2004 CHRYSLER VOYAGER brake rotor

TOWING
STANDARD PROCEDURE - TOWING
WARNINGS AND CAUTIONS
WARNING: DO NOT ALLOW TOWING ATTACHMENT
DEVICES TO CONTACT THE FUEL TANK OR LINES,
FUEL LEAK CAN RESULT.
DO NOT LIFT OR TOW VEHICLE BY FRONT OR
REAR BUMPER.
DO NOT GO UNDER A LIFTED VEHICLE IF NOT
SUPPORTED PROPERLY ON SAFETY STANDS.
DO NOT ALLOW PASSENGERS TO RIDE IN A
TOWED VEHICLE.
USE A SAFETY CHAIN THAT IS INDEPENDENT
FROM THE TOWING ATTACHMENT DEVICE.
CAUTION: Do not damage brake lines, exhaust sys-
tem, shock absorbers, sway bars, or any other
under vehicle components when attaching towing
device to vehicle.
Do not secure vehicle to towing device by the use
of front or rear suspension or steering components.
Remove or secure loose or protruding objects from
a damaged vehicle before towing.
Refer to state and local rules and regulations before
towing a vehicle.
Do not allow weight of towed vehicle to bear on
lower fascia, air dams, or spoilers.
RECOMMENDED TOWING EQUIPMENT
To avoid damage to bumper fascia and air dams
use:
²FWD vehicles, use of a flat bed towing device or
a wheel lift is recommended (Fig. 7).
²AWD vehicles, a flat bed towing device or a
wheel lift and towing dolly is recommended (Fig. 7).
When using a wheel lift towing device, be sure the
disabled vehicle has at least 100 mm (4 in.) ground
clearance. If minimum ground clearance cannot be
reached, use a towing dolly. If a flat bed device is
used, the approach angle should not exceed 15
degrees.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels removed,
install lug nuts to retain brake drums or rotors.
A towed vehicle should be raised until the lifted
wheels are a minimum 100 mm (4 in.) from the
ground. Be sure there is at least 100 mm (4 in.)
clearance between the tail pipe and the ground. If
necessary, remove the wheels from the front end ofthe vehicle and lower the front end closer to the
ground, to increase the ground clearance at the rear
of the vehicle. Install lug nuts on wheel attaching
studs to retain brake drums or rotors.
LOCKED VEHICLE TOWING
When a locked vehicle must be towed with the
front wheels on the ground, use a towing dolly or flat
bed hauler.
FLAT TOWING WITH TOW BAR
²Three speed automatic transaxle vehicles can be
flat towed at speeds not to exceed 40 km/h (25 mph)
for not more than 25 km (15 miles). The steering col-
umn must be unlocked and gear selector in neutral.
²Four speed electronic automatic transaxle vehi-
cles can be flat towed at speeds not to exceed 72
km/h (44 mph) for not more than 160 km (100 miles).
The steering column must be unlocked and gear
selector in neutral.
²AWD models should not be flat towed. For addi-
tional information, refer toRECOMMENDED TOW-
ING EQUIPMENTin this section.
FLAT BED TOWING TIE DOWNS
CAUTION: Do not tie vehicle down by attaching
chains or cables to suspension components or
engine mounts, damage to vehicle can result.
The vehicle can be tied to a flat bed device using
the two pair of front slots on the bottom surface of
the rails, behind the front wheels. The two pair of
rear slots on the bottom of the rail between the
bumper extension bolts and on the bottom of the rail
just rearward of the jounce bumper. Vehicles
equipped with a rear sway bar have brackets at this
location.
Fig. 7 RECOMMENDED TOWING
1 - WHEEL LIFT
2 - FLAT BED
RSLUBRICATION & MAINTENANCE0-29

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

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.
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)

(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.
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 holeson 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.
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)

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.
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 wheel and tire assembly from the
vehicle.
(3) Remove the cotter pin, nut lock and spring
washer from the end of the stub axle and hub nut
(Fig. 8).
(4) Have a helper apply the vehicle's brakes to
keep hub from turning,loosen and removethe hub
nut (Fig. 8).
(5) Remove disc brake caliper and adapter as an
assembly from knuckle as shown (Fig. 9). Hang
assembly out of the way using a bungee cord or wire
(Fig. 10).Do not allow caliper to hang by brake
hose.
Fig. 8 Hub Nut
1 - HUB NUT
2 - NUT LOCK
3 - COTTER PIN
4 - SPRING WASHER
Fig. 9 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. 10 Caliper And Driveshaft Suspended
1 - HANGER SUSPENDING CALIPER
2 - HANGER SUSPENDING DRIVESHAFT
3 - DRIVESHAFT
4 - BRAKE CALIPER
RSFRONT SUSPENSION2-7
KNUCKLE (Continued)

(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.).
(7) If equipped with antilock brakes, install wheel
speed sensor and mounting bolt on steering knuckle
(Fig. 13). Tighten the speed sensor bolt to a torque of
7 N´m (60 in. lbs.).
(8) Install brake rotor on hub and bearing (Fig. 9).
(9) Install disc brake caliper and adapter assembly
on steering knuckle. Install adapter amounting bolts
and tighten to 169 N´m (125 ft. lbs.).
(10) Clean any debris from the threads of the
outer C/V joint stub axle.
(11) Install the washer and hub nut on stub axle.
(12) Have a helper apply the vehicle's brakes to
keep hub from turning, then tighten hub nut to a
torque of 244 N´m (180 ft. lbs.).
(13) Install the spring wave washer on the end of
the stub axle.
(14) Install the hub nut lock, and anewcotter pin
(Fig. 8). Wrap cotter pin prongs tightly around the
hub nut lock.
(15) Install wheel and tire assembly. Install and
tighten the wheel mounting nuts in proper sequence
until all nuts are torqued to half the required speci-
fication. Then repeat the tightening sequence to the
full specified torque of 135 N´m (100 ft. lbs.).
(16) Lower vehicle.
(17) Set front wheel alignment camber and toe as
necessary. (Refer to 2 - SUSPENSION/WHEEL
ALIGNMENT - STANDARD PROCEDURE)
LOWER BALL JOINT
DESCRIPTION
The ball joint is an integral part of the lower con-
trol arm (Fig. 1). The ball joint has a tapered stud
that is pressed into the aluminum knuckle. The ball
joint stud is threaded on the end for a retainer nut.
The ball joint has a non-vented seal boot. The seal
boot has an integrated heat shield.
The ball joint used in the lower control arm of this
vehicle is a sealed-for-life ball joint and requires no
maintenance lubrication. The ball joint has been
lubricated-for-life during the manufacturing process.
A special fitting cap is installed on the fill port. This
cap must not be removed and replaced with a com-
mon zirc fitting. The special cap is there to eliminate
the possibility of lubrication latter during the ball
joints life, thus damaging the non-vented seal boot.
NOTE: The ball joint does not require any type of
additional lubrication for the life of the vehicle. No
attempt should be made to ever add any lubrication
to the lower ball joint.
OPERATION
The ball joint is a pivotal joint on the lower control
arm that allows the knuckle to move up and down,
and turn with ease.
DIAGNOSIS AND TESTING - LOWER BALL
JOINT
With the weight of the vehicle resting on the road
wheels, grasp the special fitting cap on the bottom of
the ball joint and with no mechanical assistance or
added force, attempt to rotate the grease fitting.
If the ball joint is worn, the grease fitting will
rotate easily. If movement is noted, replacement of
the control arm is recommended.
LOWER BALL JOINT SEAL
BOOT
DESCRIPTION - EXPORT
The lower ball joint seal boot is a two piece unit. It
consists of the seal boot, plus a separate shield that
is located in a groove at the top of the seal boot.
NOTE: The seal boot should only be replaced if
damaged during vehicle service. The entire lower
control arm should be replaced if the joint has been
contaminated.
Fig. 16 Correctly Installed Eccentric Attaching Bolt
1 - STEERING KNUCKLE
2 - FLANGED BOLT IN TOP HOLE
3 - CAM BOLT IN BOTTOM HOLE
4 - STRUT CLEVIS BRACKET
2 - 10 FRONT SUSPENSIONRS
KNUCKLE (Continued)

(6) Back off the forcing screw and remove tool.
(7) Install lower control arm on vehicle. (Refer to 2
- SUSPENSION/FRONT/LOWER CONTROL ARM -
INSTALLATION)
INSTALLATION - LOWER CONTROL ARM
(1) Position lower control arm assembly into front
suspension cradle crossmember guiding bushings into
mounting position (Fig. 22).
(2) Install NEW pivot bolt attaching front bushing
of lower control arm to front suspension cradle cross-
member (Fig. 29).Do not tighten or torque pivot
bolt at this time.
(3) Install the reinforcement on the front suspen-
sion cradle crossmember and install the bolts attach-
ing the reinforcement to the cradle crossmember
(Fig. 22). Tighten the M-14 size bolts to a torque of
153 N´m (113 ft. lbs.). Tighten the M-12 size bolts to
a torque of 106 N´m (78 ft. lbs.).
(4) Install the lower control arm rear bushing
retainer bolts through reinforcement on each side of
each lower control arm rear bushing. Tighten these
M-10 size bolts to a torque of 61 N´m (45 ft. lbs.).
(5) Install the two bolts and bushings attaching
the reinforcement and rear of cradle crossmember to
body of vehicle (Fig. 22). Tighten bolts to a torque of
163 N´m (120 ft. lbs.).
(6) Install the power steering cooler (Fig. 21).
Tighten bolts to a torque of 11 N´m (100 in. lbs.).
(7) Reinstall steering knuckle, brake rotor and cal-
iper. (Refer to 2 - SUSPENSION/FRONT/KNUCKLE
- INSTALLATION)CAUTION: When locating jack stands under lower
control arms, do not place the jack stands under
the ball joints (Fig. 30).
(8) Position jack stands under the lower control
arms as close to the ball joints as possible (Fig. 30).
Lower the vehicle onto the jack stands until the jack
stands are supporting the total weight of the vehicle.
(9) Tighten front lower control arm pivot bolt to a
torque of 183 N´m (135 ft. lbs.).
(10) Install the wheel and tire assembly. Install
and 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.).
(11) Raise vehicle, remove jack stands and lower
vehicle to the ground.
(12) Perform front wheel alignment as necessary.
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
STANDARD PROCEDURE)
STABILIZER BAR
DESCRIPTION
The stabilizer bar interconnects both front struts of
the vehicle and is attached to the front crossmember
(Fig. 1).
Attachment of the stabilizer bar to the front cross-
member is through 2 rubber-isolator cushion bush-
ings and retainers. A double ball jointed stabilizer
bar link is used to attach each end of the stabilizer
bar to the front strut assemblies. All parts of the sta-
bilizer bar are replaceable as individual components.
Fig. 29 Lower Control Arm Bushing Pivot Bolt
Correctly Installed
1 - PIVOT BOLT
2 - LOWER CONTROL ARM
3 - FRONT SUSPENSION CRADLE CROSSMEMBER
Fig. 30 Jack Stands Supporting Vehicle Weight
1 - LOWER CONTROL ARMS
2 - BALL JOINT
3 - JACK STANDS
4 - BALL JOINT
2 - 16 FRONT SUSPENSIONRS
LOWER CONTROL ARM (Continued)

(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.
(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.
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.
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)