2005 CHRYSLER CARAVAN Service Manual

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Page 49 of 2339

CHRYSLER CARAVAN 2005 Service Manual (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. 1

Page 50 of 2339

CHRYSLER CARAVAN 2005 Service Manual 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

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)

Page 51 of 2339

CHRYSLER CARAVAN 2005 Service Manual (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 at

(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)

Page 52 of 2339

CHRYSLER CARAVAN 2005 Service Manual 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).
(

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)

Page 53 of 2339

CHRYSLER CARAVAN 2005 Service Manual CAUTION: Do not use an arbor press to install the
sealing boot on the ball joint. Damage to the seal-
ing boot will occur if excessive pressure is applied
to the sealing boot when it is being installe

CAUTION: Do not use an arbor press to install the
sealing boot on the ball joint. Damage to the seal-
ing boot will occur if excessive pressure is applied
to the sealing boot when it is being installed.
(3) Place Installer, Special Tool 6758, over seal
boot and squarely align it with bottom edge of seal
boot (Fig. 20). Apply hand pressure to Special Tool
6758 until seal boot is pressed squarely against top
surface of lower control arm.
(4) Wipe any grease off the ball joint stem.(5) Place the shield over the top of the seal boot
and stretch it into the groove at the top of the seal
boot.
CAUTION: Do not attempt to install a normal grease
zirc in the ball joint and lubricate the joint through
the zirc fitting.
(6) Reinstall steering knuckle on vehicle. (Refer to
2 - SUSPENSION/FRONT/KNUCKLE - INSTALLA-
TION)
LOWER CONTROL ARM
DESCRIPTION
The lower control arm is mounted to the front sus-
pension crossmember using a pivot bolt through the
center of the front pivot bushing, and the front sus-
pension cradle crossmember reinforcement traps the
rear bushing in the crossmember (Fig. 1).
The lower control arm is an iron casting with two
rubber bushings and a ball joint. The lower control
arm front bushing is the spool type and is pressed
into the lower control arm. The standard (Low-line,
High-line) lower control arm rear bushing is a
push-on bushing that is pushed over a stem on the
rear of the lower control arm. The lower control arm
rear bushing used on all other models is a hydro-
bushing that is pressed on. It has liquid filled voids
that provide more effective dampening than the stan-
dard bushing. Vehicles with rear hydro-bushings uti-
lize a different lower control arm than vehicles with
standard bushings. They have a straight slightly
tapered round stem where the hydro-bushing is
mounted whereas the standard arm has a straight
stem with a squared knob on the end to retain the
bushing.
The lower control arm ball joint is pressed into the
outer end of the arm. The ball joint has a tapered
stud and retainer nut for fastening it to the steering
knuckle.
OPERATION
The lower control arm supports the lower end of
the steering knuckle and allows for the up and down
movement of the suspension during the jounce and
rebound travel. The lower control arm ball joint con-
nects the arm to the steering knuckle.
REMOVAL - LOWER CONTROL ARM
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) Remove wheel and tire assembly.
(3) Remove the steering knuckle. (Refer to 2 -
SUSPENSION/FRONT/KNUCKLE - REMOVAL)
Fig. 19 Installer Positioned On Ball Joint Seal Boot
1 - INSTALLER 6758
2 - LOWER CONTROL ARM
3 - SEAL BOOT SHIELD
Fig. 20 Installing Ball Joint Seal Boot (Typical)
1 - SHIELD (NOT ON RG VEHICLE)
2 - SPECIAL TOOL 6758
3 - LOWER CONTROL ARM
4 - BALL JOINT SEAL BOOT
2 - 12 FRONT SUSPENSIONRS
LOWER BALL JOINT SEAL BOOT (Continued)

Page 54 of 2339

CHRYSLER CARAVAN 2005 Service Manual (4) Remove the bolts fastening the power steering
cooler to the front suspension cradle crossmember
reinforcement (Fig. 21).
(5) Remove the lower control arm rear bushing
retainer bolts located on eac

(4) Remove the bolts fastening the power steering
cooler to the front suspension cradle crossmember
reinforcement (Fig. 21).
(5) 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 three different thread sizes.
Note the location of the various sizes.
(6) Remove the bolts attaching the cradle cross-
member reinforcement to the front suspension cradle
crossmember (Fig. 22). Remove the 2 bolts fastening
the reinforcement and rear of cradle crossmember to
the body of the vehicle. Remove the reinforcement.
(7) Remove the pivot bolt attaching the front bush-
ing of the lower control arm to the front suspension
cradle crossmember.
(8) Remove the lower control arm.
DISASSEMBLY
DISASSEMBLY - LOWER CONTROL ARM
(REAR BUSHING - STANDARD)
(1) Remove the lower control arm from the front
suspension cradle. (Refer to 2 - SUSPENSION/
FRONT/LOWER CONTROL ARM - REMOVAL)
(2) Mount the lower control arm in a visewithout
using excessive clamping force.(3) Using a sharp knife (such as a razor), slit the
bushing lengthwise (Fig. 23) to allow its removal
from the lower control arm (Fig. 23).
(4) Remove the bushing from the lower control
arm.
DISASSEMBLY - LOWER CONTROL ARM
(REAR BUSHING - HYDRO)
(1) Remove the lower control arm from the front
suspension cradle. (Refer to 2 - SUSPENSION/
FRONT/LOWER CONTROL ARM - REMOVAL)
(2) Mount the lower control arm in a visewithout
using excessive clamping force.
(3) Install Remover, Special Tool 8460, on hydro-
bushing as shown (Fig. 24). Removal Pin, Special
Tool 8460±3, must extend though hole in center of
bushing rear.
(4) Tighten forcing screw of Bridge (Special Tool
8460±1), removing bushing from lower control arm.
Fig. 21 Power Steering Cooler
1 - CRADLE CROSSMEMBER REINFORCEMENT
2 - POWER STEERING COOLER
Fig. 22 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 SUSPENSION2-13
LOWER CONTROL ARM (Continued)

Page 55 of 2339

CHRYSLER CARAVAN 2005 Service Manual INSPECTION - LOWER CONTROL ARM
Inspect lower control arm for signs of damage from
contact with the ground or road debris. If lower con-
trol arm shows any sign of damage, inspect lower
control arm for

INSPECTION - LOWER CONTROL ARM
Inspect lower control arm for signs of damage from
contact with the ground or road debris. If lower con-
trol arm shows any sign of damage, inspect lower
control arm for distortion. Do not attempt to repair
or straighten a broken or bent lower control arm. If
damaged, the lower control arm casting is serviced
only as a complete component.
Inspect both lower control arm isolator bushings
for severe deterioration, and replace as required.
Inspect the rear hydro-bushing for seepage. Both
type rear bushings are serviceable. If the front bush-
ing fails, the lower control arm must be replaced.
Inspect and test the ball joint per the procedure
listed in Lower Ball Joint. (Refer to 2 - SUSPEN-SION/FRONT/LOWER BALL JOINT - DIAGNOSIS
AND TESTING)
ASSEMBLY
ASSEMBLY - LOWER CONTROL ARM (REAR
BUSHING - STANDARD)
CAUTION: Do not apply grease or any other type of
lubricant other than the silicone lubricant specified
below to the control arm bushing.
(1) Apply Mopar Silicone Spray Lube or an equiv-
alent, to the hole in lower control arm rear bushing.
This will aid in the installation of the bushing on the
lower control arm.
(2) With the lower control arm held securely in a
vise, install bushing on lower control arm. Install
bushing by pushing and rocking the bushing until it
is fully installed on lower control arm. Be sure that
when bushing is installed it is past the upset on the
end of the lower control arm (Fig. 25).
(3) The rear bushing of the lower control arm,
when correctly installed, is to be positioned on the
lower control arm as shown (Fig. 25).
(4) Install lower control arm on vehicle. (Refer to 2
- SUSPENSION/FRONT/LOWER CONTROL ARM -
INSTALLATION)
Fig. 23 Slit Lower Control Arm Rear Bushing
1 - REAR BUSHING
2 - SLIT CUT IN BUSHING
3 - LOWER CONTROL ARM
Fig. 24 HYDRO-BUSHING REMOVAL
1 - REMOVAL PIN (8460-3)
2 - BRIDGE (8460-1)
3 - HYDRO-BUSHING
4 - LOWER CONTROL ARM
Fig. 25 Correctly Installed Lower Control Arm
Bushing
1 - ROUND SURFACE OF BUSHING
2 - LOWER CONTROL ARM
3 - LOWER CONTROL ARM REAR BUSHING
4 - UPSET
5 - FLAT SURFACE OF BUSHING
2 - 14 FRONT SUSPENSIONRS
LOWER CONTROL ARM (Continued)

Page 56 of 2339

CHRYSLER CARAVAN 2005 Service Manual ASSEMBLY - LOWER CONTROL ARM (REAR
BUSHING - HYDRO)
CAUTION: Do not apply grease or any other type of
lubricant to the arm stem where the bushing is to
be mounted. Such action will reduce proper bush-

ASSEMBLY - LOWER CONTROL ARM (REAR
BUSHING - HYDRO)
CAUTION: Do not apply grease or any other type of
lubricant to the arm stem where the bushing is to
be mounted. Such action will reduce proper bush-
ing adhesion to arm.
(1) Secure lower control arm in a vise.
NOTE: Hydro bushings and grooves on control arm
stems are unique for right and left sides. Left side
bushing master spline and control arm groove are
on the top (when mounted on vehicle). Right side
bushing master spline and control arm groove are
on the bottom (when mounted on vehicle).
(2) Align master spline on bushing inner sleeve
with groove on lower control arm rear bushing stem
(Fig. 26). Start bushing on stem by hand.
(3) Install Remover/Installer, Special Tool 8460,
over bushing and lower control arm as shown (Fig.
27). Engage flange on lower control arm with tips of
Bridge, Special Tool 8460±1 as shown (Fig. 27). The
contoured side of Installer Cup, Special Tool 8460±2,
should be fitted up against rear of the bushing.
(4) Begin to tighten forcing screw. As bushing
nears lower control arm flange, place Spacer Plate,
Special Tool 8460±4 between flange and bushing
inner sleeve, straddling the stem as shown (Fig. 28).
(5) Install bushing up against Spacer Plate, tight-
ening the bridge forcing screw with a torque wrench
until approximately 50 N´m (37 ft. lbs.) torque is
reached. This will properly space bushing on the
stem in relation to the flange.(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.
Fig. 26 BUSHING MASTER SPLINE LINED UP WITH
GROOVE (RIGHT SIDE SHOWN)
1 - GROOVE
2 - HYDRO-BUSHING
3 - MASTER SPLINE
Fig. 27 HYDRO-BUSHING INSTALLATION
1 - LOWER CONTROL ARM FLANGE
2 - INSTALLER CUP (8460-2)
3 - BRIDGE (8460-1)
4 - HYDRO-BUSHING
Fig. 28 SPACER PLATE POSITIONED
1 - SPACER PLATE (8460-4)
2 - LOWER CONTROL ARM FLANGE
3 - BRIDGE (8460-1)
4 - INSTALLER CUP (8460-2)
5 - HYDRO-BUSHING
RSFRONT SUSPENSION2-15
LOWER CONTROL ARM (Continued)

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