1996 CHRYSLER VOYAGER boot

MAINTENANCE SCHEDULES
INDEX
page page
GENERAL INFORMATION
INTRODUCTION......................... 3
SCHEDULE ± A.......................... 3SCHEDULE ± B.......................... 4
UNSCHEDULED INSPECTION............... 3
GENERAL INFORMATION
INTRODUCTION
Service and maintenance procedures for compo-
nents and systems listed in Schedule ± A or B can be
found by using the Group Tab Locator index at the
front of this manual. If it is not clear which group
contains the information needed, refer to the index at
the back of this manual.
There are two maintenance schedules that show
proper service based on the conditions that the vehi-
cle is subjected to.
Schedule ±A, lists scheduled maintenance to be
performed when the vehicle is used for general trans-
portation.
Schedule ±B, lists maintenance intervals for vehi-
cles that are operated under the conditions listed at
the beginning of the Maintenance Schedule section.
Use the schedule that best describes your driving
conditions.
Where time and mileage are listed, follow the
interval that occurs first.
UNSCHEDULED INSPECTION
At Each Stop for Fuel
²Check engine oil level, add as required.
²Check windshield washer solvent and add if
required.
Once a Month
²Check tire pressure and look for unusual wear
or damage.
²Inspect battery and clean and tighten terminals
as required.
²Check fluid levels of coolant reservoir, brake
master cylinder, power steering and transaxle and
add as needed.
²Check all lights and all other electrical items for
correct operation.
²Check rubber seals on each side of the radiator
for proper fit.
At Each Oil Change
²Inspect exhaust system.
²Inspect brake hoses
²Inspect the CV joints and front suspension com-
ponents
²Rotate the tires at each oil change interval
shown on Schedule ± A (7,500 miles) or every other
interval shown on Schedule ± B (6,000 miles).
²Check the coolant level, hoses, and clamps.
²If your mileage is less than 7,500 miles (12 000
km) yearly, replace the engine oil filter at each oil
change.
²Replace engine oil filter on 2.4L engines.
SCHEDULE ± A
7,500 Miles (12 000 km) or at 6 months
²Change engine oil.
15,000 Miles (24 000 km) or at 12 months
²Change engine oil.
²Replace engine oil filter.
22,500 Miles (36 000 km) or at 18 months
²Change engine oil.
²Inspect brake linings.
30,000 Miles (48 000 km) or at 24 months
²Change engine oil.
²Change automatic transmission fluid.
²Replace engine oil filter.
²Replace air cleaner element.
²Inspect tie rod ends and boot seals.
37,500 Miles (60 000 km) or at 30 months
²Change engine oil.
45,000 Miles (72 000 km) or at 36 months
²Change engine oil.
²Replace engine oil filter.
²Inspect brake linings.
²Flush and replace engine coolant at 36 months,
regardless of mileage.
NSLUBRICATION AND MAINTENANCE 0 - 3

52,500 Miles (84 000 km) or at 42 months
²Change engine oil.
²Flush and replace engine coolant if not done at
36 months.
60,000 Miles (96 000 km) or at 48 months
²Change engine oil.
²Replace engine oil filter.
²Replace air cleaner element.
²Check PCV valve and replace, if necessary.
*
²Inspect serpentine drive belt, replace if neces-
sary.
²Inspect tie rod ends and boot seals.
67,500 Miles (108 000 km) or at 54 months
²Change engine oil.
²Inspect brake linings.
75,000 Miles (120 000 km) or at 60 months
²Change engine oil.
²Replace engine oil filter.
²Inspect serpentine drive belt, replace if neces-
sary. This maintenance is not required if belt was
previously replaced.
²Flush and replace engine coolant if it has been
30,000 miles (48 000 km) or 24 months since last
change.
82,500 Miles (132 000 km) or at 66 months
²Change engine oil.
²Flush and replace engine coolant if it has been
30,000 miles (48 000 km) or 24 months since last
change.
90,000 Miles (144 000 km) or at 72 months
²Change engine oil.
²Replace engine oil filter.
²Replace air cleaner element.
²Check PCV valve and replace, if necessary.
Not required if previously changed. *
²Inspect serpentine drive belt, replace if neces-
sary. This maintenance is not required if belt was
previously replaced.
²Inspect tie rod ends and boot seals.
²Inspect brake linings.
97,500 Miles (156 000 km) or at 78 months
²Change engine oil.
100,000 Miles (160,000 km)
²Replace spark plugs on 3.3L and 3.8L
engines.
²Replace ignition cables on 3.3L and 3.8L
engines.
105,000 Miles (168 000 km) or at 84 months
²Change engine oil.
²Replace engine oil filter.
²Inspect serpentine drive belt, replace if neces-
sary. This maintenance is not required if belt was
previously replaced.
²Flush and replace engine coolant if it has been
30,000 miles (48 000 km) or 24 months since last
change.
112,500 Miles (180 000 km) or at 90 months
²Change engine oil.
²Inspect brake linings.
²Flush and replace engine coolant if it has been
30,000 miles (48 000 km) or 24 months since last
change.
120,000 Miles (192 000 km) or at 96 months
²Change engine oil.
²Replace engine oil filter.
²Replace automatic transmission fluid.
²Replace engine air cleaner element.
²Check and replace PCV valve, if necessary.
*
²Inspect serpentine drive belt. Not required if
replaced at 75,000, 90,000 or 105,000 miles.
²Inspect tie rod ends and boot seals.
* This maintenance is recommended by Chrysler to
the owner but is not required to maintain the war-
ranty on the PCV valve.
** If California vehicle, this maintenance is recom-
mended by Chrysler to the owner but is not required
to maintain the warranty of the timing belt.
SCHEDULE ± B
3,000 Miles (5 000 km)
²Change engine oil.
6,000 Miles (10 000 km)
²Change engine oil.
²Replace engine oil filter.
9,000 Miles (14 000 km)
²Change engine oil.
²Inspect brake linings.
12,000 Miles (19 000 km)
²Change engine oil.
²Replace engine oil filter.
15,000 Miles (24 000 km)
²Change engine oil.
²Inspect air cleaner element. Replace as
necessary.
0 - 4 LUBRICATION AND MAINTENANCENS
GENERAL INFORMATION (Continued)

²Drain and refill automatic transmission fluid
and replace filter. Adjust bands, if so equipped. (See
note)
²Change AWD powertransfer fluid unit.
18,000 Miles (29 000 km)
²Change engine oil.
²Replace engine oil filter.
²Inspect brake linings.
21,000 Miles (34 000 km)
²Change engine oil.
²Check AWD overrunning clutch and rear carrier
fluid.
24,000 Miles (38 000 km)
²Change engine oil.
²Replace engine oil filter.
27,000 Miles (43 000 km)
²Change engine oil.
²Inspect brake linings.
30,000 Miles (48 000 km)
²Change engine oil.
²Replace engine oil filter.
²Replace air cleaner element.
²Inspect PCV valve. Replace as necessary. *
²Drain and refill automatic transmission fluid
and replace filter. Adjust bands, if so equipped. (See
note)
²Change AWD power transfer unit fluid.
²Inspect tie rod ends and boot seals.
33,000 Miles (53 000 km)
²Change engine oil.
36,000 Miles (58 000 km)
²Change engine oil.
²Replace engine oil filter.
²Inspect brake linings.
39,000 Miles (62 000 km)
²Change engine oil.
42,000 Miles (67 000 km)
²Change engine oil.
²Replace engine oil filter.
²Change AWD overrunning clutch and rear car-
rier fluid.
45,000 Miles (72 000 km)
²Change engine oil.
²Inspect air cleaner element. Replace as
necessary.²Drain and refill automatic transmission fluid
and replace filter. Adjust bands, if so equipped. (See
note)
²Inspect brake linings.
²Change AWD power transfer unit fluid.
48,000 Miles (77 000 km)
²Change engine oil.
²Replace engine oil filter.
51,000 Miles (82 000 km)
²Change engine oil.
²Flush and replace engine coolant.
54,000 Miles (86 000 km)
²Change engine oil.
²Replace engine oil filter.
²Inspect brake linings.
57,000 Miles (91 000 km)
²Change engine oil.
60,000 Miles (96 000 km)
²Change engine oil.
²Replace engine oil filter.
²Replace air cleaner element.
²Inspect PCV valve, replace if necessary. *
²Inspect serpentine drive belt, replace if neces-
sary.
²Drain and refill automatic transmission fluid
and replace filter. Adjust bands, if so equipped. (See
note)
²Change AWD power transfer unit fluid.
²Inspect tie rod ends and boot seals.
63,000 Miles (101 000 km)
²Change engine oil.
²Change AWD overrunning clutch and rear car-
rier fluid.
²Inspect brake linings.
66,000 Miles (106 000 km)
²Change engine oil.
²Replace engine oil filter.
69,000 Miles (110 000 km)
²Change engine oil.
72,000 Miles (115 000 km)
²Change engine oil.
²Replace engine oil filter.
²Inspect brake linings.
75,000 Miles (120 000 km)
²Change engine oil.
²Inspect air cleaner element. Replace as
necessary.
NSLUBRICATION AND MAINTENANCE 0 - 5
GENERAL INFORMATION (Continued)

²Replace spark plugs.
²Replace ignition cables.
²Inspect serpentine drive belt, replace if neces-
sary. This maintenance is not required if belt was
previously replaced.
²Drain and refill automatic transaxle fluid and
replace filter. Adjust band, if so equipped. (See note)
²Change AWD power transfer unit fluid.
78,000 Miles (125 000 km)
²Change engine oil.
²Replace engine oil filter.
81,000 Miles (130 000 km)
²Change engine oil.
²Inspect brake linings.
²Flush and replace engine coolant.
84,000 Miles (134 000 km)
²Change engine oil.
²Replace engine oil filter.
²Change AWD overrunning clutch and rear car-
rier fluid.
87,000 Miles (139 000 km)
²Change engine oil.
90,000 Miles (144 000 km)
²Change engine oil.
²Replace engine oil filter.
²Replace air cleaner element.
²Check PCV valve and replace if necessary.
Not required if previously changed. *
²Inspect serpentine drive belt, replace if neces-
sary. This maintenance is not required if belt was
previously replaced.
²Drain and refill automatic transmission fluid
and replace filter. Adjust bands, if so equipped. (See
note)
²Change AWD power transfer unit fluid.
²Inspect tie rod ends and boot seals.
²Inspect brake linings.
93,000 Miles (149 000 km)
²Change engine oil.
96,000 Miles (154 000 km)
²Change engine oil.
²Replace engine oil filter.
99,000 Miles (158 000 km)
²Change engine oil.
²Inspect brake linings.
102,000 Miles (163 000 km)
²Change engine oil.
²Replace engine oil filter.
105,000 Miles (168 000 km)
²Change engine oil.
²Inspect air cleaner element. Replace as
necessary.
²Inspect serpentine drive belt, replace if neces-
sary. This maintenance is not required if belt was
previously replaced.
²Drain and refill automatic transmission fluid
and filter. Adjust bands, if so equipped. (See note)
²Change AWD power transfer unit fluid.
²Change AWD overrunning clutch and rear car-
rier fluid.
108,000 Miles (173 000 km)
²Change engine oil.
²Replace engine oil filter.
²Inspect brake linings.
111,000 Miles (178 000 km)
²Change engine oil.
²Flush and replace engine coolant.
114,000 Miles (182 000 km)
²Change engine oil.
²Replace engine oil filter.
117,000 Miles (187 000 km)
²Change engine oil.
²Inspect brake linings.
120,000 Miles (192 000 km)
²Change engine oil.
²Replace engine oil filter.
²Replace air cleaner element.
²Inspect PCV valve. Replace as necessary. *
²Inspect serpentine drive belt. Not required if
replaced at 75,000, 90,000 or 105,000 miles.
²Drain and refill automatic transmission fluid
and replace filter. Adjust bands, if so equipped.
²Change AWD power transfer unit fluid.
²Inspect tie rod ends and boot seals.
* This maintenance is recommended by Chrysler to
the owner but is not required to maintain the war-
ranty on the PCV valve.
** If California vehicle, this maintenance is recom-
mended by Chrysler to the owner but is not required
to maintain the warranty of the timing belt.
NOTE: Operating vehicle more than 50% in heavy
traffic during hot weather, above 90ÉF (32ÉC), using
vehicle for police, taxi, limousine type operation or
trailer towing require the more frequent transaxle
service noted in Schedule ± B. Perform these ser-
vices if vehicle is usually operated under these con-
ditions.
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
0 - 6 LUBRICATION AND MAINTENANCENS
GENERAL INFORMATION (Continued)

(11) When vehicle is at correct camber setting
torque both front strut to steering knuckle attaching
bolts to 90 N´m (65 ft. lbs.) plus an additional 1/4
turn after required torque is met.
(12) If Toe readings obtained are not within the
required specification range, adjust Toe to meet the
preferred specification setting. Toe is adjustable
using the following Toe setting procedure.
FRONT TOE SETTING PROCEDURE
(1) Prepare vehicle as described in the Pre-Align-
ment Vehicle Inspection procedure.
(2) Center steering wheel and lock in place using a
steering wheel clamp.
CAUTION: Do not twist front inner tie rod to steer-
ing gear rubber boots during front wheel Toe
adjustment.(3) Loosen front inner to outer tie rod end jam
nuts (Fig. 7). Grasp inner tie rods at serrations and
rotate inner tie rods of steering gear (Fig. 7) to set
front Toe to the preferred Toe specification. See
Alignment Specifications in this group of the service
manual for preferred specification.
(4) Tighten tie rod jam nuts (Fig. 7) to 75 N´m (55
ft.lbs.) torque.
(5) Adjust steering gear to tie rod boots at tie rod.
(6) Remove steering wheel clamp.
SPECIFICATIONS
ALIGNMENT SPECIFICATIONS
All alignment specifications are to be checked and
adjusted with the vehicle at its correct ride height.
Refer to the ride height specifications listed in the
following alignment specifications chart.
Fig. 6 Camber Adjustment Cam Bolt
Fig. 7 Front Wheel Toe Adjustment
NSSUSPENSION 2 - 7
SERVICE PROCEDURES (Continued)

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

COIL SPRING
Coil springs are rated separately for each corner or
side of the vehicle depending on optional equipment
and type of vehicle service. During service procedures
when both springs are removed, mark springs to
ensure installation in original position. Each coil
spring comes with a plastic sleeve on the second coil
of the spring. This plastic sleeve is a noise insulator
for the coil spring.
NOTE: If coil springs require replacement, be sure
that the springs needing replacement, are replaced
with springs meeting the correct load rating for the
vehicle and its specific options.
BALL JOINT
The ball joint (Fig. 2) is pressed into the lower con-
trol arm. The ball joint has a non-tapered stud with
a notch (Fig. 2) to provide clearance for the steering
knuckle clamp bolt and to provide retention of the
ball stud in the steering knuckle. The ball joint stud
is clamped and locked into the steering knuckle leg
using a pinch bolt. The ball joint used on this vehicle
is replaceable and if found defective can be serviced
as a separate component of the lower control arm
assembly.
WHEEL MOUNTING STUDS
If wheel attaching studs need to be replaced in the
hub and bearing assembly the studsCAN NOTbe
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.
Use the procedure and special tools shown in the
service procedures section for the wheel mounting
studs when replacing the wheel attaching studs.
The hub and bearing assembly does not require
removal from the steering knuckle or the rearknuckle to replace the wheel attaching studs in the
hub and bearing assembly.
DIAGNOSIS AND TESTING
Mc PHERSON STRUT
(1) Inspect for damaged or broken coil springs (Fig. 3).
(2) Inspect for torn or damaged strut assembly
dust boots (Fig. 3).
(3) Inspect the coil spring isolator on the lower
spring seat, (Fig. 3) for any signs of damage or dete-
rioration.
(4) Lift dust boot (Fig. 4) and inspect strut assembly for
evidence of fluid running from the upper end of fluid res-
ervoir. (Actual leakage will be a stream of fluid running
down the side and dripping off lower end of unit). A slight
amount of seepage between the strut rod and strut shaft
seal is not unusual and does not affect performance of the
strut assembly (Fig. 4). Also inspect jounce bumpers for
signs of damage or deterioration.
Fig. 2 Ball Joint Assembly
Fig. 3 Mc Pherson Strut Assembly Inspection
Fig. 4 Strut Assembly Leakage Inspection
NSSUSPENSION 2 - 11
DESCRIPTION AND OPERATION (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)