2002 CHRYSLER CARAVAN Service Manual

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Page 25 of 2399

CHRYSLER CARAVAN 2002 Service Manual FRONT SUSPENSION
DESCRIPTION - FRONT SUSPENSION
This vehicle has a MacPherson Strut type front
suspension (Fig. 1).
OPERATION - FRONT SUSPENSION
The front suspension allows each wheel on a vehi-
cle t

FRONT SUSPENSION
DESCRIPTION - FRONT SUSPENSION
This vehicle has a MacPherson Strut type front
suspension (Fig. 1).
OPERATION - FRONT SUSPENSION
The front suspension allows each wheel on a vehi-
cle to adapt to different road surfaces and conditions
without greatly affecting the opposite wheel and the
ability to control the vehicle. Each side of the front
suspension is allowed to pivot so the vehicle can be
steered in the direction preferred.
A strut assembly is used in place of the front sus-
pension upper control arm and upper ball joint.
When a vehicle strikes a bump, the force is trans-
ferred through the hub, bearing, and knuckle, into
the strut assembly to absorb the force and dampen it.
The top of the strut is mounted directly to the strut
tower of the vehicle. During steering maneuvers, thestrut assembly (through a pivot bearing in the upper
strut mount) and steering knuckle (through the lower
ball joint) turn as an assembly.
STANDARD PROCEDURE - LUBRICATION
There are no serviceable lubrication points on the
front suspension. The ball joints are sealed-for-life
and require no maintenance. The lower ball joints
have special grease fitting caps that prevent normal
grease gun attachment. This has been done to elimi-
nate the possibility of over-filling, damaging the non-
vented seal. Do not attempt to remove the special
grease fitting cap and replace it with a normal grease
zirc fitting.
CAUTION: No attempt should be made to replace
the ball joint grease fitting cap with a normal zirc
fitting or fill the ball joint with grease. Damage to
the grease seal can result.
Fig. 1 Front Suspension
1 - TOWER
2 - CROSSMEMBER TAPPING PLATES
3 - LEFT STRUT ASSEMBLY
4 - LEFT STEERING KNUCKLE (WITH HUB AND BEARING)
5 - STABILIZER BAR LINK
6 - STABILIZER BAR
7 - LEFT LOWER CONTROL ARM
8 - CRADLE/CROSSMEMBER9 - CRADLE/CROSSMEMBER REINFORCEMENT
10 - BALL JOINT
11 - ISOLATOR BUSHING
12 - STEERING GEAR TIE ROD
13 - RIGHT STEERING KNUCKLE
14 - RIGHT HUB AND BEARING
15 - RIGHT STRUT ASSEMBLY
2 - 2 FRONT SUSPENSIONRS
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CHRYSLER CARAVAN 2002 Service Manual SPECIFICATIONS
FRONT SUSPENSION FASTENER TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Ball Joint Nut 108 80 Ð
Cradle Crossmember Mounting
Bolts163 120 Ð
Cradle Crossmember
Reinforcement Bolts - Size M-14

Page 27 of 2399

CHRYSLER CARAVAN 2002 Service Manual BUSHINGS
REMOVAL - STABILIZER BAR CUSHION
(1) Raise Vehicle. Refer to Hoisting in Lubrication
and Maintenance.
(2) Remove the 2 bolts fastening the emission leak
detection pump to the cradle crossmemb

BUSHINGS
REMOVAL - STABILIZER BAR CUSHION
(1) Raise Vehicle. Refer to Hoisting in Lubrication
and Maintenance.
(2) Remove the 2 bolts fastening the emission leak
detection pump to the cradle crossmember reinforce-
ment.
(3) Move the leak detection pump to the side
allowing access to the stabilizer bar cushion retain-
ers.
(4) Remove the nut and bolt securing each stabi-
lizer bar cushion retainer to the cradle crossmember
(Fig. 2) and remove the retainers.
(5) Remove each stabilizer bar cushion from the
stabilizer bar by opening the slit in the cushion and
peeling it off the stabilizer bar.
INSTALLATION - STABILIZER BAR CUSHION
(1) Install each new cushion on stabilizer bar by
spreading cushion at slit and forcing it onto stabilizer
bar.
NOTE: Cushions must be installed on stabilizer bar
so the square corner of the bushing will be down
and slit in cushion will be facing the rear of the
vehicle when the stabilizer bar is installed (Fig. 3).
(2) Place stabilizer bar into mounted position with
cushions properly aligned.
(3) Hook each retainer into cradle crossmember
mounting hole and over cushion.(4) Install each mounting bolt from rear of cradle
crossmember through retainer. Install the two nuts
and tighten to 68 N´m (50 ft. lbs.) torque.
(5) Reattach emission leak detection pump to cra-
dle crossmember reinforcement with two mounting
bolts.
(6) Lower the vehicle.
HUB / BEARING
DESCRIPTION
The front wheel bearing and front wheel hub of
this vehicle are a hub and bearing unit type assem-
bly (Unit III). This unit combines the front wheel
mounting hub (flange) and the front wheel bearing
into a sealed one-piece unit. The hub and bearing is
mounted to the center of the steering knuckle (Fig.
1). It is retained by four mounting bolts accessible
from the inboard side of the steering knuckle. The
hub flange has five wheel mounting studs.
The wheel mounting studs used to mount the tire
and wheel to the vehicle are the only replaceable
components of the hub and bearing assembly. Other-
wise, the hub and bearing is serviced only as a com-
plete assembly.
OPERATION
The hub and bearing has internal bearings that
allow the hub to rotate with the driveshaft, along
with the tire and wheel. The five wheel mounting
studs mount the tire and wheel, and brake rotor to
the vehicle.
Fig. 2 Front Stabilizer Bar Cushion Retainers
1 - STEERING GEAR
2 - STABILIZER BAR
3 - RAISED BEAD
4 - FRONT CRADLE CROSSMEMBER
5 - RETAINERS
Fig. 3 Correctly Installed Stabilizer Bar Cushion
1 - SLIT IN SWAY BAR BUSHING.
2 - SQUARE CORNER
3-SWAYBAR
4 - SWAY BAR ISOLATOR BUSHING
2 - 4 FRONT SUSPENSIONRS
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CHRYSLER CARAVAN 2002 Service Manual DIAGNOSIS AND TESTING - HUB AND
BEARING
The condition of the front hub and bearing assem-
bly is diagnosed using the inspection and testing pro-
cedure detailed below.
The bearing contained in the Uni

DIAGNOSIS AND TESTING - HUB AND
BEARING
The condition of the front hub and bearing assem-
bly is diagnosed using the inspection and testing pro-
cedure detailed below.
The bearing contained in the Unit III front hub/
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
unload the bearings and change the noise level.
When bearing damage is slight, the noise is some-
times noticeable at lower speeds and at other times
is more noticeable at speeds above 105 km/h (65
mph).
REMOVAL
NOTE: Replacement of the Unit III front hub/bearing
assembly can be normally done without having to
remove the steering knuckle from the vehicle. In the
event that the hub/bearing is frozen in the steering
knuckle and cannot be removed by hand, it will
have to be pressed out of the steering knuckle. The
steering knuckle will require removal from the vehi-
cle to allow the hub/bearing assembly to be
pressed out of the steering knuckle. (Refer to 2 -
SUSPENSION/FRONT/KNUCKLE - REMOVAL)
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) Remove wheel lug nuts, and front tire and
wheel assembly.
(3) Remove the cotter pin, nut lock and spring
washer from the stub axle (Fig. 4).
(4) With aid of a helper applying the brakes to
keep the front hub from turning, remove the hub nut
(Fig. 4).
(5) Remove disc brake caliper and adapter as an
assembly from knuckle as shown (Fig. 5). Hang
assembly out of the way using a bungee cord or wire.
Do not allow caliper hang by brake hose.
(6) Remove brake rotor from hub and bearing (Fig.
5).
(7) Push in on end of driveshaft stub shaft, push-
ing its splines out of the hub splines.(8) Remove the four hub and bearing mounting
bolts from the rear of steering knuckle (Fig. 6).Use
care not to come in contact with and damage
the ABS tone wheel on the driveshaft stub shaft
upon bolt removal.
(9) Remove the hub and bearing assembly from
the steering knuckle.
Fig. 4 Hub Nut
1 - HUB NUT
2 - NUT LOCK
3 - COTTER PIN
4 - SPRING WASHER
Fig. 5 Front Brake Mounting
1 - BRAKE ROTOR
2 - HUB AND BEARING
3 - STEERING KNUCKLE
4 - ADAPTER MOUNTING BOLTS
5 - BRAKE CALIPER
6 - ADAPTER
7 - CLIP
RSFRONT SUSPENSION2-5
HUB / BEARING (Continued)
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Page 29 of 2399

CHRYSLER CARAVAN 2002 Service Manual INSTALLATION
CAUTION: Hub and bearing assembly mounting
surfaces on the steering knuckle and stub axle (Fig.
7) must be smooth and completely free of foreign
material or nicks prior to installing hub

INSTALLATION
CAUTION: Hub and bearing assembly mounting
surfaces on the steering knuckle and stub axle (Fig.
7) must be smooth and completely free of foreign
material or nicks prior to installing hub and bearing
assembly.
CAUTION: When installing hub and bearing into
steering knuckle, be careful not to damage the
bearing seal (Fig. 7) on the outer C/V joint.(1) Install hub and bearing onto stub axle and into
steering knuckle until squarely seated on the face of
the steering knuckle.
(2) Install the 4 hub and bearing mounting bolts
from the rear of the knuckle. Equally tighten all 4
mounting bolts in a criss-cross pattern until hub/
bearing assembly is squarely seated against front of
steering knuckle. Tighten mounting bolts to a torque
of 65 N´m (45 ft. lbs.)
(3) Install the brake rotor on the hub and bearing
(Fig. 5).
(4) Install brake caliper and adapter assembly
back over brake rotor and align with mounting holes
on steering knuckle (Fig. 5). Install the mounting
bolts and tighten to 169 N´m (125 ft. lbs.) torque.
(5) Install the hub nut on the end of the stub axle
(Fig. 4). With aid of a helper applying the brakes to
keep the front hub from turning, tighten the hub nut
to Install the mounting bolts and tighten to 244 N´m
(180 ft. lbs.) torque.
(6) Install wheel and tire assembly on vehicle.
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.).
(7) Lower vehicle to the ground.
(8) Check the front wheel alignment toe setting
and reset if not within specifications. (Refer to 2 -
SUSPENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE)
KNUCKLE
DESCRIPTION
The steering knuckle is a singlealuminumcast-
ing with legs machined for attachment of the strut
assembly, steering linkage, disc brake caliper
adapter, lower control arm ball joint and steering
linkage (Fig. 1). The hub and bearing assembly is
mounted in the center of the steering knuckle using
4 bolts. The driveshaft's constant velocity (C/V) stub
axle is splined through the center of the hub and
bearing and is held in place using a nut, nut lock and
cotter pin.
Service replacement of the front hub and bearing
assembly can be done with the steering knuckle
remaining on the vehicle.
OPERATION
The steering knuckle pivots with the strut assem-
bly between the lower ball joint and the pivot bearing
in the strut assembly. The steering gear outer tie rod
end connects to the trailing end of each knuckle,
allowing the vehicle to be steered.
Fig. 6 Hub And Bearing Mounting Bolts
1 - HUB
2 - STEERING KNUCKLE
3 - MOUNTING BOLTS (4)
4 - DRIVESHAFT
Fig. 7 Mounting Surfaces (Typical)
1 - BEARING SEAL
2 - STUB AXLE
3 - THESE SURFACES MUST BE CLEAN AND FREE OF NICKS
BEFORE INSTALLING BEARING ASSEMBLY
4 - STEERING KNUCKLE
2 - 6 FRONT SUSPENSIONRS
HUB / BEARING (Continued)
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Page 30 of 2399

CHRYSLER CARAVAN 2002 Service Manual The center of the knuckle supports the hub and
bearing and axle shaft.
REMOVAL - STEERING KNUCKLE
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) Remove the

Page 31 of 2399

CHRYSLER CARAVAN 2002 Service Manual (11) Remove ball joint nut using a power impact
wrench. Because the tapered stud is held sufficientlyin the knuckle at this time, it is not necessary to
hold the stud stationary to remove the nut.
(12

Page 32 of 2399

CHRYSLER CARAVAN 2002 Service Manual If inspection leads to the hub and bearing, (Refer
to 2 - SUSPENSION/FRONT/HUB / BEARING -
DIAGNOSIS AND TESTING)
INSTALLATION - STEERING KNUCKLE
(1) If the hub and bearing needs to be installed in
th

If inspection leads to the hub and bearing, (Refer
to 2 - SUSPENSION/FRONT/HUB / BEARING -
DIAGNOSIS AND TESTING)
INSTALLATION - STEERING KNUCKLE
(1) If the hub and bearing needs to be installed in
the knuckle, place the hub and bearing squarely into
the center hole of the steering knuckle aligning the
threaded mounting holes of the hub and bearing with
the mounting holes in the steering knuckle. Install
the four mounting bolts and tighten them to a torque
of 65 N´m (45 ft. lbs.).
CAUTION: Before installing the knuckle on the ball
joint stud, wipe the ball joint stud and knuckle con-
tact area free of any grease or debris, otherwise
damage to the knuckle can occur. Use a clean shop
cloth with MoparTBrake Parts Cleaner applied to it
for proper cleaning. Do not spray the stud directly.
(2) Place the knuckle on the ball joint stud.
(3) Install a NEW steering knuckle to ball joint
stud nut. Tighten the nut by holding ball joint stud
with hex wrench while turning nut with a wrench
(Fig. 15). Using a crowsfoot wrench on a torquewrench, tighten the nut to a torque of 108 N´m (80 ft.
lbs.).
(4) Slide driveshaft stub axle into hub and bearing
assembly.
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 knuckle.
CAUTION: If the vehicle being serviced is equipped
with eccentric strut assembly attaching bolts, the
eccentric bolt must be installed in the bottom (slot-
ted) hole on the strut clevis bracket (Fig. 16).
NOTE: The strut clevis-to-steering knuckle bolts are
installed differently on each side. 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.
(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.
Tighten the tie rod end nut to a torque of 75 N´m (55
ft. lbs.).
Fig. 14 Using C-4150A To Release Ball Joint
1 - ALUMINUM KNUCKLE
2 - SPECIAL TOOL C-4150A
3 - LOWER CONTROL ARM
4 - NUT INSTALLED ON BALL JOINT STEM
Fig. 15 Ball Joint Nut Installation
1 - KNUCKLE
2 - BALL JOINT STUD
3 - LOWER CONTROL ARM
RSFRONT SUSPENSION2-9
KNUCKLE (Continued)
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