2005 CHRYSLER CARAVAN brake

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 ofsteering 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 holes
on 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
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
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)

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.
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.
(6) Remove nut attaching outer tie rod end to
steering knuckle by holding the tie rod end studwhile loosening and removing nut with a wrench
(Fig. 11).
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)

(7) Remove tie rod end from steering knuckle
using Remover, Special Tool C-3894±A (Fig. 12).(8) If equipped with antilock brakes, remove the
front wheel speed sensor from the steering knuckle
(Fig. 13).
(9) Remove the two steering knuckle-to-strut clevis
bracket attaching bolts.
(10) Tip the knuckle outward and remove the
driveshaft stub axle from the hub and bearing. Sus-
pend driveshaft straight outward using a bungee
cord or wire (Fig. 10).Do not allow driveshaft to
hang by inner joint.
(11) Remove ball joint nut using a power impact
wrench. Because the tapered stud is held sufficiently
in the knuckle at this time, it is not necessary to
hold the stud stationary to remove the nut.
(12) Reinstall the ball joint nut until the top of the
nut is even with the top of the ball joint stud. This
will keep the stud from distorting while the stud is
released from the knuckle in the following step.
CAUTION: Do not remove ball joint stud from steer-
ing knuckle using a hammer. Damage to the Alumi-
num knuckle, ball joint or control arm will result.
(13) Release ball joint stud from steering knuckle
using Remover, Special Tool C-4150A, as shown (Fig.
14). To ease Remover installation and use, it may
help to rotate the knuckle around so the inside of the
knuckle faces outward.
(14) Remove the nut from the top of the ball joint
stud.
(15) Remove the steering knuckle from the vehicle.
(16) If the hub and bearing needs to be trans-
ferred, remove the four bolts attaching the hub and
bearing to the knuckle, then remove the hub and
bearing.
Fig. 11 Removing Tie Rod End Attaching Nut
1 - TIE ROD END
2 - STEERING KNUCKLE
3 - WRENCH
4 - SOCKET
5 - TIE ROD END STUD
Fig. 12 Tie Rod Removal With Tool C-3894-A
1 - OUTER TIE ROD
2 - SPECIAL TOOL C-3894-A
3 - STEERING KNUCKLE
Fig. 13 Front Wheel Speed Sensor
1 - MOUNTING BOLT
2 - WHEEL SPEED SENSOR
3 - STEERING KNUCKLE
2 - 8 FRONT SUSPENSIONRS
KNUCKLE (Continued)

INSPECTION - STEERING KNUCKLE
Inspect the knuckle for the following:
²Cracks or breaks
²Dents or damage
²Stress marks indicating a bend
The front suspension knuckle is not a repairable
component of the vehicles front suspension. If bent,
broken or damaged in any way, do not attempt to
straighten or repair the steering knuckle. It must be
replaced.
If inspection leads to the hub and bearing, (Refer
to 2 - SUSPENSION/FRONT/HUB / BEARING -
DIAGNOSIS AND TESTING)
INSTALLATION - STEERING KNUCKLE
(1) If the hub and bearing needs to be installed in
the knuckle, place the hub and bearing squarely into
the center hole of the steering knuckle aligning the
threaded mounting holes of the hub and bearing with
the mounting holes in the steering knuckle. Install
the four mounting bolts and tighten them to a torque
of 65 N´m (45 ft. lbs.).
CAUTION: Before installing the knuckle on the ball
joint stud, wipe the ball joint stud and knuckle con-
tact area free of any grease or debris, otherwisedamage to the knuckle can occur. Use a clean shop
cloth with MoparTBrake Parts Cleaner applied to it
for proper cleaning. Do not spray the stud directly.
(2) Place the knuckle on the ball joint stud.
(3) Install a NEW steering knuckle to ball joint
stud nut. Tighten the nut by holding ball joint stud
with hex wrench while turning nut with a wrench
(Fig. 15). Using a crowsfoot wrench on a torque
wrench, tighten the nut to a torque of 108 N´m (80 ft.
lbs.).
(4) Slide driveshaft stub axle into hub and bearing
assembly.
CAUTION: The steering knuckle to strut assembly
attaching bolts are serrated and must not be turned
during installation. Install nuts while holding bolts
stationary in the steering knuckle.
CAUTION: If the vehicle being serviced is equipped
with eccentric strut assembly attaching bolts, the
eccentric bolt must be installed in the bottom (slot-
ted) hole on the strut clevis bracket (Fig. 16).
NOTE: The strut clevis-to-steering knuckle bolts are
installed differently on each side. Left hand side
bolts are to be installed from vehicle rear to front.
Right side bolts are to be installed from vehicle
front to rear.
(5) Install steering knuckle in clevis bracket of
strut damper assembly. Install the strut clevis-to-
steering knuckle attaching bolts. Tighten both bolts
to a torque of 81 N´m (60 ft. lbs.) plus an additional
1/4 (90É) turn.
Fig. 14 Using C-4150A To Release Ball Joint
1 - ALUMINUM KNUCKLE
2 - SPECIAL TOOL C-4150A
3 - LOWER CONTROL ARM
4 - NUT INSTALLED ON BALL JOINT STEMFig. 15 Ball Joint Nut Installation
1 - KNUCKLE
2 - BALL JOINT STUD
3 - LOWER CONTROL ARM
RSFRONT SUSPENSION2-9
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)

REMOVAL
REMOVAL
(1) Remove steering knuckle from vehicle. (Refer
to 2 - SUSPENSION/FRONT/KNUCKLE -
REMOVAL)
(2) Using a screwdriver or other suitable tool, pry
seal boot off of ball joint (Fig. 17).
(3) Inspect ball joint for evidence of dirt or water
intrusion and wipe clean as necessary. If dirt or
water intrusion is extreme and joint cannot be prop-
erly cleaned, lower control arm will need to be
replaced. (Refer to 2 - SUSPENSION/FRONT/
LOWER CONTROL ARM - REMOVAL)
REMOVAL - EXPORT
(1) Remove steering knuckle from vehicle. (Refer
to 2 - SUSPENSION/FRONT/KNUCKLE -
REMOVAL)
(2) Remove shield from seal boot by gently pulling
on it.
(3) Using a screw driver or other suitable tool, pry
seal boot off lower ball joint.
INSTALLATION
INSTALLATION
(1) Place a liberal dab of MopartWheel Bearing
Grease around base of ball joint stud at socket.(2) Install aNEWseal boot by hand as far as pos-
sible on ball joint. Ensure seal boot shield is posi-
tioned outward from control arm as shown (Fig. 18).
CAUTION: Do not use an arbor press to install seal
boot on ball joint. Damage to seal boot will occur if
excessive pressure is applied while it is being
installed.
(3) Place Installer, Special Tool 6758, over top of
seal boot and squarely align it with bottom edge of
seal boot (Fig. 19). Apply hand pressure (or gently
tap with a hammer if necessary) to top of Installer
until seal boot is pressed squarely down against top
surface of lower control arm.
(4) Wipe any grease off ball joint stem using a
clean shop towel with MopartBrake Parts Cleaner
applied to it.
CAUTION: Do not attempt to install a normal grease
zirc in ball joint in an effort to lubricate joint
through zirc fitting.
(5) Install steering knuckle on vehicle. (Refer to 2 -
SUSPENSION/FRONT/KNUCKLE - INSTALLA-
TION)
INSTALLATION - EXPORT
(1) Place a liberal dab of MopartWheel Bearing
Grease around the base of the ball joint stem at the
socket.
(2) Install aNEWseal boot by hand as far as pos-
sible on the ball joint.
Fig. 17 Ball Joint Seal Boot Removal
1 - BALL JOINT STUD
2 - SCREWDRIVER
3 - SEAL BOOT
Fig. 18 Ball Joint Seal Boot Installed Position
1 - BALL JOINT STUD
2 - LOWER CONTROL ARM
3 - SEAL BOOT SHIELD
RSFRONT SUSPENSION2-11
LOWER BALL JOINT SEAL BOOT (Continued)

(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.
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.
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)

(2) Remove the wheel and tire assembly from loca-
tion on front of vehicle requiring strut removal.
(3) If both strut assemblies are to be removed,
mark the strut assemblies right or left according to
which side of the vehicle they were removed from.
(4) Remove the hydraulic brake hose routing
bracket and the speed sensor cable routing bracket
from the strut damper brackets (Fig. 40).
CAUTION: When removing the nut from the stud of
the stabilizer bar link, do not allow the stud to
rotate in it's socket. Hold the stud from rotating by
placing an open-end wrench on the flat machined
into the stud (Fig. 41).
(5) Remove the stabilizer bar link from the bracket
on the strut assembly (Fig. 41). To do so, place an
open-end wrench on the flat machined into the link's
mounting stud, then remove the nut while holding
the wrench in place. Push the stud out of the
bracket.
CAUTION: The steering knuckle to strut assembly
attaching bolts are serrated and must not be turned
during removal. Remove nuts while holding bolts
stationary in the steering knuckles.
(6) Remove the 2 strut assembly clevis bracket to
steering knuckle attaching bolts (Fig. 42).
(7) Remove the 3 nuts attaching the strut assem-
bly upper mount to the strut tower (Fig. 43) and
remove the strut assembly from the vehicle.
(8) To disassemble the strut assembly, (Refer to 2 -
SUSPENSION/FRONT/STRUT - DISASSEMBLY).
DISASSEMBLY - STRUT ASSEMBLY
The strut assembly must be removed from the
vehicle for it to be disassembled and assembled.
For the disassembly and assembly of the strut
assembly, use of Strut Spring Compressor, Pentastar
Service Equipment (PSE) tool W-7200, or the equiva-
lent, is recommended to compress the coil spring.
Follow the manufacturer's instructions closely.
Fig. 40 Brake Hose And Speed Sensor Cable
Routing
1 - STRUT DAMPER
2 - WHEEL SPEED SENSOR CABLE
3 - ROUTING BRACKET
4 - HYDRAULIC BRAKE HOSE
5 - ATTACHING BOLT
6 - ROUTING BRACKET
Fig. 41 Stabilizer Bar Link To Strut Attachment
1 - NUT
2 - STRUT
3 - STABILIZER BAR LINK
Fig. 42 Strut Damper Attachment To Steering
Knuckle
1 - STRUT CLEVIS BRACKET
2 - ATTACHING BOLTS
3 - TIE ROD END
4 - ROTOR
5 - STEERING KNUCKLE
RSFRONT SUSPENSION2-21
STRUT (Continued)