2002 CHRYSLER VOYAGER torque

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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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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(6) Position spring mounting bracket over spring
eye and install pivot bolt through center of bushing
from theoutboardside.
NOTE: The pivot bolt must be installed from the
outboard side to allow proper bracket to body
mounting.
(7) Install the nut on the pivot bolt and lightly
tighten. Do not fully tighten bolt at this time.
(8) Raise the under-hoist utility jack or transmis-
sion jack, guiding the forward mounting bracket into
place against the body. It may help to use a drift
punch placed through the hole centered between the
mounting bolt holes in the bracket and the pilot hole
in the body of the vehicle as a guide. When the four
mounting bolt holes line up with their threads in the
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 88 N´m (65 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 (Unit III). The hub and bear-
ing 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.
Fig. 5 TOOL 8459 MOUNTED FOR BUSHING
REMOVAL
1 - BUSHING
2 - BEARING
3 - WASHER
4 - NUT
5 - BODY (8459-1)
6 - PIN
7 - REMOVER PLATE (8459-2)
8 - SET SCREW
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)
2 - 30 REAR SUSPENSIONRS
BUSHINGS (Continued)
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(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.(2) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(3) Remove the wheel/tire assembly. (Refer to 22 -
TIRES/WHEELS - REMOVAL)
(4) Remove the cotter pin and nut retainer (Fig.
18) from the stub shaft of the outer C/V joint.
(5) Remove the spring washer (Fig. 17) 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 mounting the driveshaft
inner joint to the output shaft of the rear drive line
module.
(8) Remove the rear wheel speed sensor (Fig. 19)
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 front of caliper up
from the adapter. Then pull the rear of the caliper
and the outboard brake shoe anti-rattle clip out from
under the rear 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
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
Fig. 10 Correctly Supported Caliper
1 - WIRE
2 - CALIPER
3 - ADAPTER
4 - ROTOR
5 - INNER FENDER
2 - 32 REAR SUSPENSIONRS
HUB / BEARING (Continued)
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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.INSTALLATION
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 and 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 5 - BRAKES/HYDRAULIC/
MECHANICAL/DRUM - INSTALLATION)(Refer to 5
- BRAKES/HYDRAULIC/MECHANICAL/ROTOR -
INSTALLATION)
(6) Install wheel and tire (Refer to 22 - TIRES/
WHEELS - INSTALLATION). 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 5
- BRAKES/HYDRAULIC/MECHANICAL/BRAKE
PADS/SHOES - ADJUSTMENTS)
(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.).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
RSREAR SUSPENSION2-33
HUB / BEARING (Continued)
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(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.
(6) Install the disc brake caliper guide pin bolts
(Fig. 15). Tighten the guide pin bolts to a torque of
35 N´m (26 ft. lbs.).
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
Fig. 14 Removing/Installing Caliper (Left Side
Shown)
1 - LIFT THIS END OF CALIPER AWAY FROM ADAPTER FIRST
2 - DISC BRAKE CALIPER
3 - ADAPTER ABUTMENT
4 - OUTBOARD BRAKE SHOE HOLD DOWN CLIP
5 - OUTBOARD BRAKE SHOE
6 - ROTOR
7 - ADAPTER
Fig. 15 Caliper Guide Pin Bolts
1 - STUD PIN BOLTS
2 - DISC BRAKE CALIPER
3 - DRIVESHAFT
4 - AXLE
5 - DISC BRAKE CALIPER ADAPTER
2 - 34 REAR SUSPENSIONRS
HUB / BEARING (Continued)
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(7) Clean all foreign material off the threads of the
outer C/V joint stub shaft. Install the washer and
hub nut (Fig. 16) on the stub shaft of the outer C/V
joint.
(8) Lower vehicle.
(9) Set the park brake.This is required to keep
the driveshaft from rotating when tightening
and torquing the hub nut and driveshaft inner
joint to driveline module mounting nuts.
(10) Raise vehicle.
(11) Tighten the driveshaft inner joint to drive line
module output shaft mounting bolts to a torque of 61
N´m (45 ft. lbs.).
(12) Tighten the outer C/V joint hub nut (Fig. 16)
to a torque of 244 N´m (180 ft. lbs.).
(13) Install the spring washer (Fig. 17) on the stub
shaft of the outer C/V joint.
(14) Install the nut retainer and cotter pin (Fig.
18) 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. 19). Tighten the wheel speed sen-
sor attaching bolt to a torque of 12 N´m (105 in. lbs).
(16) Install wheel and tire. (Refer to 22 - TIRES/
WHEELS - INSTALLATION)
(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) Lower vehicle.CAUTION: Before moving vehicle, pump the brake
pedal several times to insure the vehicle has a firm
brake pedal to adequately stop vehicle.
Fig. 16 Hub Nut And Washer
1 - CALIPER
2 - HUB NUT
3 - WASHER
4 - ROTOR
5 - ADAPTER
Fig. 17 Spring Washer
1 - HUB NUT
2 - STUB SHAFT
3 - ROTOR
4 - SPRING WASHER
Fig. 18 Cotter Pin And Nut Retainer
1 - CALIPER
2 - COTTER PIN
3 - ROTOR
4 - NUT RETAINER
5 - OUTER C/V JOINT
RSREAR SUSPENSION2-35
HUB / BEARING (Continued)
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(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
REMOVAL - AWD AND HEAVY DUTY
(1) Using slip-joint pliers grasp the base of the
jounce bumper. Turn the base counterclockwise (Fig.
20).
(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. 21).
(2) Remove the jounce bumper from the frame rail.
INSTALLATION
INSTALLATION - AWD AND HEAVY DUTY
(1) Install jounce bumper through bumper support
plate and thread into welded nut in frame rail.
(2) Tighten the jounce bumper to 33 N´m (290 in.
lbs.) torque.
INSTALLATION - FRONT-WHEEL-DRIVE
(1) Hook the forward end of the jounce bumper
bracket in the mounting hole of the frame rail, then
install the mounting bolt in the opposite end, secur-
ing the bumper to the frame rail. Tighten the jounce
bumper mounting bolt to 33 N´m (290 in. lbs.) torque.
Fig. 19 Wheel Speed Sensor
1 - MOUNTING BOLT
2 - WHEEL SPEED SENSOR
Fig. 20 Jounce Bumper
1 - JOUNCE BUMPER
Fig. 21 Jounce Bumper - FWD
1-JOUNCE BUMPER
2 - 36 REAR SUSPENSIONRS
HUB / BEARING (Continued)
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