2005 CHRYSLER VOYAGER Service Manual

jump start terminals manual transmission OBD port technical data buttons lug pattern

Page 73 of 2339

CHRYSLER VOYAGER 2005 Service Manual (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 tig

(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.
(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 module
and hub/bearing. Driveshaft is removed by first com-
pressing the inner joint on the driveshaft and remov-
ing it from the drive line module. Then, slide the
outer joint of the driveshaft out of the hub/bearing.
(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 will
remove 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.
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
Fig. 10 Correctly Supported Caliper
1 - WIRE
2 - CALIPER
3 - ADAPTER
4 - ROTOR
5 - INNER FENDER
2 - 32 REAR SUSPENSIONRS
HUB / BEARING (Continued)

Page 74 of 2339

CHRYSLER VOYAGER 2005 Service Manual (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
a

(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.)
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 seatedFig. 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
RSREAR SUSPENSION2-33
HUB / BEARING (Continued)

Page 75 of 2339

CHRYSLER VOYAGER 2005 Service Manual 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

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
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)
Fig. 13 Hub/Bearing Mounting Bolts
1 - HUB/BEARING
2 - AXLE
3 - MOUNTING BOLTS
4 - CALIPER ADAPTER
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
2 - 34 REAR SUSPENSIONRS
HUB / BEARING (Continued)

Page 76 of 2339

CHRYSLER VOYAGER 2005 Service Manual (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

Page 77 of 2339

CHRYSLER VOYAGER 2005 Service Manual REMOVAL
REMOVAL - AWD, HEAVY DUTY, CARGO
(1) Using slip-joint pliers grasp the base of the
jounce bumper. Turn the base counterclockwise (Fig.
20).
(2) Remove the jounce bumper from the frame rail.
RE

REMOVAL
REMOVAL - AWD, HEAVY DUTY, CARGO
(1) Using slip-joint pliers grasp the base of the
jounce bumper. Turn the base counterclockwise (Fig.
20).
(2) Remove the jounce bumper from the frame rail.
REMOVAL - FRONT-WHEEL-DRIVE
(1) Remove the bolt attaching the jounce bumper
to frame rail (Fig. 21).
(2) Remove the jounce bumper from the frame rail.
INSTALLATION
INSTALLATION - AWD, HEAVY DUTY, CARGO
(1) Install jounce bumper through bumper support
plate and thread into welded nut in frame rail.(2) Tighten the jounce bumper to 33 N´m (290 in.
lbs.) torque.
INSTALLATION - FRONT-WHEEL-DRIVE
(1) Hook the forward end of the jounce bumper
bracket in the mounting hole of the frame rail, then
install the mounting bolt in the opposite end, secur-
ing the bumper to the frame rail. Tighten the jounce
bumper mounting bolt to 33 N´m (290 in. lbs.) torque.
SHOCK ABSORBER
DESCRIPTION
There is one shock absorber on each side of the
rear suspension. The top of each shock absorber is
bolted to the frame rail. The bottom of each shock
absorber is bolted to the rear axle.
This vehicle is available with either standard type
or load-leveling shock absorbers. On the exterior,
load-leveling shock absorbers are larger in diameter
than standard shock absorbers. The load-leveling
shock absorbers mount the same as the standard
shock absorbers.
OPERATION
The shock absorber dampens jounce and rebound
motions of the spring and suspension.
Each load-leveling shock absorber is a self-leveling,
self-contained vehicle leveling system and shock
absorber combined. It does not require an external
compressor, hoses, or height leveling sensors. All the
height leveling sensors, hydraulic pump, etc., are
contained inside the shock absorber. It uses road
inputs (bumps, stops, starts, turns, acceleration,
deceleration, etc.) to activate pumping, which results
in the extension and compression of the shock
absorber.
REMOVAL - SHOCK ABSORBER
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) Support the rear axle of the vehicle using 2
jackstands positioned at the outer ends of the axle.
NOTE: If the shock absorber lower mounting bolt
deflects upward during removal, raise axle by
adjusting the support jack. If the lower shock
absorber bolt deflects downward during removal,
lower the axle by adjusting the support jack.
(3) Remove the shock absorber lower mounting
bolt.
Fig. 20 Jounce Bumper
1 - JOUNCE BUMPER
Fig. 21 Jounce Bumper - FWD
1-JOUNCE BUMPER
2 - 36 REAR SUSPENSIONRS
JOUNCE BUMPER (Continued)

Page 78 of 2339

CHRYSLER VOYAGER 2005 Service Manual (4) While holding shock absorber, remove the
shock absorber upper mounting bolt and shock
absorber.
DISASSEMBLY - SHOCK ABSORBER (UPPER
BUSHING)
NOTE: This procedure applies to load-leveling
shock abs

(4) While holding shock absorber, remove the
shock absorber upper mounting bolt and shock
absorber.
DISASSEMBLY - SHOCK ABSORBER (UPPER
BUSHING)
NOTE: This procedure applies to load-leveling
shock absorbers only.
(1) Remove the shock absorber from the vehicle.
(2) Install the Receiver, Special Tool 8526-1, into
the cup of the Ball Joint Press, Special Tool C-4212F,
and tighten the set screw. Install the Driver, Special
Tool 8526-2, on the tip of the Ball Joint Press screw
drive as shown (Fig. 22).
NOTE: It works well to place the Ball Joint Press,
Special Tool C-4212F, in a bench vise as shown
(Fig. 22) to perform this procedure.
(3) Place the shock absorber upper mounting eye
in the Receiver so the notch in the Receiver clears
the shock absorber body (Fig. 23).
(4) Tighten the screw drive until the Driver con-
tacts the outer circumference of the bushing evenly
(Fig. 23). Continue to tighten the screw drive until
the bushing is pressed completely out of the shock
absorber eye and into the Receiver.
(5) Back off the screw drive and remove the bush-
ing from the Receiver.
ASSEMBLY - SHOCK ABSORBER (UPPER
BUSHING)
NOTE: This procedure applies to load-leveling
shock absorbers only.(1) Install the Receiver, Special Tool 8526-1, into
the cup of the Ball Joint Press, Special Tool C-4212F,
and tighten the set screw. Install the Driver, Special
Tool 8526-2, on the tip of the Ball Joint Press screw
drive as shown (Fig. 24). Position the Driver this way
to seat the bushing to its correct depth.
(2) Place the shock absorber upper mounting eye
in the Receiver so the notch in the Receiver clears
the shock absorber body (Fig. 25).
(3) Position the bushing between the shock
absorber eye and the Driver (Fig. 25). Tighten the
screw drive until the Driver, bushing, and shock
absorber eye are touching and squarely aligned.
(4) Press the bushing into the shock absorber eye
until the Driver bottoms against the face of the eye.
(5) Back off the Ball Joint Press screw drive and
remove the shock absorber from the press.
Fig. 22 Special Tools Positioned For Removal
1 - SCREW DRIVE
Fig. 23 Removing Bushing From Shock Absorber
1 - SCREW DRIVE
2 - SHOCK ABSORBER
3 - NOTCH
Fig. 24 Special Tools Positioned For Installation
1 - SCREW DRIVE
RSREAR SUSPENSION2-37
SHOCK ABSORBER (Continued)

Page 79 of 2339

CHRYSLER VOYAGER 2005 Service Manual (6) Install the shock absorber on the vehicle. Refer
to REMOVAL AND INSTALLATION in this section
for the procedure.
INSTALLATION - SHOCK ABSORBER
(1) While holding shock absorber in position
against t

(6) Install the shock absorber on the vehicle. Refer
to REMOVAL AND INSTALLATION in this section
for the procedure.
INSTALLATION - SHOCK ABSORBER
(1) While holding shock absorber in position
against the frame rail, install the shock absorber
upper mounting bolt.
(2) Install the shock absorber lower mounting bolt
securing the lower end of the shock absorber to the
axle.
(3) Remove the support jack.
(4) Lower the vehicle to the ground so the full curb
weight of the vehicle is supported by the suspension.
(5) Tighten the upper and lower shock absorber
mounting bolt to a torque of 88 N´m (65 ft. lbs.).
SPRING - AWD
REMOVAL
(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. 26).
(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
spring replacement. Jack pad should just contact
axle.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).
(3) Begin removal of the shock absorber lower
mounting bolt (Fig. 27).
(4) Using 2 jack stands positioned under the outer
ends of the axle, raise the axle enough to remove the
weight of the axle from the rear springs.
Fig. 25 Installing Bushing In Shock Absorber
1 - BUSHING
2 - SCREW DRIVE
3 - SHOCK ABSORBER
4 - NOTCH
Fig. 26 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. 27 Rear Shock Absorber Mounting Bolt
1 - SHOCK BOLT
2 - 38 REAR SUSPENSIONRS
SHOCK ABSORBER (Continued)

Page 80 of 2339

CHRYSLER VOYAGER 2005 Service Manual (5) Loosen and remove the axle plate bolts from
the rear axle (Fig. 28).
(6) Using the jack standsslowlylower the rear
axle, permitting the rear springs to hang free.
(7) Loosen and remove the 4 bolts

(5) Loosen and remove the axle plate bolts from
the rear axle (Fig. 28).
(6) Using the jack standsslowlylower the rear
axle, permitting the rear springs to hang free.
(7) Loosen and remove the 4 bolts at the front
mount of the rear leaf spring (Fig. 26).
(8) Loosen and remove the 2 bolts and the 2 pin
nuts from the spring shackle for the rear leaf spring
(Fig. 29). Then remove the inner half of the spring
shackle from the outer half hanger of the spring
hanger and the spring.
(9) Remove the rear leaf spring from the outer half
of the spring shackle.(10) Remove the leaf spring from the vehicle.
(11) Loosen and remove the pivot bolt from the
front mount of the rear leaf spring. (Fig. 30).
INSTALLATION
CAUTION: Pivot bolt must face inboard to prevent
structural damage during installation of spring.
(1) Install the front eyelet of the rear leaf spring
into the spring mount. Install the pivot bolt and nut.
Do not tighten the pivot bolt at this time.
(2) Position the front spring mount for the rear
leaf spring against the floor pan of the vehicle.
Install the 4 mounting bolts for the front spring
mount (Fig. 26). Tighten the 4 mounting bolts to a
torque of 61 N´m (45 ft. lbs.).
(3) Install the rear of the leaf spring onto the outer
half of the rear shackle. Install the inner half of the
rear hanger. Install the pin nuts and bolts on the
rear shackle,but do not tighten at this time.
(4) Raise axle assembly into correct position with
axle centered under spring locator post.
(5) Install axle plate bolts (Fig. 28). Tighten bolts
to 95 N´m (70 ft. lbs.) torque.
(6) Install shock absorber bolts.Do not tighten
at this time.
(7) Lower the vehicle and remove hoist arms and
block of wood from under vehicle.
Fig. 28 Axle Plate Bolts
1 - LEAF SPRING
2 - AXLE PLATE BOLTS (4)
3 - AXLE PLATE
4 - AXLE
Fig. 29 All-Wheel-Drive Rear Suspension
1 - SHACKLE
2 - REAR MOUNT (HANGER)
3 - LEAF SPRING (MULTI-LEAF)
4 - AWD REAR AXLE
Fig. 30 Leaf Spring Front Mount (Typical)
1 - LEAF SPRING
2 - SPRING MOUNT
RSREAR SUSPENSION2-39
SPRING - AWD (Continued)

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