1996 CHRYSLER VOYAGER ABS

DISCONNECT CABLE CLAMPS AS FOLLOWS:
²Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
²When using a Booster vehicle, disconnect
BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive
terminal.
²Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle.
TOWING RECOMMENDATIONS
WARNINGS AND CAUTIONS
WARNING: DO NOT ALLOW TOWING ATTACH-
MENT DEVICES TO CONTACT THE FUEL TANK OR
LINES, FUEL LEAK CAN RESULT.
DO NOT LIFT OR TOW VEHICLE BY FRONT OR
REAR BUMPER, OR BUMPER ENERGY ABSORBER
UNITS.
DO NOT GO UNDER A LIFTED VEHICLE IF NOT
SUPPORTED PROPERLY ON SAFETY STANDS.
DO NOT ALLOW PASSENGERS TO RIDE IN A
TOWED VEHICLE.
USE A SAFETY CHAIN THAT IS INDEPENDENT
FROM THE TOWING ATTACHMENT DEVICE.
CAUTION: Do not damage brake lines, exhaust sys-
tem, shock absorbers, sway bars, or any other
under vehicle components when attaching towing
device to vehicle.
Do not attach towing device to front or rear sus-
pension components.
Do not secure vehicle to towing device by the use
of front or rear suspension or steering components.
Remove or secure loose or protruding objects
from a damaged vehicle before towing.
Refer to state and local rules and regulations
before towing a vehicle.
Do not allow weight of towed vehicle to bear on
lower fascia, air dams, or spoilers.
RECOMMENDED TOWING EQUIPMENT
To avoid damage to bumper fascia and air dams
use of a flat bed towing device or wheel lift (Fig. 2) is
recommended. When using a wheel lift towing device,
be sure the disabled vehicle has at least 100 mm (4
in.) ground clearance. If minimum ground clearance
cannot be reached, use a towing dolly. If a flat bed
device is used, the approach angle should not exceed
15 degrees.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels
removed, install lug nuts to retain brake drums or
rotors.
A towed vehicle should be raised until the lifted
wheels are a minimum 100 mm (4 in.) from the
ground. Be sure there is at least 100 mm (4 in.)
clearance between the tail pipe and the ground. If
necessary, remove the wheels from the lifted end of
the vehicle and lower the vehicle closer to the
ground, to increase the ground clearance at the rear
of the vehicle. Install lug nuts on wheel attaching
studs to retain brake drums or rotors.
LOCKED VEHICLE TOWING
When a locked vehicle must be towed with the
front wheels on the ground, use a towing dolly or flat
bed hauler.
FLAT TOWING WITH TOW BAR
²3-speed automatic transaxle vehicles can be flat
towed at speeds not to exceed 40 km/h (25 mph) for
not more than 25 km (15 miles). The steering column
must be unlocked and gear selector in neutral.
²4-speed electronic automatic transaxle vehicles
can be flat towed at speeds not to exceed 72 km/h (44
mph) for not more than 160 km (100 miles). The
steering column must be unlocked and gear selector
in neutral.
FLAT BED TOWING TIE DOWNS
CAUTION: Do not tie vehicle down by attaching
chains or cables to suspension components or
engine mounts, damage to vehicle can result.
NS vehicles can be tied to a flat bed device using
the reinforced loops located under the front and rear
bumpers on the drivers side of the vehicle. There are
also four reinforced elongated holes for T or R-hooks
located on the bottom of the front frame rail torque
Fig. 2 Recommended Towing Devices
0 - 8 LUBRICATION AND MAINTENANCENS
SERVICE PROCEDURES (Continued)

JUMP STARTING, HOISTING AND TOWING
INDEX
page
SERVICE PROCEDURES
TOWING RECOMMENDATIONS............. 5
SERVICE PROCEDURES
TOWING RECOMMENDATIONS
WARNINGS AND CAUTIONS
WARNING: DO NOT ALLOW TOWING ATTACH-
MENT DEVICES TO CONTACT THE FUEL TANK OR
LINES, FUEL LEAK CAN RESULT.
DO NOT LIFT OR TOW VEHICLE BY FRONT OR
REAR BUMPER, OR BUMPER ENERGY ABSORBER
UNITS.
DO NOT GO UNDER A LIFTED VEHICLE IF NOT
SUPPORTED PROPERLY ON SAFETY STANDS.
DO NOT ALLOW PASSENGERS TO RIDE IN A
TOWED VEHICLE.
USE A SAFETY CHAIN THAT IS INDEPENDENT
FROM THE TOWING ATTACHMENT DEVICE.
CAUTION: Do not damage brake lines, exhaust sys-
tem, shock absorbers, sway bars, or any other
under vehicle components when attaching towing
device to vehicle.
Do not attach towing device to front or rear sus-
pension components.
Do not secure vehicle to towing device by the use
of front or rear suspension or steering components.
Remove or secure loose or protruding objects
from a damaged vehicle before towing.
Refer to state and local rules and regulations
before towing a vehicle.
Do not allow weight of towed vehicle to bear on
lower fascia, air dams, or spoilers.
RECOMMENDED TOWING EQUIPMENT
To avoid damage to bumper fascia and air dams
use of a flat bed towing device or wheel lift (Fig. 1) is
recommended. When using a wheel lift towing device,
be sure the disabled vehicle has at least 100 mm (4
in.) ground clearance. If minimum ground clearance
cannot be reached, use a towing dolly. If a flat bed
device is used, the approach angle should not exceed
15 degrees.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels
removed, install lug nuts to retain brake drums or
rotors.
A towed vehicle should be raised until the lifted
wheels are a minimum 100 mm (4 in.) from the
ground. Be sure there is at least 100 mm (4 in.)
clearance between the tail pipe and the ground. If
necessary, remove the wheels from the lifted end of
the vehicle and lower the vehicle closer to the
ground, to increase the ground clearance at the rear
of the vehicle. Install lug nuts on wheel attaching
studs to retain brake drums or rotors.
LOCKED VEHICLE TOWING
When a locked vehicle must be towed with the
front wheels on the ground, use a towing dolly or flat
bed hauler.
FLAT TOWING WITH TOW BAR
²4-speed electronic automatic transaxle vehicles
can be flat towed at speeds not to exceed 72 km/h (44
mph) for not more than 160 km (100 miles). The
steering column must be unlocked and gear selector
in neutral.
FLAT BED TOWING TIE DOWNS
CAUTION: Do not tie vehicle down by attaching
chains or cables to suspension components or
engine mounts, damage to vehicle can result.
Fig. 1 Recommended Towing Devices
NS/GSLUBRICATION AND MAINTENANCE 0 - 5

FRONT SUSPENSION
INDEX
page page
DESCRIPTION AND OPERATION
BALL JOINT............................ 11
COIL SPRING........................... 11
FRONT SUSPENSION DESCRIPTION......... 9
HUB AND BEARING ASSEMBLY............ 10
LOWER CONTROL ARM.................. 10
Mc PHERSON STRUT ASSEMBLY........... 10
STABILIZER BAR ATTACHING LINK.......... 10
STABILIZER BAR........................ 10
STEERING KNUCKLE.................... 10
SUSPENSION CRADLE (CROSSMEMBER)..... 9
WHEEL MOUNTING STUDS................ 11
DIAGNOSIS AND TESTING
BALL JOINT (LOWER).................... 12
HUB AND BEARING ASSEMBLY............ 12
LOWER CONTROL ARM.................. 12
Mc PHERSON STRUT.................... 11
STABILIZER BAR........................ 12
STEERING KNUCKLE.................... 12SERVICE PROCEDURES
SUSPENSION CRADLE THREAD REPAIR
PROCEDURE......................... 12
REMOVAL AND INSTALLATION
BALL JOINT............................ 22
FRONT WHEEL MOUNTING STUDS......... 28
HUB AND BEARING ASSEMBLY............ 25
LOWER CONTROL ARM.................. 19
Mc PHERSON STRUT.................... 13
REAR WHEEL MOUNTING STUDS.......... 29
STABILIZER BAR........................ 23
STEERING KNUCKLE.................... 14
DISASSEMBLY AND ASSEMBLY
BALL JOINT SEAL BOOT.................. 33
LOWER CONTROL ARM FRONT BUSHING.... 34
LOWER CONTROL ARM REAR BUSHING..... 35
Mc PHERSON STRUT.................... 30
STABILIZER BAR BUSHING................ 35
SPECIFICATIONS
FRONT SUSPENSION FASTENER TORQUES . . 36
SPECIAL TOOLS
FRONT SUSPENSION.................... 37
DESCRIPTION AND OPERATION
FRONT SUSPENSION DESCRIPTION
An independent Mc Pherson Strut type front sus-
pension is used on these vehicles. Vertical shock
absorbing Mc Pherson Struts attach to the top of the
steering knuckle and to the front strut tower. This
interconnection between the steering knuckle and the
body of the vehicle, provides for the correct steering
knuckle position. This steering knuckle position pro-
vides for the correct front Caster and Camber set-
tings for the vehicle, at the time the vehicle is
designed.
Lower control arms are attached inboard to the
cast aluminum front suspension cradle and outboard
to the bottom of the steering knuckle. Attachment of
the lower control arm to the steering knuckle is done
through a ball joint in the lower control arm.
During steering maneuvers, the strut and the
steering knuckle (through the ball joint and a pivot
bearing in the strut's upper retainer) turn as an
assembly.
SUSPENSION CRADLE (CROSSMEMBER)
This vehicle uses a one piece cast aluminum cradle
for the front suspension. The cradle is used as theattaching points for the lower control arms, stabilizer
bar and steering gear. The cradle also has the power
steering hoses and the chassis brake tubes attached
to it.
The cradle is mounted to the front frame rails at
four points, two on each side of the vehicle. The cra-
dle is isolated from the body of the vehicle using four
isolators, one located at each mounting bolt location.
WARNING: If a threaded hole in the suspension
cradle needs to be repaired, only use the type of
thread insert and installation procedure specified
for this application.
The threaded holes in the cradle that are
used for attachment of the lower control arm
rear bushing retainer, power steering hose and
chassis brake tubes can be repaired. The repair
is done by the installation of a Heli-Coilt
thread insert which has been specifically devel-
oped for this application. Refer to the Mopar
Parts Catalog for the specified Heli-Coil thread
insert to be used for this application. The pro-
cedure for installing the Heli-Coiltthread
insert is detailed in the Service Procedures sec-
tion in this group of the service manual.
NSSUSPENSION 2 - 9

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)

REAR SUSPENSION
INDEX
page page
GENERAL INFORMATION
REAR SUSPENSION..................... 38
DESCRIPTION AND OPERATION
REAR TRACK BAR....................... 39
REAR WHEEL ALIGNMENT................ 39
SHOCK ABSORBERS (REAR LOAD LEVELING) . 40
STABILIZER BAR........................ 39
REMOVAL AND INSTALLATION
JOUNCE BUMPER....................... 46
LEAF SPRING FRONT MOUNT............. 47LEAF SPRING REAR MOUNT.............. 47
REAR SPRINGS (AWD)................... 43
REAR SPRINGS (FWD)................... 40
REAR TRACK BAR....................... 45
SHOCK ABSORBER...................... 45
STABILIZER BAR........................ 46
TRACK BAR MOUNT..................... 45
SPECIFICATIONS
REAR SUSPENSION FASTENER TORQUES . . . 48
GENERAL INFORMATION
REAR SUSPENSION
The rear suspension design on this vehicle uses
leaf springs and a tube and casting axle (Fig. 1) and
(Fig. 2). It is designed to handle the various load
requirements of the vehicle. The leaf springs used on
the rear suspension of this vehicle are of either a
mono-leaf or multi-leaf design.The rear axle used on front wheel drive applica-
tions of this vehicle is mounted to the rear leaf
springs using isolator bushings at the axle mounting
brackets.
The rear axle used on all wheel drive applications
of this vehicle is also mounted to the rear leaf
springs but does not use isolator bushings between
the rear axle and the leaf springs.
Fig. 1 Front Wheel Drive Rear Suspension
2 - 38 SUSPENSIONNS

The rear suspension used on the front wheel drive
commercial version of this vehicle is unique to this
application. The rear axle is mounted to the rear leaf
springs as on the non-commercial application of this
vehicle but does not use any isolators between the
spring and the axle. The leaf spring used on the com-
mercial version of this vehicle is a multi-leaf spring
but is a unique design for the commercial applica-
tion.
The rear leaf spring shackle angles provide
increasing suspension rates as the vehicle is loaded.
This provides a comfortable unloaded ride and also
ample rear suspension travel when the vehicle is
loaded.
A new type of load-leveling shock is available. The
self leveling shock absorbers are a self-contained
vehicle leveling system and shock absorber combined.
The shock absorbers are mounted at an angle, paral-
lel to the springs and forward at the top. This design
provides greater stability in addition to controlling
ride motion.
The rear wheel bearings used are similar to the
bearings used in the front wheels. The bearings are
permanently sealed and require no maintenance. The
bearing and hub are serviced as an assembly. For
service procedures, refer to Group 5, Brakes.DESCRIPTION AND OPERATION
REAR WHEEL ALIGNMENT
Alignment adjustment is not required. The rear
axle alignment settings are preset at the factory and
therefore no alignment is necessary.
REAR TRACK BAR
On front wheel drive applications of this vehicle
that are equipped with single leaf rear springs a
track bar (Fig. 3) is used on the rear axle.
The track bar connects the rear axle to the frame/
body of the vehicle. The track bar is isolated from the
body of the vehicle by an isloator bushing located in
each end of the track bar.
The track bar (Fig. 3) prevents excessive side to
side movement of the rear axle. The track bar is used
to keep the location of the axle in the correct position
for optimum handling and control of the vehicle.
STABILIZER BAR
The stabilizer bar (Fig. 4) interconnects both sides
of the rear axle and attaches to the rear frame rails
using 2 rubber isolated link arms.
Jounce and rebound movements affecting one
wheel are partially transmitted to the opposite wheel
to reduce body roll.
Fig. 2 All Wheel Drive Rear Suspension
NSSUSPENSION 2 - 39
GENERAL INFORMATION (Continued)

Attachment to the rear axle tube, and rear frame
rails is through rubber-isolated bushings. All parts
are serviceable, and the stabilizer bar to axle bush-
ings are split for easy removal and installation. The
split in the bushing should be positioned up when
the stabilizer bar is installed on the vehicle.
The 2 rubber isolated link arms are connected to
the rear frame rails by brackets. These brackets are
bolted to the bottom of the frame rails.
SHOCK ABSORBERS (REAR LOAD LEVELING)
A new type of load-leveling shock is available. The
self leveling shock absorbers are a self-contained
vehicle leveling system and shock absorber combined.
It does not require an external compressor, hoses,height leveling sensors, etc. It uses road inputs
(bumps, stops, starts, turns, acceleration, decelera-
tion, etc.) to activate pumping, which is just the
extension and compression of the shock absorber. On
the outside, it looks like a larger than normal shock
absorber. Internally, it consists of a hydraulic pump
and gas-spring cushion for leveling, as well as the
normal shock absorbing mechanism. All the height
leveling sensors, pump, etc., are contained inside the
shocks. The shocks are mounted at an angle, parallel
to the springs and forward at the top. This design
provides greater stability in addition to controlling
ride motion. These new load-leveling shock absorbers
use longer fasteners than the standard shock absorb-
ers, although the fasteners are longer, the torque
specifications are the same.
REMOVAL AND INSTALLATION
REAR SPRINGS (FWD)
REMOVAL
(1) Raise vehicle on frame contact hoist to a com-
fortable working position.
(2) Support axle with a jack stand. Pad should just
contact axle.
(3) Begin removal of the shock absorber lower
mounting bolt (Fig. 5).
Fig. 4 Stabilizer Bar
Fig. 3 Rear Track Bar
2 - 40 SUSPENSIONNS
DESCRIPTION AND OPERATION (Continued)

NOTE: If shock absorber bolt deflects upward dur-
ing removal, raise axle by adjusting support jack. If
shock absorber bolt deflects downward during
removal, lower axle by adjusting support jack (or by
pulling on axle).
(4) Using 2 jack stands positioned under the outer
ends of the axle, raise the axle enough to remove the
weight of the axle from the rear springs.
(5) Loosen and remove the axle plate bolts from
the rear axle (Fig. 6).
(6) Remove the axle plate from the rear axle and
the leaf spring (Fig. 7).
(7) Using the jack standsslowlylower the rear
axle, permitting the rear springs to hang free.
(8) Loosen and remove the 4 bolts (Fig. 8) from the
front mount of the leaf spring.
(9) Loosen and remove the nuts from the spring
hanger (Fig. 9) for the rear leaf spring. Then remove
the hanger plate from the hanger and remove the
spring from the spring hanger (Fig. 9).
Fig. 5 Rear Shock Mounting Bolt
Fig. 6 Axle Plate Bolts
Fig. 7 Axle Plate
Fig. 8 Leaf Spring Front Mount
Fig. 9 Rear Spring Hanger
NSSUSPENSION 2 - 41
REMOVAL AND INSTALLATION (Continued)