2002 CHRYSLER CARAVAN wheel

(4) Wipe any grease off the ball joint stem using a
clean shop towel with MopartBrake Parts Cleaner
applied to it.
CAUTION: Do not attempt to install a normal grease
zirc in the ball joint an lubricate the joint through
the zirc fitting.
(5) Reinstall steering knuckle on vehicle. (Refer to
2 - SUSPENSION/FRONT/KNUCKLE - INSTALLA-
TION)
INSTALLATION - EXPORT
(1) Place a liberal dab of MopartWheel Bearing
Grease around the base of the ball joint stem at the
socket.
(2) Install aNEWseal boot by hand as far as pos-
sible on the ball joint.
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.
(3) Place Installer, Special Tool 6758, over seal
boot and squarely align it with bottom edge of seal
boot (Fig. 20). Apply hand pressure to Special Tool
6758 until seal boot is pressed squarely against top
surface of lower control arm.
(4) Wipe any grease off the ball joint stem.
(5) Place the shield over the top of the seal boot
and stretch it into the groove at the top of the seal
boot.CAUTION: Do not attempt to install a normal grease
zirc in the ball joint and lubricate the joint through
the zirc fitting.
(6) Reinstall steering knuckle on vehicle. (Refer to
2 - SUSPENSION/FRONT/KNUCKLE - INSTALLA-
TION)
LOWER CONTROL ARM
DESCRIPTION
The lower control arm is mounted to the front sus-
pension crossmember using a pivot bolt through the
center of the front pivot bushing, and the front sus-
pension cradle crossmember reinforcement traps the
rear bushing in the crossmember (Fig. 1).
The lower control arm is an iron casting with two
rubber bushings and a ball joint. The lower control
arm front bushing is the spool type and is pressed
into the lower control arm. The standard (Low-line)
lower control arm rear bushing is a push-on bushing
that is pushed over a stem on the rear of the lower
control arm. The optional (High-line, Premium,
Sport) lower control arm rear bushing is a hydro-
bushing that is pressed on. It has liquid filled voids
that provide more effective dampening than the stan-
dard bushing. Vehicles with rear hydro-bushings uti-
lize a different lower control arm than vehicles with
standard bushings. They have a straight slightly
tapered round stem where the hydro-bushing is
mounted whereas the standard arm has a straight
stem with a squared knob on the end to retain the
bushing.
The lower control arm ball joint is pressed into the
outer end of the arm. The ball joint has a tapered
stud and retainer nut for fastening it to the steering
knuckle.
OPERATION
The lower control arm supports the lower end of
the steering knuckle and allows for the up and down
movement of the suspension during the jounce and
rebound travel. The lower control arm ball joint con-
nects the arm to the steering knuckle.
REMOVAL - LOWER CONTROL ARM
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) Remove wheel and tire assembly.
(3) Remove the steering knuckle. (Refer to 2 -
SUSPENSION/FRONT/KNUCKLE - REMOVAL)
(4) Remove the bolts fastening the power steering
cooler to the front suspension cradle crossmember
reinforcement (Fig. 21).
Fig. 20 Installing Ball Joint Seal Boot (Typical)
1 - SHIELD (NOT ON RG VEHICLE)
2 - SPECIAL TOOL 6758
3 - LOWER CONTROL ARM
4 - BALL JOINT SEAL BOOT
2 - 12 FRONT SUSPENSIONRS
LOWER BALL JOINT SEAL BOOT (Continued)
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(2) Install NEW pivot bolt attaching front bushing
of lower control arm to front suspension cradle cross-
member (Fig. 29).Do not tighten or torque pivot
bolt at this time.
(3) Install the reinforcement on the front suspen-
sion cradle crossmember and install the bolts attach-
ing the reinforcement to the cradle crossmember
(Fig. 22). Tighten the M-14 size bolts to a torque of
153 N´m (113 ft. lbs.). Tighten the M-12 size bolts to
a torque of 106 N´m (78 ft. lbs.).
(4) Install the lower control arm rear bushing
retainer bolts through reinforcement on each side of
each lower control arm rear bushing. Tighten these
M-10 size bolts to a torque of 61 N´m (45 ft. lbs.).
(5) Install the two bolts and bushings attaching
the reinforcement and rear of cradle crossmember to
body of vehicle (Fig. 22). Tighten bolts to a torque of
163 N´m (120 ft. lbs.).
(6) Install the power steering cooler (Fig. 21).
Tighten bolts to a torque of 11 N´m (100 in. lbs.).
(7) Reinstall steering knuckle, brake rotor and cal-
iper. (Refer to 2 - SUSPENSION/FRONT/KNUCKLE
- INSTALLATION)
CAUTION: When locating jack stands under lower
control arms, do not place the jack stands under
the ball joints (Fig. 30).
(8) Position jack stands under the lower control
arms as close to the ball joints as possible (Fig. 30).
Lower the vehicle onto the jack stands until the jack
stands are supporting the total weight of the vehicle.
(9) Tighten front lower control arm pivot bolt to a
torque of 183 N´m (135 ft. lbs.).(10) Install the wheel and tire assembly. Install
and 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 135 N´m (100 ft. lbs.).
(11) Raise vehicle, remove jack stands and lower
vehicle to the ground.
(12) Perform front wheel alignment as necessary.
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
STANDARD PROCEDURE)
STABILIZER BAR
DESCRIPTION
The stabilizer bar interconnects both front struts of
the vehicle and is attached to the front crossmember
(Fig. 1) .
Attachment of the stabilizer bar to the front cross-
member is through 2 rubber-isolator cushion bush-
ings and retainers. A double ball jointed stabilizer
bar link is used to attach each end of the stabilizer
bar to the front strut assemblies. All parts of the sta-
bilizer bar are replaceable as individual components.
The stabilizer bar to front crossmember cushion
bushings are split for easy removal and installation.
The split in the bushings should be positioned toward
the rear of the vehicle, with the square corner facing
down, when the stabilizer bar is installed.
OPERATION
Jounce and rebound movements affecting one
wheel are partially transmitted to the opposite wheel
of the vehicle through the stabilizer bar. This helps
Fig. 29 Lower Control Arm Bushing Pivot Bolt
Correctly Installed
1 - PIVOT BOLT
2 - LOWER CONTROL ARM
3 - FRONT SUSPENSION CRADLE CROSSMEMBER
Fig. 30 Jack Stands Supporting Vehicle Weight
1 - LOWER CONTROL ARMS
2 - BALL JOINT
3 - JACK STANDS
4 - BALL JOINT
2 - 16 FRONT SUSPENSIONRS
LOWER CONTROL ARM (Continued)
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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
(1) Inspect for damaged or broken coil springs
(Fig. 38).
(2) Inspect for torn or damaged strut assembly
dust boots (Fig. 38).
(3) Inspect the coil spring isolator on the lower
spring seat for any signs of damage or deterioration.
(4) Lift dust boot (Fig. 39) and inspect strut
assembly for evidence of fluid running from the
upper end of fluid reservoir. (Actual leakage will be astream 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. 39). 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. 40).
Fig. 38 STRUT ASSEMBLY
1 - NUT 6 - COIL SPRING
2 - UPPER MOUNT 7 - DUST SHIELD
3 - PIVOT BEARING 8 - JOUNCE BUMPER
4 - UPPER SPRING SEAT 9 - LOWER SPRING ISOLATOR
5 - UPPER SPRING ISOLATOR 10 - STRUT (DAMPER)
2 - 20 FRONT SUSPENSIONRS
STRUT (Continued)
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CAUTION: When removing the nut from the stud of
the stabilizer bar link, do not allow the stud to
rotate in it's socket. Hold the stud from rotating by
placing an open-end wrench on the flat machined
into the stud (Fig. 41).
(5) Remove the stabilizer bar link from the bracket
on the strut assembly (Fig. 41). To do so, place anopen-end wrench on the flat machined into the link's
mounting stud, then remove the nut while holding
the wrench in place. Push the stud out of the
bracket.
CAUTION: The steering knuckle to strut assembly
attaching bolts are serrated and must not be turned
during removal. Remove nuts while holding bolts
stationary in the steering knuckles.
(6) Remove the 2 strut assembly clevis bracket to
steering knuckle attaching bolts (Fig. 42).
Fig. 39 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. 40 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
Fig. 41 Stabilizer Bar Link To Strut Attachment
1 - NUT
2 - STRUT
3 - STABILIZER BAR LINK
Fig. 42 Strut Damper Attachment To Steering
Knuckle
1 - STRUT CLEVIS BRACKET
2 - ATTACHING BOLTS
3 - TIE ROD END
4 - ROTOR
5 - STEERING KNUCKLE
RSFRONT SUSPENSION2-21
STRUT (Continued)
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(12) Slowly release the tension from the coil spring
by backing off the compressor drive fully. As the ten-
sion is relieved, make sure the upper mount, pivot
bearing and upper seat are align properly. Remove
the clamp from the lower end of the coil spring and
strut. Push back the spring compressor upper and
lower hooks, then remove the strut assembly from
the spring compressor.
(13) Install strut assembly on the vehicle. (Refer to
2 - SUSPENSION/FRONT/STRUT - INSTALLA-
TION)
INSTALLATION - STRUT ASSEMBLY
CAUTION: Front strut coil springs are side-oriented.
When installing a strut assembly, make sure the
strut being installed has the correct coil spring for
that side of the vehicle. Springs on the left side of
the vehicle have a left-hand wind top-to-bottom
while springs on the right side have a right-hand
wind top-to-bottom (Fig. 49). Do not interchange the
two sides.
(1) Install strut assembly into strut tower, aligning
and installing the 3 studs on the upper strut mount
into the holes in shock tower. Install the 3 upper
strut mount attaching nut/washer assemblies (Fig.43). Then using a crow foot. tighten the 3 attaching
nuts to a torque of 28 N´m (250 in. lbs.).
CAUTION: The steering knuckle to strut assembly
attaching bolts are serrated and must not be turned
during installation. Install nuts while holding bolts
stationary in the steering knuckles.
NOTE: The strut clevis-to-steering knuckle bolts are
installed differently on each side of the vehicle. Left
hand side bolts are to be installed from vehicle rear
to front. Right side bolts are to be installed from
vehicle front to rear.
(2) Align strut assembly with steering knuckle.
Position arm of steering knuckle into strut assembly
clevis bracket. Align the strut assembly clevis
bracket mounting holes with the steering knuckle
mounting holes. Install the 2 strut assembly to steer-
ing knuckle attaching bolts (Fig. 42).If strut assem-
bly is attached to steering knuckle using a cam
bolt, the cam bolt must be installed in the lower
slotted hole on strut clevis bracket.Tighten the
strut clevis-to-steering knuckle attaching bolts to a
torque of 81 N´m (60 ft. lbs.) plus an additional 1/4
(90É) turn after specified torque is met.
(3) Install the stabilizer bar link mounting stud
through the bracket on the strut assembly (Fig. 41).
CAUTION: When installing the nut on the mounting
stud of the stabilizer bar link, do not allow the stud
to rotate in it's socket. Hold the stud from rotating
by placing an open-end wrench on the flat
machined into the stud (Fig. 41).
(4) Hand thread the nut on the end of the stabi-
lizer bar link stud. Hold the stud from turning by
placing an open-end wrench on the flat machined
into the link's mounting stud, then tighten the nut
while holding the wrench in place (Fig. 41). Tighten
the nut to a torque of 88 N´m (65 ft. lbs.).
(5) Install the hydraulic brake hose and speed sen-
sor cable routing brackets on the strut assembly
brackets (Fig. 40). Tighten the routing bracket
attaching bolts to a torque of 13 N´m (10 ft. lbs.).
(6) Install the wheel/tire assembly on the vehicle.
(7) Install and 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.).
Fig. 50 Components Lined Up
1 - IMAGINARY VERTICAL LINE
2 - CLEVIS BRACKET
3 - END OF COIL SPRING
4 - NOTCH IN UPPER SPRING SEAT
RSFRONT SUSPENSION2-25
STRUT (Continued)
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REAR SUSPENSION
TABLE OF CONTENTS
page page
REAR SUSPENSION
DESCRIPTION - REAR SUSPENSION.......26
OPERATION - REAR SUSPENSION.........27
SPECIFICATIONS
REAR SUSPENSION FASTENER TORQUE . . 28
SPECIAL TOOLS
REAR SUSPENSION...................28
BUSHINGS
REMOVAL - LEAF SPRING FRONT BUSHING . 29
INSTALLATION - LEAF SPRING FRONT
BUSHING...........................29
HUB / BEARING
DESCRIPTION.........................30
OPERATION...........................31
DIAGNOSIS AND TESTING - HUB AND
BEARING............................31
REMOVAL.............................31
INSTALLATION.........................33
JOUNCE BUMPER
DESCRIPTION.........................36
OPERATION...........................36
REMOVAL
REMOVAL - AWD AND HEAVY DUTY......36
REMOVAL - FRONT-WHEEL-DRIVE.......36
INSTALLATION
INSTALLATION - AWD AND HEAVY DUTY . . . 36
INSTALLATION - FRONT-WHEEL-DRIVE....36
SHOCK ABSORBER
DESCRIPTION.........................37
OPERATION...........................37
REMOVAL - SHOCK ABSORBER...........37
DISASSEMBLY - SHOCK ABSORBER (UPPER
BUSHING)...........................37ASSEMBLY - SHOCK ABSORBER (UPPER
BUSHING)...........................38
INSTALLATION - SHOCK ABSORBER........38
SPRING - AWD
DESCRIPTION.........................38
OPERATION...........................38
REMOVAL - AWD.......................38
INSTALLATION - AWD....................39
SPRING - FWD
DESCRIPTION.........................40
OPERATION...........................40
REMOVAL - FWD.......................40
INSTALLATION - FWD...................41
SPRING MOUNTS - FRONT
REMOVAL.............................42
INSTALLATION.........................43
SPRING MOUNTS - REAR
REMOVAL.............................43
INSTALLATION.........................44
STABILIZER BAR
DESCRIPTION.........................44
OPERATION...........................44
REMOVAL
REMOVAL - AWD......................44
REMOVAL - FWD.....................44
INSTALLATION
INSTALLATION - AWD..................44
INSTALLATION - FWD..................45
TRACK BAR
DESCRIPTION.........................45
OPERATION...........................45
REMOVAL.............................45
INSTALLATION.........................45
REAR SUSPENSION
DESCRIPTION - REAR SUSPENSION
The rear suspension design on this vehicle uses
leaf springs, and a tube and casting axle (Fig. 1) (Fig.
2). The leaf springs used on the rear suspension of
this vehicle are of either a mono-leaf or multi-leaf
design.
There are 2 different rear suspension designs
available:
²Front-Wheel-Drive
²All-Wheel-Drive
The rear axle used on Front-Wheel-Drive applica-
tions of this vehicle is mounted to the rear leafsprings 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.
Each side of the rear suspension consists of these
major components:
²Leaf spring
²Jounce bumper
²Shock absorber
²Hub and bearing
²Track bar (one per suspension)
²Stabilizer bar (one per suspension)
2 - 26 REAR SUSPENSIONRS
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OPERATION - REAR SUSPENSION
This rear suspension is designed to handle the var-
ious load requirements of the vehicle yet allow for a
comfortable ride.
The rear wheel bearings used are similar to the
bearings used in the front suspension. A hub and
bearing assembly is used.
Fig. 1 Front-Wheel-Drive Rear Suspension
1 - SHACKLE 7 - LEAF SPRING (MONO-LEAF)
2 - REAR MOUNT (HANGER) 8 - ISOLATOR
3 - TRACK BAR 9 - FWD REAR AXLE
4 - SPRING PLATE 10 - STABILIZER BAR LINKS
5 - ISOLATOR 11 - STABILIZER BAR
6 - FRONT MOUNT (HANGER)
Fig. 2 All-Wheel-Drive Rear Suspension
1 - SHACKLE
2 - REAR MOUNT (HANGER)
3 - LEAF SPRING (MULTI-LEAF)
4 - AWD REAR AXLE
RSREAR SUSPENSION2-27
REAR SUSPENSION (Continued)
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SPECIFICATIONS
REAR SUSPENSION FASTENER TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Hub And Bearing Mounting
Bolts129 95 Ð
Hub And Bearing Axle Hub
Nut244 180 Ð
Jounce Bumper Mounting
Bolt33 24 290
Leaf Spring Front Mount-To-
Body Bolts61 45 Ð
Leaf Spring Front Pivot Bolt 156 115 Ð
Leaf Spring Plate-To-Axle
Bolts95 70 Ð
Leaf Spring Rear Mount-To-
Body Bolts61 45 Ð
Leaf Spring Shackle Plate
Nuts61 45 Ð
Shock Absorber Mounting
Bolts88 65 Ð
Stabilizer Bar Bushing
Retainer Bolts61 45 Ð
Stabilizer Bar Link Nuts 61 45 Ð
Stabilizer Bar Link Frame
Bracket Mounting Bolts61 45 Ð
Track Bar Bracket-To-Body
Mount Bolts61 45 Ð
Track Bar Pivot Bolts 95 70 Ð
Wheel Mounting (Lug) Nut 135 100 Ð
SPECIAL TOOLS
REAR SUSPENSION
Remover, Hub/Bearing 8458
Remover/Installer, Bushing 8459
Remover/Installer, Bushing 8526
Press, Ball Joint C-4212F
2 - 28 REAR SUSPENSIONRS
REAR SUSPENSION (Continued)
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