1996 CHRYSLER VOYAGER suspension

COIL SPRING
Coil springs are rated separately for each corner or
side of the vehicle depending on optional equipment
and type of vehicle service. During service procedures
when both springs are removed, mark springs to
ensure installation in original position. Each coil
spring comes with a plastic sleeve on the second coil
of the spring. This plastic sleeve is a noise insulator
for the coil spring.
NOTE: If coil springs require replacement, be sure
that the springs needing replacement, are replaced
with springs meeting the correct load rating for the
vehicle and its specific options.
BALL JOINT
The ball joint (Fig. 2) is pressed into the lower con-
trol arm. The ball joint has a non-tapered stud with
a notch (Fig. 2) to provide clearance for the steering
knuckle clamp bolt and to provide retention of the
ball stud in the steering knuckle. The ball joint stud
is clamped and locked into the steering knuckle leg
using a pinch bolt. The ball joint used on this vehicle
is replaceable and if found defective can be serviced
as a separate component of the lower control arm
assembly.
WHEEL MOUNTING STUDS
If wheel attaching studs need to be replaced in the
hub and bearing assembly the studsCAN NOTbe
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.
Use the procedure and special tools shown in the
service procedures section for the wheel mounting
studs when replacing the wheel attaching studs.
The hub and bearing assembly does not require
removal from the steering knuckle or the rearknuckle to replace the wheel attaching studs in the
hub and bearing assembly.
DIAGNOSIS AND TESTING
Mc PHERSON STRUT
(1) Inspect for damaged or broken coil springs (Fig. 3).
(2) Inspect for torn or damaged strut assembly
dust boots (Fig. 3).
(3) Inspect the coil spring isolator on the lower
spring seat, (Fig. 3) for any signs of damage or dete-
rioration.
(4) Lift dust boot (Fig. 4) and inspect strut assembly for
evidence of fluid running from the upper end of fluid res-
ervoir. (Actual leakage will be a stream of fluid running
down the side and dripping off lower end of unit). A slight
amount of seepage between the strut rod and strut shaft
seal is not unusual and does not affect performance of the
strut assembly (Fig. 4). Also inspect jounce bumpers for
signs of damage or deterioration.
Fig. 2 Ball Joint Assembly
Fig. 3 Mc Pherson Strut Assembly Inspection
Fig. 4 Strut Assembly Leakage Inspection
NSSUSPENSION 2 - 11
DESCRIPTION AND OPERATION (Continued)

STEERING KNUCKLE
The front suspension knuckle is not a repairable
component of the vehicles front suspensionIT MUST
BE REPLACED.If bent, broken or damaged in any
way, do not attempt to straighten or repair the steer-
ing knuckle.
Service replacement of the front hub/bearing
assembly can be done with the front steering knuckle
remaining on the vehicle.
LOWER CONTROL ARM
If damaged, the lower control arm casting is ser-
viced only as a complete component. Inspect lower
control arm for signs of damage from contact with
the ground or road debris. If lower control arm shows
any sign of damage, inspect lower control arm for
distortion.Do not attempt to repair or straighten
a broken or bent lower control arm.
The serviceable components of the lower control
arm are: the ball joint assembly, ball joint assembly
grease seal and control arm bushings. Inspect both
control arm bushings for severe deterioration, and
replace if required. Inspect ball joint per inspection
procedure in this section of the service manual and
replace if required. Service procedures to replace
these components are detailed in the specific compo-
nent removal and installation sections in this group
of the service manual.
BALL JOINT (LOWER)
With the weight of the vehicle resting on the road
wheels, grasp the grease fitting as shown in (Fig. 5)
and with no mechanical assistance or added force
attempt to rotate the grease fitting.
If the ball joint is worn the grease fitting will
rotate easily. If movement is noted, replacement of
the ball joint is recommended.
STABILIZER BAR
Inspect for broken or distorted sway bar bushings,
bushing retainers, and worn or damaged sway bar to
strut attaching links. If sway bar to front suspension
cradle bushing replacement is required, bushing can
be removed from sway bar by opening slit and peel-
ing bushing off sway bar.
HUB AND BEARING ASSEMBLY
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.
Where axle bearing damage is slight, the noise is
usually not noticeable at speeds above 30 m.p.h..
SERVICE PROCEDURES
SUSPENSION CRADLE THREAD REPAIR
PROCEDURE
WARNING: When performing this procedure use
only the thread inserts which are specified in the
Mopar Parts Catalog for this repair procedure.
These thread inserts have been specifically devel-
oped for this application and use of other types of
thread inserts can result in an inferior long term
repair.
The threaded holes in the front suspension cradle,
if damaged, can repaired by installing a Heli-Coilt
thread insert.
The threaded holes that are repairable using the
thread insert, are the lower control arm rear bushing
retainer mounting bolt holes, routing bracket attach-
ing locations for the power steering hoses, and brake
hose attachment holes.
This repair procedure now allows the threaded
holes in the suspension crossmember to be repaired,
eliminating the need to replace the crossmember if
damage occurs to one of the threaded holes.
The thread inserts for this application are specified
by part number in the Mopar Parts Catalog.Do not
use a substitute thread insert.
The specific tools and equipment required to install
the thread insert are listed below. Refer to the
Fig. 5 Checking Ball Joint Wear
2 - 12 SUSPENSIONNS
DIAGNOSIS AND TESTING (Continued)

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: Wheel bearing damage will result if after
loosening hub nut, vehicle is rolled on the ground
or the weight of the vehicle is allowed to be sup-
ported by the tires.
(5) With the vehicle's brakes applied to keep hub
from turning,loosen and removethe stub axle to
hub nut.
(6) Remove the 2 front disc brake caliper to steer-
ing knuckle attaching bolts (Fig. 13).
(7) Remove the disc brake caliper from the steer-
ing knuckle. Caliper is removed by first rotating top
of caliper away from steering knuckle and then
removing bottom of caliper out from under machined
abutment on steering knuckle (Fig. 14).
(8) Support disc brake caliper assembly by using a
wire hook and suspending it from the strut assembly
(Fig. 15).Do not allow the brake caliper assem-
bly to hang by the brake flex hose.
Fig. 11 Hub/Bearing To Stub Axle Retaining Nut
Fig. 12 Wave Washer
Fig. 13 Front Disc Brake Caliper Attaching Bolts
Fig. 14 Brake Caliper Mounting To Steering Knuckle
Fig. 15 Correctly Supported Disc Brake Caliper
NSSUSPENSION 2 - 15
REMOVAL AND INSTALLATION (Continued)

(9) Remove the brake rotor from the hub and bear-
ing assembly (Fig. 16).
(10) Remove nut attaching outer tie rod end to
steering knuckle (Fig. 17).Nut is to be removed
from tie rod end using the following procedure,
hold tie rod end stud with a 11/32 socket while
loosening and removing nut with a wrench.
(11) Remove tie rod end from steering knuckle
using Remover, Special Tool MB-991113 (Fig. 18).
(12) Remove the front wheel speed sensor (Fig. 19)
from the steering knuckle.
(13) If equipped, remove the wheel stop (Fig. 20)
from the steering knuckle.When installing the
pinch bolt when assembling the steering
knuckle to the ball joint, the pinch bolt must beinstalled from the rear facing the front on the
vehicle.
Fig. 16 Remove/Install Brake Rotor
Fig. 17 Removing Tie Rod End Attaching Nut
Fig. 18 Tie Rod End Removal From Steering
Knuckle Arm
Fig. 19 Front Wheel Speed Sensor
Fig. 20 Wheel Stop Location On Steering Knuckle
2 - 16 SUSPENSIONNS
REMOVAL AND INSTALLATION (Continued)

(14) Remove the steering knuckle to ball joint
stud, clamping nut and bolt (Fig. 21) from the steer-
ing knuckle.
(15) Using a pry bar, separate steering knuckle
from ball joint stud (Fig. 22).Note: Use caution
when separating ball joint stud from steering
knuckle, so ball joint seal does not get cut.
NOTE: Care must be taken not to separate the
inner C/V joint during this operation. Do not allow
driveshaft to hang by inner C/V joint after removing
outer C/V Joint from the hub/bearing assembly in
steering knuckle, end of driveshaft must be sup-
ported.
(16) Pull steering knuckle assembly out and away
from the outer C/V joint of the driveshaft assembly
(Fig. 23).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.
(17) Remove the 2 steering knuckle to strut
damper clevis bracket attaching bolts (Fig. 24).
(18) Remove the steering knuckle from the strut.
INSTALL
(1) Transfer, or install if necessary, a new hub/
bearing assembly into the steering knuckle. Refer to
Hub And Bearing Assembly Service in this section of
the service manual for the required removal and
installation procedure for the front hub/bearing
assembly.
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.
Fig. 21 Control Arm To Steering Knuckle
Attachment
Fig. 22 Separating Ball Joint Stud From Steering
Knuckle
Fig. 23 Steering Knuckle Separation From
Driveshaft
Fig. 24 Strut To Steering Knuckle Attaching Bolts
NSSUSPENSION 2 - 17
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)