2003 CHRYSLER CARAVAN torque

INSTALLATION - AWD
CAUTION: Pivot bolt must face inboard to prevent
structural damage during installation of spring.
(1) Install the front eyelet of the rear leaf spring
into the spring mount. Install the pivot bolt and nut.
Do not tighten the pivot bolt at this time.
(2) Position the front spring mount for the rear
leaf spring against the floor pan of the vehicle.
Install the 4 mounting bolts for the front spring
mount (Fig. 26). Tighten the 4 mounting bolts to a
torque of 61 N´m (45 ft. lbs.).(3) Install the rear of the leaf spring onto the outer
half of the rear shackle. Install the inner half of the
rear hanger. Install the pin nuts and bolts on the
rear shackle,but do not tighten at this time.
(4) Raise axle assembly into correct position with
axle centered under spring locator post.
(5) Install axle plate bolts (Fig. 28). Tighten bolts
to 95 N´m (70 ft. lbs.) torque.
(6) Install shock absorber bolts.Do not tighten
at this time.
(7) Lower the vehicle and remove hoist arms and
block of wood from under vehicle.
CAUTION: The following sequence must be fol-
lowed when tightening the pin nuts on the rear
hanger for the rear leaf spring. First the hanger pin
nuts must be tightened to the specified torque
shown below. Then tighten the retaining bolts for
the inner to outer half of the spring hanger to the
torque specification listed below. This sequence
must be followed to properly seat the bushings into
the springs and to avoid bending the spring hanger.
(8) Tighten the spring front pivot bolt to 156 N´m
(115 ft. lbs.) torque.
(9) Tighten rear spring shackle pin nuts to 61 N´m
(45 ft. lbs.) torque.
(10) Tighten rear spring shackle inner to outer
half retaining bolts to 61 N´m (45 ft. lbs.) torque.
(11) Tighten the lower shock absorber mounting
bolt to 102 N´m (75 ft. lbs.) torque.
Fig. 28 Axle Plate Bolts
1 - LEAF SPRING
2 - AXLE PLATE BOLTS (4)
3 - AXLE PLATE
4 - AXLE
Fig. 29 All-Wheel-Drive Rear Suspension
1 - SHACKLE
2 - REAR MOUNT (HANGER)
3 - LEAF SPRING (MULTI-LEAF)
4 - AWD REAR AXLE
Fig. 30 Leaf Spring Front Mount (Typical)
1 - LEAF SPRING
2 - SPRING MOUNT
RSREAR SUSPENSION2-39
SPRING - AWD (Continued)
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INSTALLATION - FWD
(1) Assemble front spring mount to front of spring
eye and install pivot bolt and nut.Do not tighten
at this time.
CAUTION: Pivot bolt must face inboard to prevent
structural damage during installation of spring.
(2) Raise front of spring and install four mounting
bolts (Fig. 31). Tighten bolts to 61 N´m (45 ft. lbs.)
torque.
(3) Install rear of spring onto rear spring shackle.
Install shackle plate. Do not tighten.
(4) Verify lower leaf spring isolator is in position.(5) Raise axle into correct position on leaf spring
with axle centered under spring locator post (Fig.
36).
(6) Verify that the leaf spring isolator is correctly
positioned in the spring plate.
(7) Install spring plate in position on the spring
(Fig. 33).
(8) Install spring plate bolts (Fig. 33). Tighten
bolts to 95 N´m (70 ft. lbs.) torque.
(9) Install lower shock absorber bolt.Do not
tighten at this time.
(10) Remove jack under axle.
(11) Lower the vehicle and remove hoist arms and
block of wood from under vehicle.
CAUTION: The following sequence must be fol-
lowed when tightening the pin nuts on the rear
hanger for the rear leaf spring. First the hanger pin
nuts must be tightened to the specified torque
shown below. Then tighten the retaining bolts for
the inner to outer half of the spring hanger to the
torque specification listed below. This sequence
must be followed to properly seat the bushings into
the springs and to avoid bending the spring hanger.
(12) Tighten the spring front pivot bolt to 156 N´m
(115 ft. lbs.) torque.
(13) Tighten rear spring shackle pin nuts to 61
N´m (45 ft. lbs.) torque.
(14) Tighten rear spring shackle inner to outer
half retaining bolts to 61 N´m (45 ft. lbs.) torque.
(15) Tighten the lower shock absorber mounting
bolt to 102 N´m (75 ft. lbs.) torque.
Fig. 34 Spring Plate
1 - SPRING PLATE
Fig. 35 Rear Spring Hanger
1 - SHACKLE PLATE
2 - SPRING HANGER
Fig. 36 Leaf Spring Locator Post
1 - LEAF SPRING ISOLATOR
2 - LEAF SPRING
3 - LOCATOR POST
RSREAR SUSPENSION2-41
SPRING - FWD (Continued)
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SPRING MOUNTS - FRONT
REMOVAL
(1) Raise vehicle on frame-contact hoist as follows:
(a) Position the hoist arm supporting the corner
of the vehicle to be serviced against a block of wood
placed on the body sill as shown (Fig. 37).
(b) Position the remaining hoist arms at each
corner of the vehicle in the normal fashion. (Refer
to LUBRICATION & MAINTENANCE/HOISTING
- STANDARD PROCEDURE)
(c) Raise the vehicle to a comfortable working
level.
(2) Position an under-hoist utility jack or transmis-
sion jack under rear axle toward the side needing
bushing replacement. Jack pad should just contact
axle.
(3) Remove shock absorber lower mounting bolt.
NOTE: If shock absorber bolt deflects upward dur-
ing removal, raise axle by adjusting support jack. If
shock absorber bolt deflects downward during
removal, lower axle by adjusting support jack (or by
pulling on axle).(4) Remove four bolts securing leaf spring front
mounting bracket to the body (Fig. 37).
(5) Using jack,slowlylower rear axle, permitting
the forward end of rear spring to hang down. Lower
it enough to allow access to spring pivot bolt. It may
be necessary to place a wooden block between the
spring and vehicle to hold forward end of the spring
in place.
(6) Remove leaf spring forward pivot bolt, then
remove mounting bracket.
INSTALLATION
(1) 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.
(2) Install the nut on the pivot bolt and lightly
tighten. Do not fully tighten bolt at this time.
(3) 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. 37). Tighten the
four mounting bolts to 61 N´m (45 ft. lbs.) torque.
(4) 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.
(5) Lower the vehicle and remove hoist arms and
block of wood from under vehicle.
(6) Tighten the spring front pivot bolt to 156 N´m
(115 ft. lbs.) torque.
(7) Tighten the lower shock absorber mounting
bolt to 88 N´m (65 ft. lbs.) torque.
Fig. 37 LIFTING POINT AND SPRING MOUNT
1 - BODY SILL AREA
2 - MOUNTING BOLTS
3 - SPRING MOUNTING BRACKET
4 - LEAF SPRING
5 - HOIST LIFT ARM
6 - WOODEN BLOCK
2 - 42 REAR SUSPENSIONRS
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SPRING MOUNTS - REAR
REMOVAL
(1) Remove the attaching nuts and bolts from the
leaf spring rear shackle (Fig. 38) and (Fig. 39).
(2) Install a jackstand under the side of the axle
having the leaf spring mount removed. Using the
jackstand, support the weight of the axle and leaf
spring.
(3) Remove the lower mounting bolt from the
shock absorber.
(4) Remove the bolts attaching the leaf spring rear
mount to the body of the vehicle (Fig. 40).(5) Lower the jackstand and the rear of the leaf
spring. Remove the shackle from the leaf spring
bushing.
INSTALLATION
CAUTION: The following sequence must be fol-
lowed when tightening the pin nuts on the rear
hanger for the rear leaf spring. First the hanger pin
nuts must be tightened to the specified torque.
Then tighten the retaining bolts for the inner to
outer half of the spring hanger to the specified
torque. This sequence must be followed to avoid
bending the spring hanger.
(1) For installation, reverse removal procedure. Do
not tighten rear spring shackle nuts fully until vehi-
cle is lowered and the full vehicle weight is applied
to the rear wheels. Tighten rear spring mount bolts
to 61 N´m (45 ft. lbs.). Tighten shackle nuts to 61
N´m (45 ft. lbs.).
STABILIZER BAR
DESCRIPTION
Front-wheel-drive models use a stabilizer bar that
is mounted behind the rear axle. All-wheel-drive
models use a stabilizer bar that is mounted in front
of the rear axle.
The stabilizer bar interconnects both sides of the
rear axle and attaches to the rear frame rails using 2
rubber isolated link arms.
Both type stabilizer bars have the same basic com-
ponents. Attachment to the rear axle tube, and rear
frame rails is through rubber-isolated bushings.
Fig. 38 Leaf Spring Shackle Nuts (FWD)
1 - SHACKLE PLATE
Fig. 39 All-Wheel-Drive Rear Suspension
1 - SHACKLE
2 - REAR MOUNT (HANGER)
3 - LEAF SPRING (MULTI-LEAF)
4 - AWD REAR AXLE
Fig. 40 Rear Spring Mount
1 - LEAF SPRING MOUNT
RSREAR SUSPENSION2-43
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The 2 rubber isolated links are connected to the
rear frame rails by brackets. These brackets are
bolted to the bottom of the frame rails.
OPERATION
Jounce and rebound movements affecting one
wheel are partially transmitted to the opposite wheel
to reduce body roll.
REMOVAL
REMOVAL - AWD
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) Remove the bolts securing the stabilizer bar to
links on each end of the bar.
(3) While holding the stabilizer bar in place,
remove the bolts that attach the stabilizer bar bush-
ing retainers to the rear axle.
(4) Remove the stabilizer bar from the vehicle.
(5) If the links need to be serviced, remove the
upper link arm to bracket bolt. Then remove link
arm from frame rail attaching bracket.
REMOVAL - FWD
(1) Raise vehicle. See Hoisting in Lubrication and
Maintenance.
(2) Remove the bolts securing the stabilizer bar to
links on each side of bar.
(3) While holding the stabilizer bar in place,
remove the bolts that attach the stabilizer bar bush-
ing retainers to the rear axle.
(4) Remove the stabilizer bar from the vehicle.
INSTALLATION
INSTALLATION - AWD
(1) Install the stabilizer bar on the rear axle.
(2) Install bushing retainer bolts. Do not tighten at
this time.
(3) Install bolts connecting links to stabilizer bar.
Do not tighten at this time.
(4) Lower the vehicle so that the full weight of the
vehicle is on all four tires. With the vehicle at its
curb height, tighten the following bolts to the torques
listed:
²Stabilizer bar bushing retainer-to-axle bracket
bolts Ð 61 N´m (45 ft. lbs.)
²Stabilizer bar-to-link bolts Ð 61 N´m (45 ft. lbs.)
INSTALLATION - FWD
(1) Lift the stabilizer bar onto the rear axle and
install the two retainer mounting bolts. DO NOT
TIGHTEN.
(2) Install the bolts attaching the stabilizer bar
links to the stabilizer bar. DO NOT TIGHTEN.
(3) Lower the vehicle so that the full weight of the
vehicle is on all four tires. With the vehicle at its
curb height, tighten the following bolts to the torques
listed:
²Stabilizer bar bushing retainer-to-axle bracket
bolts Ð 61 N´m (45 ft. lbs.)
²Stabilizer bar-to-link Ð 61 N´m (45 ft. lbs.)
TRACK BAR
DESCRIPTION
On front-wheel-drive applications of this vehicle
that are equipped with single leaf rear springs, a
track bar is used on the rear axle (Fig. 1).
The track bar connects the rear axle to the frame/
body of the vehicle. The track bar is isolated from the
body of the vehicle by an isolator bushing located in
each end of the track bar.
OPERATION
The track bar prevents excessive side-to-side move-
ment of the rear axle. The track bar is used to keep
the location of the axle in the correct position for
optimum handling and control of the vehicle.
REMOVAL
(1) Remove the nut and bolt mounting the track
bar to the rear axle (Fig. 41).
Fig. 41 Track Bar Mounting To Axle (Typical)
1 - LOWER TRACK BAR BOLT INSTALLATION
2 - 44 REAR SUSPENSIONRS
STABILIZER BAR (Continued)
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(2) Remove the nut and bolt attaching the track
bar to the track bar mount on the body of the vehicle.
Remove the track bar from the track bar mount.
INSTALLATION
(1) Install the track bar first into the body mount
for the track bar (Fig. 42). Install the track bar bolt
with the head of the bolt facing toward the rear of
the vehicle (Fig. 43). Do not tighten.
(2) Install the track bar into its mounting bracket
on the rear axle (Fig. 41). Install the track bar bolt
with the head of the bolt facing toward the rear of
the vehicle. Do not tighten.
(3) Lower the vehicle to the ground until the full
weight of the vehicle is supported by the wheels.
Tighten both track bar attaching bolts to a torque of
95 N´m (70 ft. lbs.).
Fig. 42 Track Bar Installation (Typical)
1 - TRACK BAR REPLACEMENT
Fig. 43 Track Bar Bolt Installation
1 - TRACK BAR BOLT
RSREAR SUSPENSION2-45
TRACK BAR (Continued)
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THRUST ANGLE
Thrust angle is the averaged direction the rear
wheels are pointing in relation to the vehicle's center
line (Fig. 6). The presence of negative or positive
thrust angle causes the rear tires to track improperly
to the left or right of the front tires (dog tracking).
²Negative thrust angle means the rear tires are
tracking to the left of the front tires.
²Positive thrust angle means the rear tires are
tracking to the right of the front tires.
Improper tracking can cause undue tire wear, a
lead or pull and a crooked steering wheel. Excessive
thrust angle can usually be corrected by adjusting
the rear wheel toe so that each wheel has one-half of
the total toe measurement.
DIAGNOSIS AND TESTING - SUSPENSION AND STEERING
CONDITION POSSIBLE CAUSES CORRECTION
Front End Whine On Turns 1. Defective wheel bearing 1. Replace wheel bearing
2. Incorrect wheel alignment 2. Check and reset wheel alignment
3. Worn tires 3. Replace tires
Front End Growl Or
Grinding On Turns1. Defective wheel bearing 1. Replace wheel bearing
2. Engine mount grounding 2. Check for motor mount hitting frame rail
and reposition engine as required
3. Worn or broken C/V joint 3. Replace C/V joint
4. Loose wheel lug nuts 4. Verify wheel lug nut torque
5. Incorrect wheel alignment 5. Check and reset wheel alignment
6. Worn tires 6. Replace tires
7. Front strut pin in upper strut mount 7. Replace the front strut upper mount and
bearing
Front End Clunk Or Snap
On Turns1. Loose lug nuts 1. Verify wheel lug nut torque
2. Worn or broken C/V joint 2. Replace C/V joint
3. Worn or loose tie rod 3. Tighten or replace tie rod end
4. Worn or loose ball joint 4. Tighten or replace ball joint
5. Worn/loose control arm bushing 5. Replace control arm bushing
6. Loose stabilizer bar. 6. Tighten stabilizer bar to specified torque
7. Loose strut mount to body
attachment7. Tighten strut attachment to specified
torque
8. Loose crossmember bolts 8. Tighten crossmember bolts to specified
torque
Fig. 6 Thrust Angle
RSWHEEL ALIGNMENT2-49
WHEEL ALIGNMENT (Continued)
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CONDITION POSSIBLE CAUSES CORRECTION
Front End Whine With
Vehicle Going Straight At A
Constant Speed1. Defective wheel bearing 1. Replace wheel bearing
2. Incorrect wheel alignment 2. Check and reset wheel alignment
3. Worn tires 3. Replace tires
4. Worn or defective transaxle gears
or bearings4. Replace transaxle gears or bearings
Front End Growl Or
Grinding With Vehicle
Going Straight At A
Constant Speed1. Engine mount grounding 1. Reposition engine as required
2. Worn or broken C/V joint 2. Replace C/V joint
Front End Whine When
Accelerating Or
Decelerating1. Worn or defective transaxle gears
or bearings1. Replace transaxle gears or bearings
Front End Clunk When
Accelerating Or
Decelerating1. Worn or broken engine mount 1. Replace engine mount
2. Worn or defective transaxle gears
or bearings2. Replace transaxle gears or bearings
3. Loose lug nuts 3. Verify wheel lug nut torque
4. Worn or broken C/V joint 4. Replace C/V joint
5. Worn or loose ball joint 5. Tighten or replace ball joint
6. Worn or loose control arm bushing 6. Replace control arm bushing
7. Loose crossmember bolts 7. Tighten crossmember bolts to specified
torque
8. Worn tie rod end 8. Replace tie rod end
Road Wander 1. Incorrect tire pressure 1. Inflate tires to recommended pressure
2. Incorrect front or rear wheel toe 2. Check and reset wheel toe
3. Worn wheel bearings 3. Replace wheel bearing
4. Worn control arm bushings 4. Replace control arm bushing
5. Excessive friction in steering gear 5. Replace steering gear
6. Excessive friction in steering shaft
coupling6. Replace steering coupler
7. Excessive friction in strut upper
bearing7. Replace strut bearing
Lateral Pull 1. Unequal tire pressure 1. Inflate all tires to recommended
pressure
2. Radial tire lead 2. Perform lead correction procedure
3. Incorrect front wheel camber 3. Check and reset front wheel camber
4. Power steering gear imbalance 4. Replace power steering gear
5. Wheel braking 5. Correct braking condition causing
lateral pull
Excessive Steering Free
Play1. Incorrect Steering Gear Adjustment 1. Adjust Or Replace Steering Gear
2. Worn or loose tie rod ends 2. Replace or tighten tie rod ends
3. Loose steering gear mounting bolts 3. Tighten steering gear bolts to specified
torque
4. Loose or worn steering shaft
coupler4. Replace steering shaft coupler
2 - 50 WHEEL ALIGNMENTRS
WHEEL ALIGNMENT (Continued)
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