2002 CHRYSLER CARAVAN wheel bolts

ment settings to the vehicle specifications for camber,
caster and toe-in. (Refer to 2 - SUSPENSION/
WHEEL ALIGNMENT - SPECIFICATIONS)
(4) If front camber and caster are not within spec-
ifications, proceed to CAMBER AND CASTER below.
If caster and camber are within specifications, pro-
ceed to TOE which can be found following CAMBER
AND CASTER. Rear camber, caster and toe are not
adjustable. If found not to be within specifications,
reinspect for damaged suspension or body compo-
nents and replace as necessary.
CAMBER AND CASTER
Camber and caster settings on this vehicle are
determined at the time the vehicle is designed, by
the location of the vehicle's suspension components.
This is referred to as NET BUILD. The result is no
required adjustment of camber and caster after the
vehicle is built or when servicing the suspension
components. Thus, when performing a wheel align-
ment, caster and camber are not normally considered
adjustable angles. Camber and caster should be
checked to ensure they meet vehicle specifications.
If front camber is found not to meet alignment
specifications, it can be adjusted using an available
camber adjustment bolt package. Before installing a
camber adjustment bolt package on a vehicle found
to be outside the specifications, inspect the suspen-
sion components for any signs of damage or bending.
CAUTION: Do not attempt to adjust the vehicles
wheel alignment by heating, bending or by perform-
ing any other modification to the vehicle's front
suspension components or body.
If camber readings are not within specifications,
use the following procedure to install the front cam-
ber adjustment bolt package and then adjust front
camber.
CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION
The camber adjustment bolt package contains 2
flange bolts, 2 cam bolts, 2 dog bone washers, and 4
nuts. This package services both sides of the vehicle.
Use the package to attach the strut clevis bracket to
the steering knuckle after the strut clevis bracket
has been modified. To install and adjust the camber
adjustment bolt package, follow the procedure below.
(1) Raise the vehicle until its tires are not support-
ing the weight of the vehicle.
(2) Remove the front tire and wheel assemblies.
CAUTION: When removing the steering knuckle
from the strut clevis bracket, do not put a strain on
the brake flex hose. Also, do not let the weight of
the steering knuckle assembly be supported by the
brake flex hose when removed from the strutassembly. If necessary use a wire hanger to sup-
port the steering knuckle assembly or if required
remove the brake flex hose from the caliper assem-
bly.
CAUTION: The knuckle to strut assembly attaching
bolt shanks are serrated and must not be turned
during removal. Remove the nuts while holding the
bolts stationary.
(3) Remove the top and bottom, strut clevis
bracket to steering knuckle attaching bolts (Fig.
7)and discard. Separate the steering knuckle from
the strut clevis bracket and position steering knuckle
so it is out of the way of the strut.
CAUTION: When slotting the bottom mounting hole
on the strut clevis bracket, do not enlarge the hole
beyond the indentations on the sides of the strut
clevis bracket (Fig. 8).
(4) Using an appropriate grinder and grinding
wheel, slot the bottom hole in both sides of the strut
clevis bracket (Fig. 8).
CAUTION: After slotting the strut clevis bracket
hole, do not install the original attaching bolts when
assembling the steering knuckle to the strut assem-
bly. Only the flange bolts, cam bolts, and dog bone
washers from the service package must be used to
attach the steering knuckle to the strut after the
mounting hole is slotted.
Fig. 7 Clevis Bracket To Steering Knuckle Attaching
Bolts
1 - STRUT CLEVIS BRACKET
2 - ATTACHING BOLTS
3 - TIE ROD END
4 - ROTOR
5 - STEERING KNUCKLE
2 - 52 WHEEL ALIGNMENTRS
WHEEL ALIGNMENT (Continued)
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NOTE: The strut clevis-to-knuckle bolts are installed
differently on each side of the vehicle. Left-hand-
side bolts are installed from vehicle rear to front
(Fig. 9). Right-hand-side bolts are installed from
vehicle front to rear.
(5) Position the knuckle back into the strut clevis
bracket. Using the direction indicated in the above
note, install a flanged bolt from the service package
into the upper mounting hole. Using the direction
indicated in the above note, install a cam bolt into
the bottom mounting hole (Fig. 9).(6) Install a dog bone washer on the steering
knuckle to strut clevis bracket attaching bolts, then
install the nuts onto the bolts from the service pack-
age (Fig. 10). Tighten the bolts just enough to hold
the steering knuckle in position when adjusting cam-
ber, while still allowing the steering knuckle to move
in clevis bracket.
(7) Repeat the procedure to the other side strut
clevis bracket.
(8) Reinstall both front tire and wheel assemblies
and tighten to specifications.
(9) Lower the vehicle. Jounce the front and rear of
vehicle an equal amount of times.
(10) Adjust the front camber to the preferred set-
ting by rotating the lower eccentric cam bolt against
the cam stop areas on the strut clevis bracket (Fig.
11). When camber is set, tighten the upper strut cle-
vis bracket bolt and lower cam bolt. Again jounce
front and rear of vehicle an equal amount of times
and verify front camber setting. Torque both front
strut to steering knuckle attaching bolts to 81 N´m
(60 ft. lbs.) plus an additional 1/4 (90É) turn after the
required torque is met.
(11) 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 procedure.
TOE
(1) Center the steering wheel and lock in place
using a steering wheel clamp.
Fig. 8 Strut Clevis Bracket Bolt Hole Grinding Area
1 - UPPER STRUT TO STEERING KNUCKLE ATTACHING HOLE
2 - CAMBER ADJUSTMENT SLOT INDENTATION AREA ON
CLEVIS BRACKET
3 - LOWER STRUT TO STEERING KNUCKLE ATTACHING HOLE
4 - STRUT CLEVIS BRACKET
Fig. 9 Package Bolts Correctly Installed
1 - STEERING KNUCKLE
2 - FLANGED BOLT IN TOP HOLE
3 - CAM BOLT IN BOTTOM HOLE
4 - STRUT CLEVIS BRACKET
Fig. 10 Dog Bone Washer And Nuts Installed
1 - STEERING KNUCKLE
2 - DOG BONE WASHER
3 - STRUT CLEVIS BRACKET
4 - ATTACHING NUTS
RSWHEEL ALIGNMENT2-53
WHEEL ALIGNMENT (Continued)
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(3) Remove the wheel and tire assembly from the
vehicle. (Refer to 22 - TIRES/WHEELS - REMOVAL)
(4) Remove the wave washer (Fig. 3) from the end
of the half shaft.
(5) With the vehicle's brakes applied to keep hub
from turning,loosen and removethe half shaft
nut.
(6) Remove the two front disc brake caliper
adapter to steering knuckle attaching bolts (Fig. 4).(7) Remove the disc brake caliper assembly from
the steering knuckle. Caliper assembly is removed by
first rotating top of caliper assembly away from
steering knuckle and then removing bottom of assem-
bly out from under machined abutment on steering
knuckle.
(8) Support disc brake caliper assembly by using a
wire hook and suspending it from the strut assembly
(Fig. 5).Do not allow the brake caliper assembly
to hang by the brake flex hose.
(9) Remove the brake rotor from the hub and bear-
ing assembly.
(10) Remove the steering knuckle-to-strut attach-
ment bolts (Fig. 6) from the steering knuckle.
(11) Pull the steering knuckle from the strut clevis
bracket.
NOTE: Care must be taken not to separate the inner
C/V joint during this operation. Do not allow half
shaft to hang by inner C/V joint after removing
outer C/V Joint from the hub/bearing assembly in
steering knuckle, end of half shaft must be sup-
ported.
(12) Pull steering knuckle assembly down and
away from the outer C/V joint of the half shaft
assembly while pulling the joint out of the hub bear-
ing.
Fig. 3 Wave Washer
1 - HUB/BEARING ASSEMBLY
2 - WAVE WASHER
3 - STUB AXLE
Fig. 4 Front Brake Mounting
1 - BRAKE ROTOR
2 - HUB AND BEARING
3 - STEERING KNUCKLE
4 - ADAPTER MOUNTING BOLTS
5 - BRAKE CALIPER
6 - ADAPTER
7 - CLIP
Fig. 5 Properly Supported Disc Brake Caliper -
Typical
1 - STEERING KNUCKLE
2 - BRAKE FLEX HOSE
3 - CALIPER ASSEMBLY
4 - WIRE HANGER
5 - STRUT ASSEMBLY
RSHALF SHAFT - FRONT3-3
HALF SHAFT - FRONT (Continued)
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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. 10).
(7) Install steering knuckle in clevis bracket of
strut damper assembly. Install the strut damper to
steering knuckle attaching bolts. Tighten both bolts
to a torque of 81 N´m (60 ft. lbs.) plus an additional
1/4 turn.
(8) Install braking disc on hub and bearing assem-
bly.(9) Install disc brake caliper assembly on steering
knuckle. Caliper is installed by first sliding bottom of
caliper assembly under abutment on steering
knuckle, and then rotating top of caliper against top
abutment.
(10) Install disc brake caliper adapter to steering
knuckle attaching bolts (Fig. 4). Tighten the disc
brake caliper adapter attaching bolts to a torque of
169 N´m (125 ft. lbs.).
(11) Clean all foreign matter from the threads of
the outer CV joint. Install the washer and half shaft
to hub/bearing assembly nut on half shaft and
securely tighten nut.
(12) Install front wheel and tire assembly. Install
and tighten the wheel mounting stud nuts in proper
sequence until all nuts are torqued to half the
required specification. Then repeat the tightening
sequence to the full specified torque of 135 N´m (100
ft. lbs.).
(13) Lower vehicle.
(14) With the vehicle's brakes applied to keep hub
from turning, tighten the hub nut to a torque of 244
N´m (180 ft. lbs.) (Fig. 11).
(15) Install the spring wave washer on the end of
the half shaft.
(16) Install the hub nut lock, and anewcotter pin
(Fig. 2). Wrap cotter pin prongs tightly around the
hub nut lock as shown in (Fig. 2).
(17) Check for correct fluid level in transaxle
assembly. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 41TE/FLUID - STANDARD
PROCEDURE)
Fig. 9 Outer CV Joint Inspection
1 - OUTER C/V JOINT
2 - THIS AREA OF OUTER C/V JOINT MUST BE FREE OF ALL
DEBRIS AND MOISTURE, BEFORE INSTALLATION INTO
STEERING KNUCKLE.
Fig. 10 Correctly Installed Eccentric Attaching Bolt
1 - STEERING KNUCKLE
2 - FLANGED BOLT IN TOP HOLE
3 - CAM BOLT IN BOTTOM HOLE
4 - STRUT CLEVIS BRACKET
Fig. 11 Torquing Front Half Shaft To Hub Nut
1 - TORQUE WRENCH
RSHALF SHAFT - FRONT3-5
HALF SHAFT - FRONT (Continued)
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SPECIFICATIONS - HALF SHAFT - FRONT
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Bolts, Caliper Adapter to Knuckle 169 125 -
Nut, Hub 244 180 -
Nuts, Front Wheel Lug 135 100 -
Nut, Tie Rod End to Knuckle 75 55 -
Nut, Strut Clevis to Knuckle 81 +90É 60 +90É -
CV BOOT - INNER
REMOVAL
(1) Remove the half shaft requiring boot replace-
ment from the vehicle. (Refer to 3 - DIFFERENTIAL
& DRIVELINE/HALF SHAFT - REMOVAL)
(2)
Remove large boot clamp which retains inner tri-
pod joint sealing boot to tripod joint housing and discard.
(3)Remove small clamp which retains inner tripod
joint sealing boot to interconnecting shaft and discard.
(4) Remove the sealing boot from the tripod hous-
ing and slide it down the interconnecting shaft.
CAUTION: When removing the tripod joint housing
from the spider assembly, hold the bearings in
place on the spider trunions to prevent the bearings
from falling away.
(5) Slide the tripod joint housing off the spider
assembly and the interconnecting shaft (Fig. 12).(6) Remove snap-ring which retains spider assem-
bly to interconnecting shaft (Fig. 13).Do not hit the
outer tripod bearings in an attempt to remove
spider assembly from interconnecting shaft.
(7) Remove the spider assembly from interconnect-
ing shaft. If spider assembly will not come off inter-
connecting shaft by hand, it can be removed by
tapping spider assembly with a brass drift (Fig. 14).
(8) Slide sealing boot off interconnecting shaft.
(9) Thoroughly clean and inspect spider assembly,
tripod joint housing, and interconnecting shaft for
any signs of excessive wear.If any parts show
signs of excessive wear, the half shaft assembly
will require replacement. Component parts of
these half shaft assemblies are not serviceable.
INSTALLATION
(1) Slide inner CV joint seal boot retaining clamp,
onto the interconnecting shaft. Then, slide the
replacement inner CV joint sealing boot onto the
interconnecting shaft.Inner CV joint seal boot
Fig. 12 Spider Assembly Removal from Tripod Joint
Housing
1 - TRIPOD JOINT HOUSING
2 - SPIDER ASSEMBLY
3 - SEALING BOOT
Fig. 13 Spider Assembly Retaining Snap-Ring
1 - INTERCONNECTING SHAFT
2 - SPIDER ASSEMBLY
3 - RETAINING SNAP-RING
3 - 6 HALF SHAFT - FRONTRS
HALF SHAFT - FRONT (Continued)
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REMOVAL
(1) Lift vehicle on hoist so that the wheels hang
freely.
(2) Remove rear wheel.
(3) Remove cotter pin, nut lock, and wave washer
(Fig. 1).
(4) Remove hub nut and washer.
CAUTION: The half shaft outer CV joint, when
installed, acts as a bolt and secures the hub/bear-
ing assembly. If the vehicle is to be supported or
moved on its wheels, install and torque a bolt
through the hub. This will ensure that the hub/bear-
ing assembly cannot loosen.
(5) Remove inner half shaft retaining bolts (Fig. 2).(6) The half shaft is spring loaded. Compress inner
half shaft joint slightly and pull downward to clear
rear differential output flange. Then pull half shaft
assembly outward to remove (Fig. 3).
INSTALLATION
(1) Install the outer CV joint stub shaft through
the hub bearing (Fig. 4).
(2) The half shaft is spring loaded. Compress inner
half shaft joint slightly and push upward until the
inner CV joint flange engages the rear differential
output flange.
(3) Install the inner half shaft retaining bolts (Fig.
5). Torque the bolts to 61 N´m (45 ft.lbs.).
Fig. 1 Cotter Pin, Nut Lock, And Wave Washer
1 - HUB NUT
2 - NUT LOCK
3 - COTTER PIN
4 - SPRING WASHER
Fig. 2 Inner Half Shaft Bolts
1 - SHAFT
2 - FLANGE
Fig. 3 Half Shaft Removal
1 - BRAKE BACKING PLATE
2 - HALF SHAFT
Fig. 4 Half Shaft Installation
1 - BRAKE BACKING PLATE
2 - HALF SHAFT
RSHALF SHAFT - REAR3-15
HALF SHAFT - REAR (Continued)
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(4) Install the half shaft washer and hub nut.
Torque the hub nut to 244 N´m (180 ft.lbs.).
(5) Install the wave washer, nut lock, and a new
cotter pin (Fig. 6). Be sure to wrap the cotter pin
prongs tightly around the hub nut lock.(6) Install rear wheel. Torque the lug nuts to 135
N´m (100 ft.lbs.).
SPECIFICATIONS - HALF SHAFT - FRONT
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Nut, Hub 244 180 -
Nuts, Rear Wheel Lug 135 100 -
Bolt, Half Shaft to Output Flange 61 45 -
Fig. 5 Inner Half Shaft Bolts
1 - SHAFT
2 - FLANGE
Fig. 6 Cotter Pin, Nut Lock, And Wave Washer
1 - HUB NUT
2 - NUT LOCK
3 - COTTER PIN
4 - SPRING WASHER
3 - 16 HALF SHAFT - REARRS
HALF SHAFT - REAR (Continued)
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DIAGNOSIS AND TESTING - REAR DRIVELINE
MODULE OPERATION
Driveline module operation requires relatively
straight-forward diagnosis. Refer to the following
chart:
DRIVELINE MODULE DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
Rear wheels not
overrunning1) Bi-directional overrunning clutch
failure1) Replace overrunning clutch
components as required
No AWD in forward or
reverse directions, propeller
shaft turning1) Bi-directional overrunning clutch
failure1) Replace overrunning clutch
components as required
2) Viscous coupling failure 2) Replace viscous coupling
3) Rear differential failure 3) Replace the rear differential
assembly
No AWD in forward or
reverse directions, propeller
shaft not turning1) Power transfer unit failure. 1) Replace power transfer unit
components as necessary
Vibration at all speeds,
continuous torque transfer1) Mis-matched tires, worn tires on
front axle.1) Replace worn or incorrect
(mis-matched) tires with same
make and size
REMOVAL
(1) Raise vehicle on hoist.
(2) Drain fluid from overrunning clutch housing
and/or differential assembly if necessary.
(3) Remove propeller shaft. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/PROPELLER SHAFT -
REMOVAL)
(4) Disconnect left and right rear halfshafts from
output flanges (Fig. 2).(5) Remove torque arm mount to body bolts.
(6) Position transmission jack to driveline module
assembly and secure assembly to jack.
(7) Remove two driveline module-to-body bolts
(Fig. 3).
(8) Lower driveline module from vehicle and
remove from jack.
Fig. 2 Half Shaft Mounting Bolts
1 - SHAFT
2 - FLANGE
Fig. 3 Rear Drive Line Module Assembly Mounting
Bolts
1 - DRIVELINE MODULE RETAINING BOLT (2)
2 - RUBBER ISOLATOR
3 - WASHER
RSREAR DRIVELINE MODULE3-27
REAR DRIVELINE MODULE (Continued)
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