1996 CHRYSLER VOYAGER steering

(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)

LOWER CONTROL ARM
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 wheel and tire assembly from the side
of vehicle requiring service to the lower control arm.
(3) Remove the wheel stop (Fig. 28) from the steer-
ing knuckle.When installing the pinch bolt when
assembling the steering knuckle to the ball
joint, the pinch bolt must be installed from the
rear facing the front on the vehicle (Fig. 28).
(4) Remove the nut and bolt clamping the steering
knuckle to the ball joint stud. (Fig. 29)NOTE: The attaching bolts for the cradle plate are
of two different thread sizes. Nine of the bolts are a
M-14 thread and one of the bolts is a M-12 thread.
Refer to (Fig. 30) for the cradle plate attaching bolt
locations.
(5) Remove the 10 bolts (Fig. 30) attaching the cra-
dle plate to the front suspension cradle. Then remove
the cradle plate from the cradle.
CAUTION: Pulling steering knuckle out from vehi-
cle after releasing from ball joint can separate inner
C/V joint. See Driveshafts.
(6) Using a pry bar, separate steering knuckle
from ball joint stud (Fig. 31).Use caution when
separating ball joint stud from steering
knuckle, so ball joint seal does not get cut.
Fig. 28 Wheel Stop Location On Steering Knuckle
Fig. 29 Control Arm To Steering Knuckle
Attachment
Fig. 30 Front Suspension Cradle Plate And
Mounting Bolts
Fig. 31 Separating Ball Joint Stud From Steering
Knuckle
NSSUSPENSION 2 - 19
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)

BALL JOINT
REMOVE
(1) Using a screw driver or other suitable tool, pry
the seal boot off of the ball joint assembly (Fig. 39)
(2) Position receiving cup, Special Tool 6758 to
support lower control arm when removing ball joint
assembly (Fig. 40). Install Remover, Special Tool
6919 on top of the ball joint assembly (Fig. 40).
(3) Using the arbor press, press the ball joint
assembly completely out of the lower control arm.
INSTALL
NOTE: When installing ball joint in lower control
arm, position the ball joint in control arm so notch
in ball joint stud is in the direction shown (Fig. 41).
This will ease assembly of the ball joint to the
steering when installing pinch bolt.(1) By hand, position ball joint into ball joint bore
of lower control arm.Be sure ball joint is not
cocked in the bore of the control arm, this will
cause the ball joint to bind when being pressed
into control arm.
(2) Position control arm with installed ball joint, in
an arbor press with Receiving Cup, Special Tool 6758
supporting the lower control arm (Fig. 42). Then cen-
ter Installer, Special Tool 6908±4 on the bottom of
the ball joint (Fig. 42)
(3) Carefully align all pieces. Then press the ball
joint into the lower control arm until it is completely
seated against surface of lower control arm. The ball
joint is correctly installed when there is no gap
between the ball joint and the lower control arm (Fig.
43).Do not apply excessive force against the
ball joint or the lower control arm.
Fig. 39 Ball Joint Seal Boot Removal
Fig. 40 Ball Joint Removal From Lower Control Arm
Fig. 41 Installation Position Of Ball Joint In Control
Arm
Fig. 42 Installing Ball Joint In Control Arm
2 - 22 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)

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
supported by the tires.
(3) With the aid of a helper applying the brakes to
keep the front hub from turning,loosen but do not
removethe hub nut.The hub and driveshaft are
splined together through the knuckle (bearing)
and retained by the hub nut.
(4) 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.
(5) Remove wheel lug nuts, and front tire and
wheel assembly.
(6) Remove front disc brake caliper to steering
knuckle attaching bolts. (Fig. 54).
(7) Remove disc brake caliper assembly from 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. (Fig. 55)
(8) Support disc brake caliper assembly using a
wire hook, (Fig. 56)do not hang caliper assembly
by hydraulic hose.
(9) Remove the braking disc from the front hub/
bearing assembly.
(10) Remove the retaining nut and the washer
(Fig. 57) from the end of the stub axle.
(11) Remove the four hub and bearing assembly
mounting bolts from the rear of steering knuckle
(Fig. 58).
(12) Remove the hub and bearing assembly from
the steering knuckle (Fig. 59).
Fig. 54 Front Disc Brake Caliper Mounting Bolts
Fig. 55 Brake Caliper Assembly Removal/Installation
Fig. 56 Supporting Brake Caliper
Fig. 57 Hub/Bearing To Stub Axle Retaining Nut And
Washer
2 - 26 SUSPENSIONNS
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)