Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 54
LARGE BUSHING
INSTALL
(1) Remove the special tools from the lower control
arm that were used for installing the small pivot
bushing.
(2) On the threaded rod from Remover/Installer, Special
Tool 6602 assemble the following pieces. Washer, thrust
bearing, Cup Special Tool 6602-2 (Fig. 9).
(3) Install the pieces assembled in step 2 through
the hole in the small pivot bushing and the large pivot
bushing hole in the lower control arm. At the large
pivot bushing hole in the lower control arm assemble
the following special tool pieces. Large Bushing Sizer,
Special Tool 6602-4, large lower control arm pivot
bushing, large bushing disc Special Tool 6602-5, thrust
bearing, washer and nut (Fig. 10). Lubricate the in-
staller cone and new bushing using Mopar
t Silicone
Spray Lube or equivalent.
(4) Hold the threaded rod stationary and turn the
long nut until the bushing is fully installed into the
control arm. Be sure that the flanges of the bushing are
fully expanded around the control arm bushing holes.
(5) If the position of the large lower control arm pivot
bushing (Fig. 11) moved during bushing installation.
Install a nut and bolt through the bushing sleeve and
tighten it down (Fig. 11). Using a wrench rotate the
bolt until the bushing is in the correct position (Fig. 10)
BALL JOINTS
The lower front suspension ball joints operate with
no free play. See Inspection Ball Joint Wear to deter-
mine if the ball joint is worn and requires replacement.
The ball joints are replaceable as an assembly, do not
attempt any type of repair on the ball joint assembly.
The replacement procedure for the ball joint assembly
is detailed in this section.
The ball joint housing is a pressed fit into the lower
control arm with the joint stud retained in the steering
knuckle by a (clamp) bolt.
INSPECTION BALL JOINT WEAR
With the weight of the vehicle resting on the road
wheels. Grasp the grease fitting as shown in (Fig. 1)
and with no mechanical assistance or added force
attempt to move the grease fitting.
Fig. 8 Bushing And Tool Position For Installation In
Control Arm
Fig. 9 Bushing Installer Tools
Fig. 10 Bushing And Tool Position For Installation
In Control Arm
Fig. 11 Positioning Control Arm Bushing
.
FRONT SUSPENSION AND DRIVE SHAFTS
2 - 13
If the ball joint is worn the grease fitting will move
easily. If movement is noted, replacement of the ball
joint is recommended.
BALL JOINT REMOVAL
(1) Pry off seal.
(2) osition Receiving Cup Tool C-4699-2 to support lower
control arm while receiving ball joint assembly (Fig. 2).
(3) Install Remover/Installer Special Tool C-4699-2
(Fig. 2) over ball joint stud and against the ball joint
upper housing.
(4) Press down against the ball joint upper housing,
to remove ball joint assembly from lower control arm.
BALL JOINT INSTALLATION
(1) By hand, position ball joint assembly into the ball
joint bore of the lower control arm. Be sure the ball
joint assembly is not cocked in the bore of the control
arm, this will cause binding of the ball assembly.
(2) Position assembly in press with Installer Tool
C-4699-2 supporting control arm (Fig. 3).
(3) Install
the
Remover/Installer,
Special
Tool
C-4699-1 over the ball joint stud and down on the lower
control arm assembly (Fig. 3).
(4) Carefully align all pieces. Using an arbor press
apply pressure against the ball joint assembly, until
ball joint is fully seated against bottom surface of
control arm. Do not apply excessive pressure against
the control arm.
BALL JOINT SEAL INSTALLATION
(1) Support ball joint housing with Installer, Special
Tool C-4699-1 (Fig. 4). Position new seal over ball joint
stud and against ball joint housing.
(2) With 1-1/2 inch socket, press seal onto ball joint
housing until it is squarely seated against top surface
of control arm as shown in (Fig. 4).
Fig. 1 Checking Ball Joint Wear
Fig. 2 Removing Ball Joint
Fig. 4 Installing Ball Joint Seal
Fig. 3 Installing Ball Joint
2 - 14
FRONT SUSPENSION AND DRIVE SHAFTS
.
SWAY BAR
The sway bar interconnects the front lower control
arms of the vehicle and attaches to the crossmember
(Fig. 1).
Jounce and rebound movements affecting one wheel
are partially transmitted to the opposite wheel to
stabilize body roll.
Attachment to the crossmember, and front lower
control arms is through rubber-isolated bushings. All
parts are serviceable, and the sway bar to crossmember
bushings are split for easy removal and installation.
The split in the sway bar to crossmember bushing
should be positioned toward the front of the vehicle.
REMOVAL
(1) Raise and support the vehicle. See Hoisting in
Lubrication and Maintenance, Group 0.
(2) Remove the nuts, bolts, and sway bar retainers
at the front lower control arms (Fig. 1).
(3) Remove the bolts at sway bar crossmember
clamps, and remove clamps and sway bar from vehicle
(Fig. 1).
INSPECTION
Inspect for broken or distorted clamps, retainers, and
bushings. If bushing replacement is required, the inner
bushing can be removed by opening the split. The outer
bushing must be cut or hammered off the bar. If
replaced, the outer bushings should be forced on so
that approximately 1/2 inch of the bar protrudes. The
sway bar to crossmember bushings, should be posi-
tioned when installed, so the void on the bushing is
positioned toward the rear of the vehicle (Fig. 2). Note
that the control arm retainers are symmetric and bend
slightly upon installation.
INSTALLATION
(1) If inspection of the sway bar assembly, deter-
mined that sway bar to lower control arm bushings
require replacement. Install the new bushings, by
forcing them onto sway bar using a rotating motion.
Bushings should be installed on sway bar so that sway
bar extends 1/2 inch out past the end of the bushing.
(2) If required position sway bar to crossmember
bushings on sway bar with external rib up and void in
the bushing facing the rear of vehicle (Fig. 2). Lift the
bar assembly into the crossmember, and install the
lower clamps and bolts. The center offset in the sway
bar should be oriented toward the front of the vehicle
(Fig. 1)
Fig. 1 Front Sway Bar
Fig. 2 Sway Bar To Crossmember Bushing Position
.
FRONT SUSPENSION AND DRIVE SHAFTS
2 - 15
(3) Position bushing retainers on lower control arms,
insert bolts, and install nuts. The bolts should be
installed so that the threaded portion of the bolt is up,
with the nut is against the lower control arm not the
bushing retainer (Fig. 1).
(4) With lower control arms raised to design height,
tighten all retainer attaching bolts to 70 N
Im (50 ft.
lbs.) torque.
(5) Lower vehicle.
KNUCKLE (FRONT SUSPENSION)
The front suspension knuckle (Fig. 1) provides for
steering control of the vehicle. Supports the brake
caliper and absorbs the loads exerted during vehicle
braking. It also supports the front (driving) hub and
bearing and stub axle assembly.
The front suspension knuckle also provides the abil-
ity to align the front wheels of the vehicle. This is done
by allowing for front wheel camber adjustment and the
ability for front tire Toe adjustments
The front suspension knuckle is not a serviceable
component. Do not attempt to straighten or repair the
front suspension knuckle in any way.
Service repair or replacement of the front (drive) hub
and bearing, can be done with the front suspension
knuckle remaining on the vehicle.
REMOVAL
(1) Remove the cotter pin, hub nut lock and spring
washer from the front axle (Fig. 2).
(2) Loosen hub nut while the vehicle is on the floor
with the brakes applied (Fig. 3). The hub and drive-
shaft are splined together through the knuckle
(bearing) and retained by the hub nut.
(3) Raise and support the vehicle. See Hoisting in
Lubrication and Maintenance, Group 0.
(4) Remove the wheel lug nuts, front tire and wheel
assembly and hub nut and washer.
(5) Remove the brake caliper adapter to steering
knuckle attaching bolts and washers (Fig. 1). Remove
the brake caliper and adapter from the steering
knuckle
and
braking
disc.
Support
brake
caliper/adapter assembly using a wire hook and not by
hydraulic hose (Fig. 4).
Fig. 3 Loosen Hub Nut
Fig. 1 Front Knuckle Assembly (Typical)
Fig. 2 Remove Cotter Pin, Hub Nut Lock, & Spring
Washer
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FRONT SUSPENSION AND DRIVE SHAFTS
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