Dodge Caliber. Manual — part 16
DIAGNOSIS AND TESTING
STRUT ASSEMBLY
Inspect the strut assembly for the following conditions:
•
Inspect for a damaged or broken coil spring (5).
•
Inspect for a torn or damaged dust shield (6).
•
Lift the dust shield and inspect the strut assem-
bly for evidence of fluid running from the upper
end of the strut fluid reservoir. (Actual leakage
will be a stream of fluid running down the side
and dripping off lower end of unit). A slight
amount of seepage between the strut shaft and
strut shaft seal is not unusual and does not affect
performance of the strut assembly.
•
Inspect the jounce bumper for signs of damage
or deterioration.
•
Inspect the clearance between the shock tower
and the coil spring. Make sure no fasteners are
protruding through the shock tower possibly con-
tacting the coil spring and strut. Because of the
minimum clearance in this area, installation of
metal fasteners could damage the coil spring
coating and lead to a corrosion failure of the spring.
CAUTION: At no time when servicing a vehicle can
a sheet metal screw, bolt or other metal fastener
be installed into the strut tower (1) to take the
place of an original plastic clip. Also, do not drill
holes into the front strut tower for the installation
of any metal fasteners into the shock tower area
indicated (3).
REMOVAL
NOTE: Before proceeding, (Refer to 2 - SUSPENSION/FRONT - WARNING).
1. Raise and support the vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
PM
FRONT SUSPENSION
2 - 29
2. Remove the wheel mounting nuts (3), then the tire
and wheel assembly (1).
NOTE: If both strut assemblies are to be removed, mark the strut assemblies right or left and keep the parts
separated to avoid mix-up. Not all parts of the strut assembly are interchangeable side-to-side.
3. Remove the screw (1) securing the flex hose (2)
routing bracket to the strut (6).
2 - 30
FRONT SUSPENSION
PM
4. While holding the stabilizer bar link (1) stud station-
ary, remove the nut (4) securing the link to the strut
(3).
CAUTION: The strut assembly-to-knuckle attaching
bolts (5) are serrated and must not be turned dur-
ing removal. Hold the bolts stationary in the
knuckle while removing the nuts, then tap the
bolts out using a pin punch.
5. While holding the bolt heads stationary, remove the
two nuts (2) from the bolts (5) attaching the strut
(3) to the knuckle (6).
6. Remove the two bolts (5) attaching the strut (3) to
the knuckle (6) using a pin punch.
7. Lower the vehicle just enough to open the hood without allowing the tires to touch the floor.
8. Remove the three nuts (1) attaching the strut
assembly (2) upper mount to the strut tower.
9. Remove the strut assembly (2) from the vehicle.
10. For disassembly, (Refer to 2 - SUSPENSION/
FRONT/STRUT - DISASSEMBLY).
DISASSEMBLY
NOTE: The strut assembly must be removed from the vehicle for it to be disassembled and assembled.
(Refer to 2 - SUSPENSION/FRONT/STRUT - REMOVAL)
For the disassembly and assembly of the strut assembly, use strut spring compressor, Pentastar Service Equipment
(PSE) tool W-7200, or equivalent, to compress the coil spring. Follow the manufacturer’s instructions closely.
WARNING: Do not remove the strut rod nut before the coil spring is properly compressed. The coil spring
is held under pressure. The coil spring must be compressed, removing spring tension from the upper
mount and bearing, before the strut rod nut is removed.
1. If both struts are being serviced at the same time, mark both the coil spring and strut assembly according to
which side of the vehicle the strut is being removed from.
PM
FRONT SUSPENSION
2 - 31
2. Position the strut assembly (2) in the strut coil
spring compressor (1) following the manufacturers
instructions and set the lower and upper hooks of
the compressor on the coil spring. Position the strut
clevis bracket (4) straight outward, away from the
compressor.
3. Compress the coil spring until all coil spring tension
is removed from the upper mount and bearing.
CAUTION: Never use impact or high speed tools
to remove the strut rod nut. Damage to the strut
internal bearings can occur.
4. Once the spring is sufficiently compressed, install
Strut Nut Wrench (2), Special Tool 9362, on the
strut rod nut. Next, install Strut Shaft Socket (1),
Special Tool 9894, on the end of the strut rod.
While holding the strut rod from turning, remove
the nut using the strut nut wrench.
5. Remove the clamp (if installed) from the bottom of
the coil spring and remove the strut (damper) (8)
out through the bottom of the coil spring. the dust
shield and jounce bumper will come out with the
strut.
6. Remove the lower isolator (7) from the strut seat.
7. Slide the dust shield and jounce bumper (6) from
the strut rod.
8. Remove the upper mount (2) and bearing (3) from
the top of the upper spring seat and isolator (4).
9. Remove the upper spring seat and isolator (4) from
the top of the coil spring (5).
10. Remove the lower spring isolator (2) from the
lower spring seat on the strut (1).
NOTE: If the coil spring needs to be serviced, pro-
ceed with the next step, otherwise, proceed with
step Step 12.
2 - 32
FRONT SUSPENSION
PM
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