2003 CHRYSLER VOYAGER suspension

The rear wheel bearings used are similar to the
bearings used in the front suspension. A hub and
bearing assembly is used.
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
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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DESCRIPTION N´mFt.
Lbs.In.
Lbs.
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
BUSHINGS
REMOVAL - LEAF SPRING FRONT BUSHING
(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. 3).
(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. 3).
(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.
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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(7) Straighten the retainer tabs on the bushing
(Fig. 4).
(8) Place Remover/Installer, Special Tool 8459 on
leaf spring and bushing as shown (Fig. 5) and tighten
Set Screw securing Remover Plate to tool threaded
shaft.
(9) Tighten nut (Fig. 5), removing bushing from
spring eye.
(10) Remove the tool from spring, then remove
bushing from tool.
INSTALLATION - LEAF SPRING FRONT
BUSHING
(1) Install by hand NEW bushing in left side of
leaf spring eye.
(2) Place Remover/Installer, Special Tool 8459 on
leaf spring and bushing as shown (Fig. 6) and tighten
Set Screw securing Installer Plate (8459±3) to tool
threaded shaft.
(3) Tighten nut (Fig. 6), installing bushing in
spring eye. Tighten nut until there is approximately
a 1 mm gap between the bushing flange and the
spring eye.Do not bottom the flange against the
spring eye.
(4) Remove Remover/Installer from the bushing
and leaf spring.
(5) Bend the retainer tabs on bushing outward
against spring eye.
(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.
Fig. 3 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
Fig. 4 STRAIGHTENED RETAINING TABS
1 - SPRING EYE
2 - RETAINING TABS
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
RSREAR SUSPENSION2-29
BUSHINGS (Continued)
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(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 4mounting 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.
OPERATION
The hub and bearing has internal bearings that
allow the hub to rotate with the tire and wheel
assembly (and driveshaft on All-Wheel-Drive vehi-
cles). The five wheel mounting studs mount the tire
and wheel assembly, and disc brake rotor or brake
drum to the vehicle.
On All-Wheel-Drive vehicles, the splined mating of
the driveshaft stub axle and hub allows the drive-
shaft to rotate with the hub and wheel.
Front-Wheel-Drive vehicles equipped with antilock
brakes have a wheel speed sensor and tone wheel
mounted to the rear of the hub and bearing. The tone
wheel rotates with the hub which is sensed by the
wheel speed sensor.
DIAGNOSIS AND TESTING - HUB AND
BEARING
The bearing contained in the hub and 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
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)
Fig. 7 Hub And Bearing - FWD With ABS
2 - 30 REAR SUSPENSIONRS
BUSHINGS (Continued)
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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
FRONT-WHEEL-DRIVE VEHICLES
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) Remove wheel and tire. (Refer to 22 - TIRES/
WHEELS - REMOVAL)
(3) Remove brake drum or disc brake caliper and
rotor from hub and bearing. (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/DRUM - REMOVAL-
)(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
ROTOR - REMOVAL)
(4) If equipped with antilock brakes, perform the
following:
(a) Remove secondary (yellow) retaining clip at
rear of wheel speed sensor head (Fig. 8).
(b) Push up on metal retaining clip (Fig. 8) until
it bottoms. This will release wheel speed sensor
head from hub and bearing.
(c) While holding metal clip up, pull back on
wheel speed sensor head removing it from hub and
bearing.
(5) Remove the 4 bolts attaching the hub and bear-
ing to the rear axle.
CAUTION: Corrosion may occur between the hub
and bearing, and the axle. If this occurs the huband bearing will be difficult to remove from the
axle. If the hub and bearing will not come out of the
axle by pulling on it by hand, do not pound on the
hub and bearing to remove it from the axle. Damage
will occur. Use the following procedure.
(6) If the hub and bearing cannot be removed from
the axle by hand, use Remover, Special Tool 8458
(Fig. 9) and the following procedure to press the hub
and bearing out of the axle.
(a) Remove the two outboard spring plate bolts.
(b) Thread Threaded Guide Pins into hub and
bearing mounting bolt holes.
(c) Using the spring plate bolts, install the
Screw Mount, Special Tool 8458±2, as shown (Fig.
9). Mount the Screw Mount to the spring plate
with the tool number facing the hub and bearing
and the beveled edge on the bottom facing the
spring, otherwise the Forcing Screw will rub the
spring plate when installed.
(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) Install Forcing Screw, Special Tool 8458±3,
through Screw Mount from rear.
(g) Tighten the Forcing Screw up against dimple
in Push Plate and press hub and bearing out of
axle by continuing to tighten screw.
(h) Remove the tool.
Fig. 8 Sensor Connector At Hub And Bearing
1 - SECONDARY SENSOR RETAINING CLIP
2 - METAL SENSOR RETAINING CLIP
3 - HUB AND BEARING
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
RSREAR SUSPENSION2-31
HUB / BEARING (Continued)
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(i) 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
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 willremove 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.)
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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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.).
(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
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
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
RSREAR SUSPENSION2-33
HUB / BEARING (Continued)
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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.).
(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.
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
Fig. 16 Hub Nut And Washer
1 - CALIPER
2 - HUB NUT
3 - WASHER
4 - ROTOR
5 - ADAPTER
2 - 34 REAR SUSPENSIONRS
HUB / BEARING (Continued)
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