1996 CHRYSLER VOYAGER torque

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)

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)

(10) 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 damper shaft
(Fig. 70). While holding strut shaft from turning,
torque strut shaft retaining nut to 94 N´m (70 ft.
lbs.).
(11) Loosen spring compressor until top coil of
spring is fully seated against upper spring seat. Then
relieve all tension from spring compressor and
remove spring compressor from strut spring.
(12) Install strut back in vehicle. Refer to Mc
Pherson Strut in the Removal And Installation Sec-
tion in this group of the service manual for the
required procedure to install the Mc Pherson Strut.
BALL JOINT SEAL BOOT
REMOVE
(1) Using a screw driver or other suitable tool, pry
the seal boot off of the ball joint assembly (Fig. 79)
INSTALL
CAUTION: When installing the ball joint seal on the
ball joint/lower control arm, the shield (Fig. 80) on
the ball joint seal must be positioned as shown.
(1) Install aNEWseal boot by hand as far as pos-
sible on the ball joint. Installation of the seal boot is
to be with the shield positioned as shown (Fig. 80).
CAUTION: Do not use an arbor press to install the
sealing boot on the ball joint. Damage to the seal-
ing boot will occur if excessive pressure is applied
to the sealing boot when it is being installed.
(2) Place Installer, Special Tool 6758 over seal boot
and squarely align it with bottom edge of seal boot
(Fig. 81). Apply hand pressure to Special Tool 6758
until seal boot is pressed squarely against top surface
of lower control arm.
CAUTION: A replacement ball joint is not prelubri-
cated. Properly lubricate the replacement ball joint
using Mopar Multi±Mile grease or an equivalent.
Lubricate ball joint after seal boot is installed but
prior to top of seal boot being pushed down below
notch in ball joint stud. Air must vent out of the
seal boot at notch when grease is pumped into ball
joint, failure to do so will balloon and damage seal
boot. Do not over grease the ball joint, this will pre-
vent the seal boot from pushing down on the stud
of the ball joint.
CAUTION: After the ball joint is properly greased,
clip the end of the grease fitting off below the hex.
The ball joint seal boot is non-purgeable and further
greasing is not required and can result in damage
to the seal boot.
Fig. 78 Installing Pivot Bearing On Upper Spring
Seat
Fig. 79 Ball Joint Seal Boot Removal
Fig. 80 Ball Joint Seal Boot Installed Position
NSSUSPENSION 2 - 33
DISASSEMBLY AND ASSEMBLY (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