1996 CHRYSLER VOYAGER Service Manual

(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)

(7) Loosen but do not remove the pivot bolt (Fig.
32) attaching the front bushing of the lower control
arm to the front suspension cradle.
(8) Remove retainer (Fig. 33) attaching rear bush-
ing of lower control arm to front suspension cradle.
CAUTION: Make location reference marks where
the front suspension cradle is mounted against the
front frame rails before loosening and lowering the
cradle. This is required so the cradle can be re-in-
stalled in the design location to achieve proper
front suspension alignment.
(9) Loosen but not fully removing the 2 left side
suspension cradle to frame rail attaching bolts (Fig.
34).
NOTE: When removing the left lower control arm
from the vehicle, the front suspension cradle needsto be lowered for the pivot bolt to clear the tran-
saxle.
(10) Lower the left front corner of the suspension
cradle until pivot bolt will clear end of transaxle (Fig.
35). Remove the pivot bolt and the lower control arm
from the cradle.
INSTALL
NOTE: If the left lower control arm is being
installed on the vehicle the front suspension cradle
needs to be lowered for the pivot bolt to clear the
transaxle.
(1) Position lower control arm assembly into front
suspension cradle.If installing the left lower con-
trol arm, pry down on the left front corner of
the suspension cradle until the pivot bolt clears
the end of the transaxle (Fig. 35).Install pivot
bolt attaching front bushing of lower control arm to
front
Fig. 32 Lower Control Arm Bushing To Cradle Pivot
Bolt
Fig. 33 Control Arm Bushing To Suspension Cradle
Retainer
Fig. 34 Suspension Cradle To Frame Rail Mounting
Bolts
Fig. 35 Lowering Front Suspension Cradle
2 - 20 SUSPENSIONNS
REMOVAL AND INSTALLATION (Continued)