Chrysler Town, Dodge Caravan. Manual — part 18
REAR SUSPENSION
TABLE OF CONTENTS
page
page
REAR SUSPENSION
REAR SUSPENSION FASTENER TORQUE
. . . . . . . . . . . . . . . . . . . 28
BUSHINGS
REMOVAL - LEAF SPRING FRONT BUSHING
INSTALLATION - LEAF SPRING FRONT
. . . . . . . . . . . . . . . . . . . . . . . . . . . 29
HUB / BEARING
. . . . . . . . . . . . . . . . . . . . . . . . . 30
. . . . . . . . . . . . . . . . . . . . . . . . . . . 30
DIAGNOSIS AND TESTING - HUB AND
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
. . . . . . . . . . . . . . . . . . . . . . . . . 32
JOUNCE BUMPER
. . . . . . . . . . . . . . . . . . . . . . . . . 35
. . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION - AWD AND HEAVY DUTY
INSTALLATION - FRONT-WHEEL-DRIVE
SHOCK ABSORBER
. . . . . . . . . . . . . . . . . . . . . . . . . 36
. . . . . . . . . . . . . . . . . . . . . . . . . . . 36
DISASSEMBLY - SHOCK ABSORBER (UPPER
. . . . . . . . . . . . . . . . . . . . . . . . . . . 36
ASSEMBLY - SHOCK ABSORBER (UPPER
. . . . . . . . . . . . . . . . . . . . . . . . . . . 37
SPRING - AWD
. . . . . . . . . . . . . . . . . . . . . . . 38
. . . . . . . . . . . . . . . . . . . . 39
SPRING - FWD
. . . . . . . . . . . . . . . . . . . . . . . 40
. . . . . . . . . . . . . . . . . . . 41
SPRING MOUNTS - FRONT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
. . . . . . . . . . . . . . . . . . . . . . . . . 42
SPRING MOUNTS - REAR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
. . . . . . . . . . . . . . . . . . . . . . . . . 43
STABILIZER BAR
. . . . . . . . . . . . . . . . . . . . . . . . . 43
. . . . . . . . . . . . . . . . . . . . . . . . . . . 44
. . . . . . . . . . . . . . . . . . . . . . 44
. . . . . . . . . . . . . . . . . . . . . 44
. . . . . . . . . . . . . . . . . . 44
. . . . . . . . . . . . . . . . . . 44
TRACK BAR
. . . . . . . . . . . . . . . . . . . . . . . . . 44
. . . . . . . . . . . . . . . . . . . . . . . . . . . 44
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
. . . . . . . . . . . . . . . . . . . . . . . . . 45
REAR SUSPENSION
DESCRIPTION - REAR SUSPENSION
The rear suspension design on this vehicle uses
leaf springs, and a tube and casting axle (Fig. 1) (Fig.
2). The leaf springs used on the rear suspension of
this vehicle are of either a mono-leaf or multi-leaf
design.
There are 2 different rear suspension designs
available:
• Front-Wheel-Drive
• All-Wheel-Drive
The rear axle used on Front-Wheel-Drive applica-
tions of this vehicle is mounted to the rear leaf
springs using isolator bushings at the axle mounting
brackets.
The rear axle used on All-Wheel-Drive applications
of this vehicle is also mounted to the rear leaf
springs, but does not use isolator bushings between
the rear axle and the leaf springs.
Each side of the rear suspension consists of these
major components:
• Leaf spring
• Jounce bumper
• Shock absorber
• Hub and bearing
• Track bar (one per suspension)
• Stabilizer bar (one per suspension)
OPERATION - REAR SUSPENSION
This rear suspension is designed to handle the var-
ious load requirements of the vehicle yet allow for a
comfortable ride.
2 - 26
REAR SUSPENSION
RS
The rear wheel bearings used are similar to the
bearings used in the front suspension. A hub and
bearing assembly is used.
SPECIFICATIONS
REAR SUSPENSION FASTENER TORQUE
DESCRIPTION
N·m
Ft.
Lbs.
In.
Lbs.
Hub And Bearing Mounting
Bolts
129
95
—
Hub And Bearing Axle Hub
Nut
244
180
—
Jounce Bumper Mounting
Bolt
33
24
290
Leaf Spring Front Mount-To-
Body Bolts
61
45
—
Leaf Spring Front Pivot Bolt
156
115
—
Fig. 1 Front-Wheel-Drive Rear Suspension
1 - SHACKLE
7 - LEAF SPRING (MONO-LEAF)
2 - REAR MOUNT (HANGER)
8 - ISOLATOR
3 - TRACK BAR
9 - FWD REAR AXLE
4 - SPRING PLATE
10 - STABILIZER BAR LINKS
5 - ISOLATOR
11 - STABILIZER BAR
6 - FRONT MOUNT (HANGER)
Fig. 2 All-Wheel-Drive Rear Suspension
1 - SHACKLE
2 - REAR MOUNT (HANGER)
3 - LEAF SPRING (MULTI-LEAF)
4 - AWD REAR AXLE
RS
REAR SUSPENSION
2 - 27
REAR SUSPENSION (Continued)
DESCRIPTION
N·m
Ft.
Lbs.
In.
Lbs.
Leaf Spring Plate-To-Axle
Bolts
95
70
—
Leaf Spring Rear Mount-To-
Body Bolts
61
45
—
Leaf Spring Shackle Plate
Nuts
61
45
—
Shock Absorber Mounting
Bolts
88
65
—
Stabilizer Bar Bushing
Retainer Bolts
61
45
—
Stabilizer Bar Link Nuts
61
45
—
Stabilizer Bar Link Frame
Bracket Mounting Bolts
61
45
—
Track Bar Bracket-To-Body
Mount Bolts
61
45
—
Track Bar Pivot Bolts
95
70
—
Wheel Mounting (Lug) Nut
135
100
—
SPECIAL TOOLS
REAR SUSPENSION
BUSHINGS
REMOVAL - LEAF SPRING FRONT BUSHING
(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. 3).
(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
bushing replacement. Jack pad should just contact
axle.
(3) Remove shock absorber lower mounting bolt.
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).
(4) Remove four bolts securing leaf spring front
mounting bracket to the body (Fig. 3).
(5) Using jack, slowly lower rear axle, permitting
the forward end of rear spring to hang down. Lower
it enough to allow access to spring pivot bolt. It may
be necessary to place a wooden block between the
spring and vehicle to hold forward end of the spring
in place.
(6) Remove leaf spring forward pivot bolt, then
remove mounting bracket.
Remover, Hub/Bearing 8458
Remover/Installer, Bushing 8459
Remover/Installer, Bushing 8526
Press, Ball Joint C-4212F
2 - 28
REAR SUSPENSION
RS
REAR SUSPENSION (Continued)
(7) Straighten the retainer tabs on the bushing
(Fig. 4).
(8) Place Remover/Installer, Special Tool 8459 on
leaf spring and bushing as shown (Fig. 5) and tighten
Set Screw securing Remover Plate to tool threaded
shaft.
(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 the outboard side.
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.
Fig. 3 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. 4 STRAIGHTENED RETAINING TABS
1 - SPRING EYE
2 - RETAINING TABS
Fig. 5 TOOL 8459 MOUNTED FOR BUSHING
REMOVAL
1 - BUSHING
2 - BEARING
3 - WASHER
4 - NUT
5 - BODY (8459-1)
6 - PIN
7 - REMOVER PLATE (8459-2)
8 - SET SCREW
RS
REAR SUSPENSION
2 - 29
BUSHINGS (Continued)
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