1996 CHRYSLER VOYAGER wheel torque

(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)

SHOCK ABSORBER
REMOVE/INSTALL
(1) Raise vehicle. Vehicle is to be raised and sup-
ported on jackstands or on a frame contact type
hoist. See Hoisting in the Lubrication And Mainte-
nance section of this service manual.
(2) Support the rear axle of the vehicle using 2
jackstands positioned at the outer ends of the axle.
NOTE: If the shock absorber lower mounting bolt
deflects upward during removal, raise axle by
adjusting the support jack. If the lower shock
absorber bolt deflects downward during removal,
lower the axle by adjusting the support jack.
(3) Remove the shock absorber lower mounting
bolt.
(4) While holding shock absorber, remove the
shock absorber upper mounting bolt.
(5) To install the shock absorber use the reverse
sequence of its removal.
(6) Lower the vehicle to the ground so the full
weight of the vehicle is supported by the suspension.
(7) Tighten the upper and lower shock absorber
mounting bolt to their specified torques.
REAR TRACK BAR
REMOVE
(1) Remove the nut and bolt mounting the track
bar to the rear axle (Fig. 19).
(2) Remove the nut and bolt attaching the track
bar to the track bar mount on the body of the vehicle.
Remove the track bar from the track bar mount.
INSTALL
(1) Install the track bar first into the body mount
for the track bar (Fig. 20). Install the track bar boltwith the head of the bolt facing toward the rear of
the vehicle (Fig. 21). Do not tighten.
(2) Install the track bar into its mounting bracket
on the rear axle (Fig. 19). Install the track bar bolt
with the head of the bolt facing toward the rear of
the vehicle. Do not tighten.
(3) Lower the vehicle to the ground until the full
weight of the vehicle is supported by the wheels.
Tighten both track bar attaching bolts to a torque of
95 N´m (70 ft. lbs.).
TRACK BAR MOUNT
REMOVE
(1) Remove the track bar from the track bar
mount.
(2) Remove the three bolts attaching the track bar
mount to the body (Fig. 22).
Fig. 19 Track Bar Mounting To Axle
Fig. 20 Track Bar Installation
Fig. 21 Track Bar Bolt Installation
NSSUSPENSION 2 - 45
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)

(2) Install a jackstand under the side of the axle
having the leaf spring mount removed. Using the
jackstand, 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 rear
mount to the body of the vehicle (Fig. 29).
(5) Lower the jackstand and the rear of the leaf
spring. Remove the shackle from the leaf spring
bushing.
INSTALL
CAUTION: The following sequence must be fol-
lowed when tightening the pin nuts on the rearhanger for the rear leaf spring. First the hanger pin
nuts must be tightened to the specified torque.
Then tighten the retaining bolts for the inner to
outer half of the spring hanger to the specified
torque. This sequence must be followed to avoid
bending the spring hanger.
(1) For installation, reverse removal procedure. Do
not tighten rear spring shackle nuts fully until vehi-
cle is lowered and the full vehicle weight is applied
to the rear wheels. Tighten rear spring mount bolts
to 61 N´m (45 ft. lbs.). Tighten shackle nuts to 61
N´m (45 ft. lbs.).
SPECIFICATIONS
REAR SUSPENSION FASTENER TORQUES
DESCRIPTION TORQUE
SHOCK ABSORBER MOUNTING BOLTS:
Standard Shock Absorber......101 N´m (75 ft. lbs.)
Self Load Leveling Shock
Absorber.................101 N´m (75 ft. lbs.)
JOUNCE BUMPER:
To Frame Rail..............33N´m(290 in. lbs.)
TRACK BAR:
To Axle And Mounting
Bracket Pivot Bolt..........95N´m(70ft.lbs.)
Bracket To Body Attaching......61N´m(45ft.lbs.)
LEAF SPRING:
Spring Plate To Axle
Attaching Bolts............108 N´m (80 ft. lbs.)
Rear Mount To Body Bolts......61N´m(45ft.lbs.)
Front Mount To Body Bolts......61N´m(45ft.lbs.)
To Front Hanger
Mounting Nut............156 N´m (115 ft. lbs.)
Shackle Plate Nuts............61N´m(45ft.lbs.)
STABILIZER BAR:
Bushing Retainer To Axle
Attaching Bolts.............61N´m(45ft.lbs.)
Attaching Link Nuts...........61N´m(45ft.lbs.)
Frame Rail Bracket
Mounting Bolts.............61N´m(45ft.lbs.)
Link Arm To Frame
Rail Bracket...............61N´m(45ft.lbs.)
HUB AND BEARING:
To Axle Mounting Bolts........129 N´m (95 ft. lbs.)
Stub Axle Nut..............224 N´m (180 ft. lbs.)
Wheel Mounting
LugNut...........110-135 N´m (85-115 ft. lbs.)
Fig. 28 Leaf Spring Shackle Nuts/Bolts (AWD)
Fig. 29 Rear Spring Mount
2 - 48 SUSPENSIONNS
REMOVAL AND INSTALLATION (Continued)

BASE BRAKE SYSTEM
INDEX
page page
DESCRIPTION AND OPERATION
CHASSIS TUBES AND HOSES.............. 7
FRONT DISC BRAKE SYSTEM.............. 4
HUB/BEARING REAR WHEEL............... 9
MASTER CYLINDER...................... 7
PARKING BRAKE SYSTEM OPERATION....... 5
POWER BRAKE VACUUM BOOSTER
OPERATION........................... 8
PROPORTIONING VALVES................. 5
REAR DISC BRAKES...................... 5
REAR DRUM BRAKES..................... 5
RED BRAKE WARNING LAMP OPERATION..... 8
STOP LAMP SWITCH...................... 9
DIAGNOSIS AND TESTING
ADJUSTER REAR DRUM BRAKE
(AUTOMATIC)......................... 14
BRAKE FLUID CONTAMINATION............ 19
BRAKE ROTOR......................... 14
BRAKE SYSTEM BASIC DIAGNOSIS GUIDE.... 9
BRAKE SYSTEM DIAGNOSIS CHARTS....... 10
PROPORTIONING VALVES................ 16
RED BRAKE WARNING LAMP TEST......... 19
STOP LAMP SWITCH TEST PROCEDURE..... 19
TRACTION CONTROL LAMP TEST.......... 19
SERVICE PROCEDURES
BLEEDING BASE BRAKE
HYDRAULIC SYSTEM................... 20
BRAKE DRUM MACHINING................ 24
BRAKE TUBE REPAIR PROCEDURE......... 24
MASTER CYLINDER BLEEDING
PROCEDURE......................... 22
MASTER CYLINDER FLUID LEVEL CHECK.... 20
PARK BRAKE AUTO ADJUSTER
MECHANISM RELEASE................. 26
ROTOR MACHINING (FRONT/REAR)......... 22
REMOVAL AND INSTALLATION
BRAKE SUPPORT PLATE (REAR DRUM
BRAKES)............................ 37
FRONT DISC BRAKE CALIPER............. 27
FRONT DISC BRAKE PADS................ 30
FRONT PARK BRAKE CABLE.............. 65
HUB/BEARING.......................... 40
HYDRAULIC BRAKE TUBES AND HOSES..... 58
INTERMEDIATE PARK BRAKE CABLE....... 66
JUNCTION BLOCK....................... 55
LEFT REAR PARK BRAKE CABLE........... 67
MASTER CYLINDER..................... 44
PARK BRAKE PEDAL MECHANISM.......... 58PARK BRAKE SHOES (WITH REAR DISC
BRAKES)............................ 60
PROPORTIONING VALVE (W/ABS BRAKES) . . . 56
PROPORTIONING VALVE
(W/O ABS BRAKES).................... 57
REAR BRAKE DRUM..................... 33
REAR BRAKE WHEEL CYLINDER........... 39
REAR DISC BRAKE CALIPER.............. 28
REAR DISC BRAKE SHOES................ 31
REAR DRUM BRAKE SHOES............... 34
RIGHT REAR PARK BRAKE CABLE......... 66
STOP LAMP SWITCH..................... 69
VACUUM BOOSTER 2.4 LITER ENGINE...... 47
VACUUM BOOSTER 3.0 LITER ENGINE...... 49
VACUUM BOOSTER 3.3/3.8 LITER ENGINE.... 52
WHEEL AND TIRE INSTALLATION........... 27
DISASSEMBLY AND ASSEMBLY
FRONT DISC BRAKE CALIPER............. 71
MASTER CYLINDER BRAKE FLUID LEVEL
SWITCH............................. 71
MASTER CYLINDER FLUID RESERVOIR
FILL TUBE............................ 71
MASTER CYLINDER FLUID RESERVOIR...... 70
MASTER CYLINDER TO POWER BRAKE
BOOSTER VACUUM SEAL............... 69
WHEEL CYLINDER REAR DRUM BRAKE...... 76
CLEANING AND INSPECTION
BRAKE HOSE AND BRAKE LINES
INSPECTION.......................... 78
FRONT DISC BRAKE PAD LINING
INSPECTION.......................... 76
REAR DISC BRAKES..................... 76
REAR DRUM BRAKE SHOE LINING
INSPECTION.......................... 77
REAR DRUM BRAKE WHEEL CYLINDER...... 78
REAR WHEEL HUB AND BEARING
ASSEMBLY........................... 78
ADJUSTMENTS
PARK BRAKE CABLE ADJUSTMENT......... 81
PARK BRAKE SHOES (WITH REAR DISC
BRAKES)............................ 79
PROPORTIONING VALVE
(HEIGHT SENSING).................... 81
REAR DRUM BRAKE SHOE ADJUSTMENT.... 79
STOP LAMP SWITCH..................... 78
SPECIFICATIONS
BRAKE ACTUATION SYSTEM.............. 83
BRAKE FASTENER TORQUE
SPECIFICATIONS...................... 83
NSBRAKES 5 - 3

both the rotor and one wheel stud on the high side of
the runout. This will ensure that the original location
of the rotor in relation to the hub can be retained
(Fig. 14). Remove rotor from hub.
Thoroughly clean the front surface of the front
hub. Then install Dial Indicator, Special Tool C-3339
and Mounting Adaptor, Special Tool SP-1910 on
steering knuckle. Position stem so it contacts hub
face near outer diameter. Care must be taken to posi-
tion stem outside the stud circle but inside the cham-
fer on the hub face (Fig. 15).Clean hub surface
before checking.
Lateral runout should not exceed 0.08 mm (0.003
inch). If runout exceeds this specification, the hub
must be replaced. See Suspension Group 2. If lateral
runout of the hub does not exceed this specification,
install rotor on hub with chalk marks two wheel
studs apart (Fig. 16). Tighten nuts in the properse-
quence and torque to specification. Finally, check lat-eral runout of rotor to see if lateral runout is now
within specification.
If lateral runout is not within specification, install
a new rotor or reface rotor, being careful to remove
as little rotor material as possible from each side of
rotor. Remove equal amounts from each side of rotor.
Do not reduce thickness below minimum thickness
marking cast into the un-machined surface (Fig. 17)
of the rotor .
Thickness variation measurements of the rotor
should be made in conjunction with the lateral
runout measurements. Measure the thickness of the
rotor at 12 circumferentially equal points with a
Fig. 16 Indexing Rotor And Wheel Stud
Fig. 13 Checking Brake Rotor For Runout
Fig. 14 Marking Rotor And Wheel Stud
Fig. 15 Checking Disc Brake Rotor For Runout
NSBRAKES 5 - 15
DIAGNOSIS AND TESTING (Continued)

(4) Remove the locking pliers from the front park
brake cable. This will allow the adjuster in the park
brake pedal mechanism to rotate around to its stop.
This will remove the tension from the adjuster and
front park brake cable.
Use the following procedure to reset the auto
adjuster in the park brake pedal mechanism.
(5) Grasp the exposed section of the front park
brake cable and pull rearward on it. While holding
the park brake in this position, install a pair of lock-
ing pliers on the front park brake cable just rearward
of the second body outrigger bracket (Fig. 42).
(6) Install the equalizer on the front park brake
cable.
(7) Install the left rear and intermediate park
brake cable in the correct location on the park brake
cable equalizer (Fig. 43).
(8) Remove the locking pliers from the front park
brake cable. This will allow the adjuster in the park
brake pedal mechanism to tension the park brake
cables.
(9) Apply and release the park brake pedal one
time. This will seat the park brake cables and allow
the auto adjuster in the park brake pedal mechanism
to correctly tension the park brake cables.
REMOVAL AND INSTALLATION
WHEEL AND TIRE INSTALLATION
To install the wheel and tire assembly, first posi-
tion it properly on the mounting surface using the
hub pilot as a guide. Then progressively tighten thelug nuts in the proper sequence to half of the
required torque. Finally tighten the lug nuts in the
proper sequence to 129 N´m (95 ft. lbs.). Never use
oil or grease on studs or nuts.
FRONT DISC BRAKE CALIPER
SERVICE PRECAUTIONS
WARNING: ALTHOUGH FACTORY INSTALLED
BRAKE LININGS ARE MADE FROM ASBESTOS
FREE MATERIALS, SOME AFTER MARKET BRAKE
LINING MAY CONTAIN ASBESTOS. THIS SHOULD
BE TAKEN INTO ACCOUNT WHEN SERVICING A
VEHICLE'S BRAKE SYSTEM, WHEN AFTERMARKET
BRAKE LININGS MAY HAVE BEEN INSTALLED ON
THE VEHICLE. ALWAYS WEAR A RESPIRATOR
WHEN CLEANING BRAKE COMPONENTS AS
ASBESTOS CAN CAUSE SERIOUS BODILY HARM
SUCH AS ASBESTOSIS AND OR CANCER. NEVER
CLEAN BRAKE COMPONENTS BY USING COM-
PRESSED AIR, USE ONLY A VACUUM CLEANER
SPECIFICALLY DESIGNED FOR THE REMOVAL OF
BRAKE DUST. IF A VACUUM CLEANER IS NOT
AVAILABLE, CLEAN BRAKE PARTS USING ONLY
WATER±DAMPENED SHOP TOWELS. DO NOT CRE-
ATE BRAKELINING DUST BY SANDING BRAKE LIN-
INGS WHEN SERVICING A VEHICLE. DISPOSE OF
ALL DUST AND DIRT SUSPECTED OF CONTAINING
ASBESTOS FIBERS USING ONLY SEALED AIR-
TIGHT BAGS OR CONTAINERS. FOLLOW ALL REC-
OMMENDED SAFETY PRACTICES PRESCRIBED BY
THE OCCUPATIONAL SAFETY AND HEALTH ADMIN-
ISTRATION (OSHA) AND THE ENVIRONMENTAL
PROTECTION AGENCY (EPA), FOR HANDLING AND
DISPOSAL OF PRODUCTS CONTAINING ASBES-
TOS.
CAUTION: During service procedures, grease or
any other foreign material must be kept off brake
shoe assemblies, and braking surfaces of brake
drum and external surfaces of hub/bearing assem-
bly.
REMOVE
(1) Raise vehicle on jackstands or centered on a
hoist. See Hoisting in the Lubrication and Mainte-
nance group of this service manual.
(2) Remove front wheel and tire assemblies.
Fig. 43 Park Brake Cable Attachment To Equalizer
NSBRAKES 5 - 27
SERVICE PROCEDURES (Continued)

(3) Remove the 2 caliper to steering knuckle guide
pin bolts (Fig. 44).
(4) Remove caliper from steering knuckle, by first
rotating free end of caliper away from steering
knuckle. Then slide opposite end of caliper out from
under machined abutment on steering knuckle (Fig.
45).
(5) Support caliper firmly to prevent weight of cal-
iper from being supported by the brake fluid flex
hose. Supporting weight of caliper by the brake fluid
flex hose, can damage the flexible brake hose (Fig.
46).
INSTALL
(1) Lubricate both steering knuckle abutments
with a liberal amount of MopartMultipurpose Lubri-
cant, or equivalent.CAUTION: Use care when installing the caliper
assembly onto the steering knuckle, so the seals on
the caliper guide pin bushings do not get damaged
by the steering knuckle bosses.
(2) Carefully position caliper and brake pad
assemblies over brake rotor by hooking lower or
upper end of caliper over the machined abutment on
steering knuckle (Fig. 45). Then rotate caliper into
position at the top of the steering knuckle (Fig. 45).
Make sure that caliper guide pin bolts, bushings and
sleeves are clear of the steering knuckle bosses.
(3) Install the caliper guide pin bolts (Fig. 44) and
tighten to a torque of 41 N´m (40 ft. lbs.).Extreme
caution should be taken not to cross thread the
caliper guide pin bolts.
(4) Install the wheel and tire assembly.
(5) Using a torque wrench, 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.).
(6) Remove jackstands or lower hoist.
(7)Before moving vehicle, pump the brake
pedal several times to insure the vehicle has a
firm brake pedal.
REAR DISC BRAKE CALIPER
During service procedures, grease or any other for-
eign material must be kept off brake shoe assem-
blies, and braking surfaces of rotor.
Handling of the rotor and caliper, must be done in
such a way as to avoid damage to the rotor and
scratching or nicking of lining on the brake shoes.
If inspection reveals that the caliper piston seal is
leaking, itMUSTbe replaced immediately.
During removal and installation of a wheel and
tire assembly, use care not to strike the caliper.
Fig. 44 Removing Caliper Guide Pin Bolts
Fig. 45 Caliper Assembly Mounting On Steering
Knuckle (Typical)
Fig. 46 Storing Front Disc Brake Caliper
5 - 28 BRAKESNS
REMOVAL AND INSTALLATION (Continued)