2004 CHRYSLER VOYAGER wheel size

SPECIFICATIONS
FRONT SUSPENSION FASTENER TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Ball Joint Nut 108 80 Ð
Cradle Crossmember
Mounting Bolts163 120 Ð
Cradle Crossmember
Reinforcement Bolts - Size
M-14153 113 Ð
Cradle Crossmember
Reinforcement Bolt - Size
M-12106 78 Ð
Cradle Crossmember
Reinforcement Bolts - Size
M-1061 45 Ð
Disc Brake Adapter Mounting
Bolts169 125 Ð
Hub And Bearing Mounting
Bolts65 45 Ð
Hub And Bearing Axle Hub
Nut244 180 Ð
Lower Control Arm Pivot Bolt 183 135 Ð
Stabilizer Bar Bushing
Retainer Bolts68 50 Ð
Stabilizer Bar Link Nuts 88 65 Ð
Strut Body/Tower Mounting
Nuts28 21 250
Strut Clevis-to-Knuckle Nuts 81 +
90É
turn60 +
90É
turnÐ
Strut Shaft Nut 100 75 Ð
Tie Rod Adjuster Jam Nut 75 55 Ð
Tie Rod Steering Arm Nut 75 55 Ð
Wheel Mounting (Lug) Nuts 135 100 Ð
SPECIAL TOOLS
FRONT SUSPENSION
Puller C-3894A
Press, Ball Joint C-4212F
Installer, Ball Joint 6758
Wrench, Strut Rod Nut 6864
REMOVER/INSTALLER, BUSHING 8460
REMOVER/INSTALLER, BALL JOINT 8490
RSFRONT SUSPENSION2-3
FRONT SUSPENSION (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)

The stabilizer bar to front crossmember cushion
bushings are split for easy removal and installation.
The split in the bushings should be positioned toward
the rear of the vehicle, with the square corner facing
down, when the stabilizer bar is installed.
OPERATION
Jounce and rebound movements affecting one
wheel are partially transmitted to the opposite wheel
of the vehicle through the stabilizer bar. This helps
to minimize the body roll of the vehicle during sus-
pension movement.
Connecting the stabilizer bar links to the strut
assemblies helps reduce the fore-and-aft rate of the
stabilizer bar from the rest of the front suspension.
REMOVAL
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) Remove the bolts fastening the power steering
cooler to the front suspension cradle crossmember
reinforcement (Fig. 31).
(3) Remove the lower control arm rear bushing
retainer bolts located on each side of each lower con-
trol arm rear bushing.
NOTE: The bolts fastening the cradle crossmember
reinforcement are of two different thread sizes. Note
the location of the various sizes.(4) Remove the bolts attaching the cradle cross-
member reinforcement to the front suspension cradle
crossmember (Fig. 32). Remove the 2 bolts fastening
the reinforcement and rear of cradle crossmember to
the body of the vehicle. Remove the reinforcement.
Fig. 31 Power Steering Cooler
1 - CRADLE CROSSMEMBER REINFORCEMENT
2 - POWER STEERING COOLER
Fig. 32 Cradle Crossmember Reinforcement
Attachment
1 - STEERING GEAR
2 - RIGHT LOWER CONTROL ARM
3 - LEFT LOWER CONTROL ARM
4 - CRADLE CROSSMEMBER REINFORCEMENT
5 - REAR CRADLE CROSSMEMBER ISOLATOR BUSHING
6 - STABILIZER BAR
7 - CRADLE CROSSMEMBER
RSFRONT SUSPENSION2-17
STABILIZER BAR (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
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 coupler 4. Replace steering shaft coupler
Excessive Steering Effort 1. Low tire pressure 1. Inflate all tires to recommended
pressure
2. Lack of lubricant in steering gear 2. Replace steering gear
3. Low power steering fluid level 3. Fill power steering fluid reservoir to
correct level
4. Loose power steering pump drive
belt4. Correctly adjust power steering pump
drive belt
5. Lack of lubricant in ball joints 5. Lubricate or replace ball joints
6. Steering gear malfunction 6. Replace steering gear
7. Lack of lubricant in steering coupler 7. Replace steering coupler
STANDARD PROCEDURE
STANDARD PROCEDURE - WHEEL ALIGNMENT
PRE-WHEEL ALIGNMENT INSPECTION
Before any attempt is made to change or correct
the wheel alignment, the following inspection and
necessary corrections must be made to ensure proper
alignment.
(1) Verify that the fuel tank is full of fuel. If the
tank is not full, the reduction in weight will affect
the curb height of the vehicle and the alignment
angles.
(2) The passenger and luggage compartments of
the vehicle should be free of any load that is not fac-
tory equipment.
(3) Check the tires on the vehicle. All tires must be
the same size and in good condition with approxi-
mately the same amount of tread wear. Inflate all
the tires to the recommended air pressure.
(4) Check the front wheel and tire assemblies for
excessive radial runout.
(5) Inspect lower ball joints and all steering link-
age for looseness, binding, wear or damage. Repair as
necessary.
(6) Check suspension fasteners for proper torque
and retighten as necessary.
(7) Inspect all suspension component rubber bush-
ings for signs of wear or deterioration. Replace any
faulty bushings or components before aligning the
vehicle.
(8) Check the vehicle's curb height to verify it is
within specifications. Refer to Curb Height Measure-
ment.
WHEEL ALIGNMENT SETUP
(1) Position the vehicle on an alignment rack.
(2) Install all required alignment equipment on
the vehicle per the alignment equipment manufactur-
er's instructions. On this vehicle, a four-wheel align-
ment is recommended.
NOTE: Prior to reading the vehicle's alignment
readouts, the front and rear of vehicle should be
jounced. Induce jounce (rear first, then front) by
grasping the center of the bumper and jouncing
each end of vehicle an equal number of times. The
bumper should always be released when vehicle is
at the bottom of the jounce cycle.
(3) Read the vehicle's current front and rear align-
ment settings. Compare the vehicle's current align-
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
2 - 52 WHEEL ALIGNMENTRS
WHEEL ALIGNMENT (Continued)

rotate inner tie rods of steering gear (Fig. 12) to set
front toe to the preferred toe specification. (Refer to 2
- SUSPENSION/WHEEL ALIGNMENT - SPECIFI-
CATIONS)
(3) Tighten tie rod jam nuts (Fig. 12) to 75 N´m
(55 ft. lbs.) torque.
(4) Adjust steering gear to tie rod boots at the
inner tie rod.
(5) Remove steering wheel clamp.
(6) Remove the alignment equipment.
(7) Road test the vehicle to verify the steering
wheel is straight and the vehicle does not wander or
pull.STANDARD PROCEDURE - CURB HEIGHT
MEASUREMENT
The wheel alignment is to be checked and all align-
ment adjustments made with the vehicle at its
required curb height specification.
Vehicle height is to be checked with the vehicle on
a flat, level surface, preferably a vehicle alignment
rack. The tires are to be inflated to the recommended
pressure. All tires are to be the same size as stan-
dard equipment. Vehicle height is checked with the
fuel tank full of fuel, and no passenger or luggage
compartment load.
Vehicle height is not adjustable. If the measure-
ment is not within specifications, inspect the vehicle
for bent or weak suspension components. Compare
the parts tag on the suspect coil spring(s) to the
parts book and the vehicle sales code, checking for a
match. Once removed from the vehicle, compare the
coil spring height to a correct new or known good coil
spring. The heights should vary if the suspect spring
is weak.
(1) Measure from the inboard edge of the wheel
opening fender lip directly above the wheel center
(spindle), to the floor or alignment rack surface.
(2) When measuring, the maximum left-to-right
differential is not to exceed 12.5 mm (0.5 in.).
(3) Compare the measurements to the specifica-
tions listed in the following Curb Height Specifica-
tions charts.
CURB HEIGHT SPECIFICATIONS
VEHICLE FRONT REAR
CARGO VAN755mm 11mm
29.72 in.   0.43 in795mm 11mm
31.30 in.   0.43 in.
ALL OTHERS755mm 11mm
29.72 in.   0.43 in770mm 11mm
30.31 in.   0.43 in.
Fig. 12 Front Wheel Toe Adjustment
1 - INNER TIE ROD SERRATION
2 - OUTER TIE ROD JAM NUT
3 - OUTER TIE ROD END
4 - INNER TIE ROD
5 - STEERING KNUCKLE
RSWHEEL ALIGNMENT2-55
WHEEL ALIGNMENT (Continued)

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
3 - 26 REAR DRIVELINE MODULERS
REAR DRIVELINE MODULE (Continued)

CAUTION: When replacing a master cylinder, be
sure to use the correct master cylinder for the type
of brake system the vehicle is equipped with.
The body of the master cylinder is an anodized alu-
minum casting. It has a machined bore to accept the
master cylinder pistons and threaded ports with
seats for the hydraulic brake line connections.
The brake fluid reservoir is mounted on the top of
the master cylinder. It is made of a see-through
polypropylene type plastic for easy fluid level view-
ing. A brake fluid level switch is attached to the
brake fluid reservoir.
The master cylinder is not a repairable component
and must be replaced if diagnosed to be functioning
improperly. The brake fluid reservoir and brake fluid
level switch can be replaced separately.
CAUTION: Do not hone the bore of the cylinder as
this will remove the anodized surface from the bore.
DESCRIPTION - RHD
The master cylinder used on right hand drive
(RHD) vehicles functions similarly to that used on
left hand drive (LHD) vehicles. The RHD master cyl-
inder, as well as the RHD power brake booster, is
located in the same area, but lower in the engine
compartment than LHD models (Fig. 47). For that
reason an extension manifold is placed between the
fluid reservoir and master cylinder housing allowing
the fluid reservoir to be positioned in the same loca-
tion as on LHD models.
OPERATION
When the brake pedal is depressed, the master cyl-
inder primary and secondary pistons apply brake
pressure through the chassis tubes to the brakes at
each tire and wheel assembly.
The master cylinder primary outlet port supplies
hydraulic pressure to the right front and left rear
brakes. The secondary outlet port supplies hydraulic
pressure to the left front and right rear brakes.
STANDARD PROCEDURE - MASTER CYLINDER
BLEEDING
CAUTION: When clamping master cylinder in vise,
only clamp master cylinder by its mounting flange.
Do not clamp master cylinder piston rod, reservoir,
seal or body.
(1) Clamp master cylinder in a vise.
NOTE: Use correct bleeder tubes when bleeding
master cylinder. Master cylinder outlet ports vary in
size and type depending on whether master cylin-
der is for a vehicle equipped with traction control or
not. Traction control equipped master cylinders
require the additional use of ISO style flare adapt-
ers supplied in Special Tool Package 8822 to be
used in conjunction with Bleeder Tubes, Special
Tool Package 8358.
(2) Attach special tools for bleeding master cylin-
der in the following fashion:
(a)For non-traction control equipped mas-
ter cylinders, thread a Bleeder Tube, Special Tool
8358±1, into each outlet port. Tighten each tube to
17 N´m (145 in. lbs.) torque. Flex bleeder tubes and
place open ends into mouth of fluid reservoir as far
down as possible (Fig. 48).
(b)For traction control equipped master
cylinders, thread one Adapter, Special Tool
8822±2, in each outlet port. Tighten Adapters to 17
N´m (145 in. lbs.) torque. Next, thread a Bleeder
Tube, Special Tool 8358±1, into each Adapter.
Tighten each tube to 17 N´m (145 in. lbs.) torque.
Flex bleeder tubes and place open ends into mouth
of fluid reservoir as far down as possible (Fig. 48).
NOTE: Make sure open ends of bleeder tubes stay
below surface of brake fluid once reservoir is filled
to proper level.
(3) Fill brake fluid reservoir with Mopartbrake
fluid or equivalent conforming to DOT 3 (DOT 4 and
DOT 4+ are acceptable) specifications. Make sure
fluid level is above tips of bleeder tubes in reservoir
to ensure no air is ingested during bleeding.
Fig. 47 RHD MASTER CYLINDER AND POWER
BRAKE BOOSTER
1 - POWER BRAKE BOOSTER
2 - BRAKE FLUID LEVEL SWITCH
3 - FLUID RESERVOIR
4 - MASTER CYLINDER
RSBRAKES - BASE5-35
MASTER CYLINDER (Continued)

CAUTION: When replacing a master cylinder, be
sure to use the correct master cylinder for the type
of brake system the vehicle is equipped with.The body of the master cylinder is an anodized alu-
minum casting. It has a machined bore to accept the
master cylinder pistons and threaded ports with
seats for the hydraulic brake line connections. The brake fluid reservoir is mounted on the top of
the master cylinder. It is made of a see-through
polypropylene type plastic for easy fluid level view-
ing. A brake fluid level switch is attached to the
brake fluid reservoir. The master cylinder is not a repairable component
and must be replaced if diagnosed to be functioning
improperly. The brake fluid reservoir and brake fluid
level switch can be replaced separately.
CAUTION: Do not hone the bore of the cylinder as
this will remove the anodized surface from the bore.
DESCRIPTION - RHD
The master cylinder used on right hand drive
(RHD) vehicles functions similarly to that used on
left hand drive (LHD) vehicles. The RHD master cyl-
inder, as well as the RHD power brake booster, is
located in the same area, but lower in the engine
compartment than LHD models (Fig. 46). For that
reason an extension manifold is placed between the
fluid reservoir and master cylinder housing allowing
the fluid reservoir to be positioned in the same loca-
tion as on LHD models.
OPERATION
When the brake pedal is depressed, the master cyl-
inder primary and secondary pistons apply brake
pressure through the chassis tubes to the brakes at
each tire and wheel assembly. The master cylinder primary outlet port supplies
hydraulic pressure to the right front and left rear
brakes. The secondary outlet port supplies hydraulic
pressure to the left front and right rear brakes.
STANDARD PROCEDURE - MASTER CYLINDER
BLEEDING
CAUTION: When clamping master cylinder in vise,
only clamp master cylinder by its mounting flange.
Do not clamp master cylinder piston rod, reservoir,
seal or body.
(1) Clamp master cylinder in a vise.
NOTE: Use correct bleeder tubes when bleeding
master cylinder. Master cylinder outlet ports vary in
size and type depending on whether master cylin-
der is for a vehicle equipped with traction control or
not. Traction control equipped master cylinders
require the additional use of ISO style flare adapt-
ers supplied in Special Tool Package 8822 to be
used in conjunction with Bleeder Tubes, Special
Tool Package 8358. (2) Attach special tools for bleeding master cylin-
der in the following fashion: (a)For non-traction control equipped mas-
ter cylinders , thread a Bleeder Tube, Special Tool
8358±1, into each outlet port. Tighten each tube to
17 N´m (145 in. lbs.) torque. Flex bleeder tubes and
place open ends into mouth of fluid reservoir as far
down as possible (Fig. 47). (b) For traction control equipped master
cylinders , thread one Adapter, Special Tool
8822±2, in each outlet port. Tighten Adapters to 17
N´m (145 in. lbs.) torque. Next, thread a Bleeder
Tube, Special Tool 8358±1, into each Adapter.
Tighten each tube to 17 N´m (145 in. lbs.) torque.
Flex bleeder tubes and place open ends into mouth
of fluid reservoir as far down as possible (Fig. 47).
NOTE: Make sure open ends of bleeder tubes stay
below surface of brake fluid once reservoir is filled
to proper level. (3) Fill brake fluid reservoir with Mopar tbrake
fluid or equivalent conforming to DOT 3 (DOT 4 and
DOT 4+ are acceptable) specifications. Make sure
fluid level is above tips of bleeder tubes in reservoir
to ensure no air is ingested during bleeding.
Fig. 46 RHD MASTER CYLINDER AND POWER BRAKE BOOSTER
1 - POWER BRAKE BOOSTER
2 - BRAKE FLUID LEVEL SWITCH
3 - FLUID RESERVOIR
4 - MASTER CYLINDER
5s - 34 BRAKESRS
MASTER CYLINDER (Continued)