strut shaft (Fig. 70).
While holding strut shaft from turning, remove nut
from strut shaft.
(5) Remove the upper mount (Fig. 71) from the
strut shaft and coil spring upper seat.
(6) Release the coil spring from the spring com-
pressor. Remove spring compressor from coil spring
(Fig. 72).
(7) Remove the coil spring upper seat and pivot
bearing (Fig. 72) as an assembly from the coil spring.
Remove the coil spring from the strut.Mark left
Fig. 67 Installing Wheel Stud Into Hub And BearingFig. 68 Strut Assembly Correctly Installed In Vise
Fig. 69 Compressing Strut Assembly Coil Spring
2 - 30 SUSPENSIONNS
REMOVAL AND INSTALLATION (Continued)

NOTE: Bushings must be installed on stabilizer bar
so the square corner of the bushing will be down
and slit in bushing will be facing the rear of the
vehicle when the stabilizer is installed (Fig. 88).SPECIFICATIONS
FRONT SUSPENSION FASTENER TORQUES
DESCRIPTION TORQUE
McPHERSON STRUT:
To Strut Tower
Attaching Nuts............28N´m(250 in. lbs.)
Clevis Bracket To Steering
Knuckle..................88N´m(65ft.lbs.)
Plus 1/4 Additional Turn
Strut Shaft Nut.............100 N´m (75 ft. lbs.)
STEERING KNUCKLE:
Ball Joint Stud To Steering
Knuckle Nut/Bolt.........136 N´m (100 ft. lbs.)
Disc Brake Caliper Bolts.......22N´m(16ft.lbs.)
Wheel Stop..................95N´m(70ft.lbs.)
STEERING GEAR:
To Suspension Cradle
Attaching Bolts...........183 N´m (135 ft. lbs.)
Tie Rod End Adjusting
Sleeve Nut................75N´m(55ft.lbs.)
Tie Rod End To Steering
Knuckle Nut...............61N´m(45ft.lbs.)
FRONT SUSPENSION CRADLE:
To Body Attaching Bolts......163 N´m (120 ft. lbs.)
Lower Control Arm
Pivot Bolt...............185 N´m (137 ft. lbs.)
Lower Control Arm Rear
Bushing Retainer Bolt.......68N´m(50ft.lbs.)
Reinforcement Plate
Attaching Bolts M-12.......108 N´m (80 ft. lbs.)
Reinforcement Plate
Attaching Bolts M-14......166 N´m (123 ft. lbs.)
STABILIZER BAR:
Bushing Retainer ToSuspension
Cradle Attaching Bolts.......70N´m(50ft.lbs.)
Attaching Link Nuts...........88N´m(65ft.lbs.)
HUB AND BEARING:
To Steering Knuckle Bolts......110N´m(80ft.lbs.)
Front Stub Axle To Hub
Bearing Nut.............183 N´m (135 ft. lbs.)
Wheel Mounting
LugNut...........110-135 N´m (85-115 ft. lbs.)
Fig. 88 Correctly Installed Stabilizer Bar To Cradle
Bushing
2 - 36 SUSPENSIONNS
DISASSEMBLY AND ASSEMBLY (Continued)

REAR SUSPENSION
INDEX
page page
GENERAL INFORMATION
REAR SUSPENSION..................... 38
DESCRIPTION AND OPERATION
REAR TRACK BAR....................... 39
REAR WHEEL ALIGNMENT................ 39
SHOCK ABSORBERS (REAR LOAD LEVELING) . 40
STABILIZER BAR........................ 39
REMOVAL AND INSTALLATION
JOUNCE BUMPER....................... 46
LEAF SPRING FRONT MOUNT............. 47LEAF SPRING REAR MOUNT.............. 47
REAR SPRINGS (AWD)................... 43
REAR SPRINGS (FWD)................... 40
REAR TRACK BAR....................... 45
SHOCK ABSORBER...................... 45
STABILIZER BAR........................ 46
TRACK BAR MOUNT..................... 45
SPECIFICATIONS
REAR SUSPENSION FASTENER TORQUES . . . 48
GENERAL INFORMATION
REAR SUSPENSION
The rear suspension design on this vehicle uses
leaf springs and a tube and casting axle (Fig. 1) and
(Fig. 2). It is designed to handle the various load
requirements of the vehicle. The leaf springs used on
the rear suspension of this vehicle are of either a
mono-leaf or multi-leaf design.The rear axle used on front wheel drive applica-
tions of this vehicle is mounted to the rear leaf
springs using isolator bushings at the axle mounting
brackets.
The rear axle used on all wheel drive applications
of this vehicle is also mounted to the rear leaf
springs but does not use isolator bushings between
the rear axle and the leaf springs.
Fig. 1 Front Wheel Drive Rear Suspension
2 - 38 SUSPENSIONNS