1996 CHRYSLER VOYAGER Service Manual

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Page 57 of 1938

CHRYSLER VOYAGER 1996 Service Manual 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)

Page 58 of 1938

CHRYSLER VOYAGER 1996 Service Manual 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

Page 59 of 1938

CHRYSLER VOYAGER 1996 Service Manual 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

Page 60 of 1938

CHRYSLER VOYAGER 1996 Service Manual 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

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)

Page 61 of 1938

CHRYSLER VOYAGER 1996 Service Manual (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 m

(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)

Page 62 of 1938

CHRYSLER VOYAGER 1996 Service Manual (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 h

(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)

Page 63 of 1938

CHRYSLER VOYAGER 1996 Service Manual and right springs for installation back on cor-
rect side of vehicle.(8) Remove the dust shield and jounce bumper
(Fig. 73) as an assembly from the strut shaft. The
dust shield can not be removed from

Page 64 of 1938

CHRYSLER VOYAGER 1996 Service Manual ²Inspect jounce bumper for cracks and signs of
deterioration.
(13) Replace any components of the strut assembly
found to be worn or defective during the inspection,
before re-assembling the strut.
AS

²Inspect jounce bumper for cracks and signs of
deterioration.
(13) Replace any components of the strut assembly
found to be worn or defective during the inspection,
before re-assembling the strut.
ASSEMBLY
(1) Clamp strut in vise, with strut in vertical posi-
tion.Do not clamp strut in vise by body of strut,
only by the clevis bracket (Fig. 68).
(2) Install the spring isolator on the strut lower
spring seat (Fig. 74). When installing the spring iso-
lator, be sure the 2 retaining tabs on the spring iso-
lator (Fig. 74) are installed in the 2 holes in the
spring seat. When properly installed, the oversize
holes in the spring seat should line up with the holes
in the spring isolator.
(3) Install the jounce bumper (Fig. 75) on the strut
shaft. Jounce bumper is to be installed with the
small end of the jounce bumper pointing down (Fig.
75).
(4) Install dust shield (Fig. 76) on the strut.After
dust shield is installed on strut, collapse dust
shield down on top of jounce bumper until
jounce bumper snaps into dust shield. Then
return the dust shield to its fully extended
length.
(5) Install coil spring on strut. Spring is to be
installed with the end of the bottom coil aligned with
the clevis bracket on the strut assembly (Fig. 77).
(6) Install the upper spring seat on the coil spring
(Fig. 77). Spring seat must be installed with the
notch in the spring seat (Fig. 77) aligned with the
clevis bracket on the strut.
WARNING: WHEN COMPRESSING THE COIL
SPRING, THE COIL SPRING UPPER SEAT AND THE
BOTTOM COIL OF THE SPRING MUST BE CAP-TURED BY THE JAWS OF THE COIL SPRING COM-
PRESSOR.
(7) Compress strut coil spring using Pentastar Ser-
vice Equipment Spring Compressor, 7522A (Fig. 69).
Be sure the top and bottom attachment shoe selected,
(Fig. 69) properly fit the coil spring.
(8) Install the pivot bearing on the top of the
upper spring seat (Fig. 78).Bearing must be
installed on spring seat with the smaller diam-
eter side of the pivot bearing toward the spring
seat (Fig. 78). Also, be sure the pivot bearing is
sitting flat on the spring seat.
(9) Install the strut mount on the upper spring
seat of the strut. Loosely install the nut on strut
shaft.
WARNING: THE FOLLOWING 2 STEPS MUST BE
COMPLETELY DONE BEFORE SPRING COMPRES-
SOR IS RELEASED FROM THE COIL SPRING.
Fig. 75 Correctly Installed Jounce Bumper
Fig. 76 Installing Dust Boot
Fig. 77 Coil Spring And Spring Seat Correctly
Installed
2 - 32 SUSPENSIONNS
DISASSEMBLY AND ASSEMBLY (Continued)

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