1996 CHRYSLER VOYAGER Service Manual

(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)

LOWER CONTROL ARM FRONT BUSHING
REMOVE
(1) Remove the lower control arm from the front
suspension cradle. Refer to Lower Control Arm in the
Removal And Installation Section in this section of
the service manual for the required procedure.
(2) Securely mount the lower control arm in a vise.
(3) Assemble for removal of the front bushing, the
Bushing Receiver, Special Tool 6908±2, Bushing
Remover, Special Tool 6908±1, Nut, Special Tool
6908±3 thrust washer, threaded rod and small nut,
as shown in (Fig. 82) on the lower control arm and
front bushing.
(4) To remove front bushing from lower control
arm, hold the threaded rod stationary and tighten
the Nut, Special Tool 6908±3 (Fig. 82). This will force
the front bushing out of the lower control arm and
into Bushing Receiver, Special Tool 6908±2 (Fig. 82).
INSTALL
(1) Securely mount the lower control arm in a vise.
NOTE: The lower control arm front bushing is a
directional bushing. It must be installed in the lower
control arm positioned as shown in (Fig. 83).
(2) Position the front bushing in the lower control
arm so that the 2 rubber blocks on the bushing are
positioned horizontally as shown in (Fig. 83).
(3) Assemble for installation of the front bushing,
the Bushing Receiver, Special Tool 6908±5, Bushing
Installer, Special Tool 6908±4, Nut, Special Tool
6908±3 thrust washer, threaded rod and small nut,
as shown in (Fig. 84) on the lower control arm and
front bushing.
(4) To install the front bushing in lower control
arm, hold the threaded rod stationary and tighten
Fig. 81 Installing Ball Joint Seal Boot
Fig. 82 Tools Assembled For Removal Of Front
Bushing
Fig. 83 Installation Position Of Lower Control Arm
Front Bushing
Fig. 84 Tools Assembled For Installation Of Front
Bushing
2 - 34 SUSPENSIONNS
DISASSEMBLY AND ASSEMBLY (Continued)

the Nut, Special Tool 6908±3 (Fig. 84). This will pull
the front bushing into the lower control arm.
(5) Continue pulling the bushing into the lower
control arm until bushing is seated squarely against
the lower control arm and there is no gap between
the bushing and the lower control arm (Fig. 85).
(6) Install the lower control arm on the front sus-
pension cradle. Refer to Lower Control Arm in the
Removal And Installation Section in this group of the
service manual for the required procedure.
LOWER CONTROL ARM REAR BUSHING
REMOVE
(1) Remove the lower control arm from the front
suspension cradle. Refer to Lower Control Arm in the
Removal And Installation Section in this group of the
service manual for the required procedure.
(2) Mount the lower control arm in a visewithout
using excessive clamping force.
(3) Using a sharp knife, (such as a razor) slit the
bushing lengthwise (Fig. 86) to allow its removal
from the lower control arm (Fig. 86).
(4) Remove the bushing from the lower control
arm.
INSTALL
CAUTION: Do not apply grease or any other type of
lubricant other than the silicone lubricant specified
below to the control arm bushing.
(1) Apply Mopar Silicone Spray Lube or an equiv-
alent, to the hole in lower control arm rear bushing.
This will aid in the installation of the bushing on the
lower control arm.
(2) With the lower control arm held securely in a
vise, install bushing on lower control arm. Installbushing by pushing and rocking the bushing until it
is fully installed on lower control arm. Be sure when
bushing is installed it is past the upset on the end of
the lower control arm (Fig. 87).
(3) The rear bushing of the lower control arm,
when correctly installed, is to be positioned on the
lower control arm as shown in (Fig. 87).
STABILIZER BAR BUSHING
Disassembly/Assembly
(1) If stabilizer bar to front suspension cradle
bushings require replacement at time of inspection,
install new bushings before installing stabilizer bar.
Stabilizer bar bushings are replaced by opening the
slit on the bushings and peeling them off the stabi-
lizer bar. Install new bushings on stabilizer bar, by
spreading bushing at slit and forcing them on stabi-
lizer bar.
Fig. 85 Correctly Installed Lower Control Arm
Bushing
Fig. 86 Slit Lower Control Arm Rear Bushing
Fig. 87 Correctly Installed Lower Control Arm
Bushing
NSSUSPENSION 2 - 35
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)