2001 CHRYSLER VOYAGER sensor

(11) Remove ball joint nut by holding ball joint
stud with hex wrench while loosening and removing
nut with a wrench (Fig. 14).
CAUTION: Do not remove ball joint stud from steer-
ing knuckle using a hammer. Damage to the Alumi-
num knuckle, ball joint or control arm will result.
(12) Release ball joint stud from steering knuckle
using Remover, Special Tool C-4150A, as shown (Fig.
15).
Fig. 11 Removing Tie Rod End Attaching Nut
1 - TIE ROD END
2 - STEERING KNUCKLE
3 - WRENCH
4 - SOCKET
5 - TIE ROD END STUD
Fig. 12 TIE ROD REMOVAL WITH TOOL C-3894-A
1 - OUTER TIE ROD
2 - SPECIAL TOOL C-3894-A
3 - STEERING KNUCKLE
Fig. 13 Front Wheel Speed Sensor
1 - MOUNTING BOLT
2 - WHEEL SPEED SENSOR
3 - STEERING KNUCKLE
Fig. 14 BALL JOINT NUT REMOVAL/INSTALLATION
1 - KNUCKLE
2 - BALL JOINT STUD
3 - LOWER CONTROL ARM
2 - 8 FRONTRS
KNUCKLE (Continued)

(5) Install steering knuckle in clevis bracket of
strut damper assembly. Install the strut clevis-to-
steering knuckle attaching bolts. Tighten both bolts
to a torque of 81 N´m (60 ft. lbs.) plus an additional
1/4 (90É) turn.
(6) Install tie rod end into knuckle steering arm.
Start nut onto stud of tie rod end. While holding stud
of tie rod end stationary using a socket (Fig. 11),
tighten tie rod end to steering knuckle attaching nut.
Then using a crowfoot on a torque wrench (Fig. 17),
tighten the tie rod end nut to a torque of 75 N´m (55
ft. lbs.).
(7) If equipped with antilock brakes, install wheel
speed sensor and mounting bolt on steering knuckle
(Fig. 13). Tighten the speed sensor bolt to a torque of
7 N´m (60 in. lbs.).
(8) Install brake rotor on hub and bearing (Fig. 9).
(9) Install disc brake caliper and adapter assembly
on steering knuckle. Install adapter amounting bolts
and tighten to 169 N´m (125 ft. lbs.).
(10) Clean any debris from the threads of the
outer C/V joint stub axle.
(11) Install the washer and hub nut on stub axle.
(12) Have a helper apply the vehicle's brakes to
keep hub from turning, then tighten hub nut to a
torque of 244 N´m (180 ft. lbs.).
(13) Install the spring wave washer on the end of
the stub axle.
(14) Install the hub nut lock, and anewcotter pin
(Fig. 8). Wrap cotter pin prongs tightly around the
hub nut lock.(15) Install wheel and tire assembly. Install and
tighten the wheel mounting nuts in proper sequence
until all nuts are torqued to half the required speci-
fication. Then repeat the tightening sequence to the
full specified torque of 135 N´m (100 ft. lbs.).
(16) Lower vehicle.
(17) Set front wheel alignment camber and toe as
necessary. (Refer to 2 - SUSPENSION/WHEEL
ALIGNMENT - STANDARD PROCEDURE)
LOWER BALL JOINT
DESCRIPTION
The ball joint is an integral part of the lower con-
trol arm (Fig. 1). The ball joint has a tapered stud
that is pressed into the aluminum knuckle. The ball
joint stud is threaded on the end for a retainer nut.
The ball joint has a non-vented seal boot. The seal
boot has an integrated heat shield (Fig. 18).
The ball joint used in the lower control arm of this
vehicle is a sealed-for-life ball joint and requires no
maintenance lubrication. The ball joint has been
lubricated-for-life during the manufacturing process.
A special fitting cap is installed on the fill port. This
cap must not be removed and replaced with a com-
mon zirc fitting. The special cap is there to eliminate
the possibility of lubrication latter during the ball
joints life, thus damaging the non-vented seal boot.
NOTE: The ball joint does not require any type of
additional lubrication for the life of the vehicle. No
attempt should be made to ever add any lubrication
to the lower ball joint.
Fig. 17 Torquing Tie Rod End Attaching Nut
(Typical)
1 - STEERING KNUCKLE
2 - TIE ROD END
3 - CROWFOOT
4 - SOCKET
5 - TORQUE WRENCH
Fig. 18 Ball Joint Seal Boot (Typical)
1 - BALL JOINT SEAL BOOT
2 - BALL JOINT STUD
3 - LOWER CONTROL ARM
4 - SHIELD
2 - 10 FRONTRS
KNUCKLE (Continued)

arately for each corner or side of the vehicle depend-
ing on optional equipment and type of vehicle
service. If the coil springs require replacement, be
sure that the springs are replaced with springs meet-
ing the correct load rating and spring rate for the
vehicle and its specific options.
OPERATION - STRUT ASSEMBLY
The strut assembly cushions the ride of the vehicle,
controlling vibration, along with jounce and rebound
of the suspension.
The coil spring controls ride quality and maintains
proper ride height.
The spring isolators isolate the coil spring at the
top and bottom from coming into metal-to-metal con-
tact with the upper seat and strut.
The jounce bumper limits suspension travel and
metal-to-metal contact under full jounce condition.
The strut dampens jounce and rebound motions of
the coil spring and suspension.
During steering maneuvers, the strut assembly
(through a pivot bearing in the upper strut mount)
and steering knuckle (through the lower ball joint)
turn as an assembly.
DIAGNOSIS AND TESTING - STRUT ASSEMBLY
(FRONT)
(1) Inspect for damaged or broken coil springs
(Fig. 39).
(2) Inspect for torn or damaged strut assembly
dust boots (Fig. 39).
(3) Inspect the coil spring isolator on the lower
spring seat for any signs of damage or deterioration.
(4) Lift dust boot (Fig. 40) and inspect strut
assembly for evidence of fluid running from the
upper end of fluid reservoir. (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. 40). Also inspect jounce bumpers for
signs of damage or deterioration.
REMOVAL - STRUT ASSEMBLY
WARNING: DO NOT REMOVE THE NUT FROM THE
STRUT ROD WHILE STRUT ASSEMBLY IS
INSTALLED IN VEHICLE, OR BEFORE STRUT
ASSEMBLY SPRING IS COMPRESSED.
(1) Raise the vehicle. See Hoisting in Lubrication
and Maintenance.
(2) Remove the wheel and tire assembly from loca-
tion on front of vehicle requiring strut removal.(3) If both strut assemblies are to be removed,
mark the strut assemblies right or left according to
which side of the vehicle they were removed from.
(4) Remove the hydraulic brake hose routing
bracket and the speed sensor cable routing bracket
from the strut damper brackets (Fig. 41).
Fig. 40 Strut Assembly Leakage Inspection (Typical)
1 - DUST BOOT
2 - STRUT SHAFT
3 - STRUT FLUID RESERVOIR
4 - INSPECT THIS AREA FOR EVIDENCE OF EXCESSIVE FLUID
LEAKAGE
Fig. 41 Brake Hose And Speed Sensor Cable
Routing
1 - STRUT DAMPER
2 - WHEEL SPEED SENSOR CABLE
3 - ROUTING BRACKET
4 - HYDRAULIC BRAKE HOSE
5 - ATTACHING BOLT
6 - ROUTING BRACKET
2 - 20 FRONTRS
STRUT (Continued)

body, Install the mounting bolts (Fig. 3). Tighten the
four mounting bolts to 61 N´m (45 ft. lbs.) torque.
(9) Raise or lower the jack until shock absorber
lower eye aligns with threads in axle housing. Install
shock absorber lower mounting bolt. Do not fully
tighten bolt at this time.
(10) Lower the vehicle and remove hoist arms and
block of wood from under vehicle.
(11) Tighten the spring front pivot bolt to 156 N´m
(115 ft. lbs.) torque.
(12) Tighten the lower shock absorber mounting
bolt to 102 N´m (75 ft. lbs.) torque.
HUB / BEARING
DESCRIPTION
The rear wheel bearing and rear wheel hub of this
vehicle are a one-piece sealed unit, or hub and bear-
ing unit type assembly. The hub and bearing is
mounted to the center of the rear axle using 4
mounting bolts. It has five wheel mounting studs on
the hub flange.
All-Wheel-Drive vehicles have a hub and bearing
unit with a splined hole in the center of the hub for
rear driveshaft stub axle acceptance.Front-Wheel-Drive vehicles with antilock brakes
have an internally mounted wheel speed sensor and
tone wheel. This hub and bearing can be identified
by the rounded cap and molded in connector on the
rear of the assembly (Fig. 7). The sensor and tone
wheel cannot be serviced separately from the hub
and bearing.
OPERATION
The hub and bearing has internal bearings that
allow the hub to rotate with the tire and wheel
assembly (and driveshaft on All-Wheel-Drive vehi-
cles). The five wheel mounting studs mount the tire
and wheel assembly, and disc brake rotor to the vehi-
cle.
On All-Wheel-Drive vehicles, the splined mating of
the driveshaft stub axle and hub allows the drive-
shaft to rotate with the hub and wheel.
Front-Wheel-Drive vehicles equipped with antilock
brakes have a wheel speed sensor and tone wheel
mounted to the rear of the hub and bearing. The tone
wheel rotates with the hub which is sensed by the
wheel speed sensor.
DIAGNOSIS AND TESTING - HUB AND
BEARING (REAR)
The bearing contained in the hub and bearing
assembly will produce noise and vibration when worn
or damaged. The noise will generally change when
the bearings are loaded. A road test of the vehicle is
normally required to determine the location of a
worn or damaged bearing.
Find a smooth level road surface and bring the
vehicle up to a constant speed. When vehicle is at a
constant speed, swerve the vehicle back and forth
from the left and to the right. This will load and
Fig. 6 TOOL 8459 MOUNTED FOR BUSHING
INSTALLATION
1 - NUT
2 - WASHER
3 - BEARING
4 - LEAF SPRING EYE
5 - BUSHING
6 - INSTALLER PLATE (8459-3)
7 - PIN
8 - BODY (8459-1)
Fig. 7 HUB AND BEARING - FWD WITH ABS
2 - 30 REARRS
BUSHINGS (Continued)

unload the bearings and change the noise level.
When bearing damage is slight, the noise is usually
not noticeable at speeds above 48 km/h (30 mph).
REMOVAL - HUB AND BEARING
FRONT-WHEEL-DRIVE VEHICLES
(1) Raise vehicle. See Hoisting in Lubrication and
Maintenance.
(2) Remove wheel and tire.
(3) Remove brake drum or disc brake caliper and
rotor from hub and bearing. Refer to Brakes.
(4) If equipped with antilock brakes, perform the
following:
(a) Remove secondary (yellow) retaining clip at
rear of wheel speed sensor head (Fig. 8).
(b) Push up on metal retaining clip (Fig. 8) until
it bottoms. This will release wheel speed sensor
head from hub and bearing.
(c) While holding metal clip up, pull back on
wheel speed sensor head removing it from hub and
bearing.
(5) Remove the 4 bolts attaching the hub and bear-
ing to the rear axle.
CAUTION: Corrosion may occur between the hub
and bearing, and the axle. If this occurs the hub
and bearing will be difficult to remove from the
axle. If the hub and bearing will not come out of the
axle by pulling on it by hand, do not pound on the
hub and bearing to remove it from the axle. Damage
will occur. Use the following procedure.(6) If hub and bearing cannot be removed from the
axle by hand, use Remover, Special Tool 8458 (Fig. 9)
and following procedure to press the hub and bearing
out of the axle.
(a) Thread Threaded Guide Pins into hub and
bearing mounting bolt holes.
(b) Remove the two outboard spring plate bolts.
(c) Using the spring plate bolts, install the
Screw Mount, Special Tool 8458±2, as shown (Fig.
9).
(d) Place Push Plate, Special Tool 8458±1, on
ends of Threaded Guide Pins
(e) Place a dab of grease in dimple of Push
Plate.
(f) Tighten the Forcing Screw, Special Tool
8458±3, up against dimple in Push Plate and press
hub and bearing out of axle by continuing to
tighten screw.
(g) Remove the tool.
(h) Reinstall the two outboard spring plate bolts.
Tighten the bolts to 102 N´m (75 ft. lbs.) torque.
(7) Remove the hub/bearing from the rear axle and
brake support plate.
ALL-WHEEL-DRIVE VEHICLES
(1) Set the parking brake.The parking brake is
set to keep the hub and bearing, and axle shaft
from rotating when loosening the hub nut.
Fig. 8 SENSOR CONNECTOR AT HUB AND
BEARING
1 - SECONDARY SENSOR RETAINING CLIP
2 - METAL SENSOR RETAINING CLIP
3 - HUB AND BEARING
Fig. 9 REMOVAL USING SPECIAL TOOL 8458
1 - THREADED GUIDE PINS 8458-4
2 - HUB AND BEARING
3 - LEAF SPRING PLATE
4 - FORCING SCREW 8458-3
5 - SCREW MOUNT 8458-2
6 - PUSH PLATE 8458-1
RSREAR2-31
HUB / BEARING (Continued)

(2) Raise vehicle. See Hoisting in Lubrication And
Maintenance.
(3) Remove the wheel/tire assembly.
(4) Remove the cotter pin and nut retainer (Fig.
19) from the stub shaft of the outer C/V joint.
(5) Remove the spring washer (Fig. 18) from the
stub shaft of the outer C/V joint.
(6) Remove the hub nut and washer (Fig. 16) from
the stub shaft of the outer C/V joint.
(7) Remove the 6 bolts (Fig. 17) mounting the
driveshaft inner joint to the output shaft of the rear
drive line module.
(8) Remove the rear wheel speed sensor (Fig. 20)
from the rear hub/bearing.
(9) Release the parking brake.
(10) Remove the disc brake caliper to adapter
guide pin bolts (Fig. 15).
(11) Remove rear caliper from adapter using the
following procedure. First rotate rear of caliper up
from the adapter. Then pull the front of the caliper
and the outboard brake shoe anti-rattle clip out from
under the front abutment on the adapter (Fig. 14).
(12) Support caliper to prevent the weight of the
caliper from damaging the flexible brake hose (Fig.
10).
(13) Remove the rotor from the hub/bearing.
(14) Remove driveshaft from rear drive line mod-
ule and hub/bearing. Driveshaft is removed by first
compressing the inner joint on the driveshaft and
removing it from the drive line module. Then, slide
the outer joint of the driveshaft out of the hub/bear-
ing.(15) Remove the hub/bearing to axle mounting
bolts (Fig. 13).
CAUTION: Corrosion may occur between the hub/
bearing and the axle. If this occurs the hub/bearing
will be difficult to remove from the axle. If the hub/
bearing will not come out of the axle by pulling on
it by hand, do not pound on the hub/bearing to
remove it from the axle. Pounding on the hub/bear-
ing to remove it from the axle will damage the hub/
bearing. This damage will result in noise or failure
of the hub/bearing. To remove a hub/bearing which
is corroded to the axle, lightly tap the disc brake
caliper adapter using a soft faced hammer. This will
remove both the disc brake caliper adapter and
hub/bearing from the axle. The hub/bearing will
then need to be removed from the caliper adapter.
(16) Remove the hub/bearing from the axle. (Fig.
12).
(17) If the disc brake caliper adapter and hub/
bearing were removed as an assembly from the axle
and the hub/bearing cannot be removed from the
adapter by hand, use the following procedure to
remove it from the adapter. With a helper supporting
the caliper adapter in his hands, position Remover,
Special Tool 8214-1 on the cast housing of hub/bear-
ing (Fig. 11).Do not position special tool on
inner race of hub/bearing.Lightly strike Remover,
Special Tool 8214-1 with a hammer to remove the
hub/bearing from the caliper adapter.
Fig. 10 Correctly Supported Caliper
1 - WIRE
2 - CALIPER
3 - ADAPTER
4 - ROTOR
5 - INNER FENDER
Fig. 11 Hub/Bearing Removal From Caliper Adapter
1 - SPECIAL TOOL 8214-1
2 - PARK BRAKE CABLE
3 - DISC BRAKE CALIPER ADAPTER
4 - HUB/BEARING
2 - 32 REARRS
HUB / BEARING (Continued)

INSTALLATION - HUB AND BEARING
FRONT-WHEEL-DRIVE VEHICLES
(1) Install the 4 hub and bearing to axle mounting
bolts into the holes in the flange of the rear axle.
(2) Install the rear brake support plate on the 4
mounting bolts installed in the flange of the rear
axle.
(3) Align the rear hub and bearing with the 4
mounting bolts and start mounting bolts into hub
and bearing. Tighten the 4 bolts in a crisscross pat-
tern until the hub nd bearing and brake support
plate is fully and squarely seated onto flange of rear
axle. Tighten the 4 mounting bolts to a torque of 129
N´m (95 ft. lbs.)
NOTE: If equipped with antilock brakes, make sure
wheel speed sensor stays clean and dry as it is
installed into the hub and bearing cap.
(4) If the vehicle is equipped with antilock brakes,
perform the following:
(a) If metal sensor retaining clip is not in the
neutral installed position on hub and bearing cap,
install from the bottom, if necessary, and push clip
upward until it snaps into position.
(b) Install wheel speed sensor head into rear of
hub and bearing aligning index tab with the notch
in the top of the mounting hole. Push the sensor in
until it snaps into place on the metal retaining
clip.
(c) Install secondary (yellow) retaining clip over
wheel speed sensor head and engage the tabs on
each side (Fig. 8).
(5) Install brake drum or disc brake rotor and
brake caliper. Refer to Brakes.
(6) Install wheel and tire. Tighten the wheel nuts
in the proper sequence to a torque of 135 N´m (100
ft. lbs.).
(7) Adjust the rear brakes as necessary. Refer to
Brakes.
(8) Lower vehicle.
(9) Road test vehicle to ensure proper operation of
brakes.
ALL-WHEEL-DRIVE VEHICLES
(1) Install hub/bearing on end of axle. (Fig. 12).
(2) Install the hub/bearing mounting bolts. In a
progressive crisscross pattern, tighten the 4 hub/
bearing mounting bolts (Fig. 13) until the disc brake
caliper adapter and hub/bearing are squarely seated
against the axle. Then tighten the hub/bearing
mounting bolts to a torque of 129 N´m (95 ft. lbs.).
(3) Install driveshaft in hub/bearing and on output
shaft of rear drive line module. Driveshaft is
installed by first sliding the outer joint of the drive-shaft into the hub/bearing and then compressing the
inner joint on the driveshaft and installing it on the
output shaft the drive line module.
(4) Install rotor on hub/bearing.
(5) Carefully lower disc brake caliper and brake
shoes over rotor and onto caliper adapter by revers-
ing the removal procedure (Fig. 14).
CAUTION: When installing guide pin bolts extreme
caution should be taken not to cross-thread the cal-
iper guide pin bolts.
Fig. 12 Hub/Bearing Removal And Installation
1 - PARK BRAKE BRAKE SHOE
2 - HUB/BEARING
3 - PARK BRAKE BRAKE SHOE
Fig. 13 Hub/Bearing Mounting Bolts
1 - HUB/BEARING
2 - AXLE
3 - MOUNTING BOLTS
4 - CALIPER ADAPTER
RSREAR2-33
HUB / BEARING (Continued)

(13) Install the spring washer (Fig. 18) on the stub
shaft of the outer C/V joint.
(14) Install the nut retainer and cotter pin (Fig.
19) on the stub shaft of the outer C/V joint.
(15) Install the wheel speed sensor on the hub/
bearing and adapter. Install the wheel speed sensor
attaching bolt (Fig. 20). Tighten the wheel speed sen-
sor attaching bolt to a torque of 12 N´m (105 in. lbs).
(16) Install wheel and tire.(17) Tighten the wheel mounting stud nuts in
proper sequence until all nuts are torqued to half
specification. Then repeat the tightening sequence to
the full specified torque of 135 N´m (100 ft. lbs.).
(18) Remove jackstands or lower hoist.
CAUTION: Before moving vehicle, pump the brake
pedal several times to insure the vehicle has a firm
brake pedal to adequately stop vehicle.
(19) Road test vehicle to ensure proper operation
of the brake system.
JOUNCE BUMPER
DESCRIPTION
There are two jounce bumpers used in the rear
suspension. One mounts to each frame rail above the
rear axle.
OPERATION
The jounce bumper limits suspension travel and
metal-to-metal contact of the rear axle with the
frame under full jounce conditions.
REMOVAL - AWD AND HEAVY DUTY
(1) Using slip-joint pliers grasp the base of the
jounce bumper. Turn the base counterclockwise (Fig.
21).
(2) Remove the jounce bumper from the frame rail.
REMOVAL - FRONT-WHEEL-DRIVE
(1) Remove the bolt attaching the jounce bumper
to frame rail (Fig. 22).
(2) Remove the jounce bumper from the frame rail.
Fig. 18 Spring Washer
1 - HUB NUT
2 - STUB SHAFT
3 - ROTOR
4 - SPRING WASHER
Fig. 19 Cotter Pin And Nut Retainer
1 - CALIPER
2 - COTTER PIN
3 - ROTOR
4 - NUT RETAINER
5 - OUTER C/V JOINT
Fig. 20 Wheel Speed Sensor
1 - MOUNTING BOLT
2 - WHEEL SPEED SENSOR
RSREAR2-35
HUB / BEARING (Continued)