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    PT Cruiser 2006-2007

    Struts (MacPherson Struts)

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    Disassembly & Assembly



    1. Position the strut assembly in the strut coil spring compressor following the manufacturer's instructions and set the lower and upper hooks of the compressor on the coil spring. Position the strut clevis bracket straight outward, away from the compressor.
    2.  
    3. Compress the coil spring until all coil spring tension is removed from the upper mount and bearing.
    4.  
    5. Once the spring is sufficiently compressed, install Strut Nut Wrench, Special Tool 9362, on the strut rod nut. Next, install Strut Shaft Socket, 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.
    6.  
    7. Remove the clamp (if installed) from the bottom of the coil spring and remove the strut (damper) out through the bottom of the coil spring. The dust shield and jounce bumper will come out with the strut.
    8.  
    9. Remove the lower spring isolator from the strut seat.
    10.  
    11. Slide the dust shield and jounce bumper from the strut rod.
    12.  
    13. Remove the upper mount and bearing from the top of the upper spring seat and isolator.
    14.  
    15. Remove the upper spring seat and isolator from the top of the coil spring.
    16.  
    17. Release the tension from the coil spring by backing off the compressor drive completely. Push back the compressor hooks and remove the coil spring.

      Click image to see an enlarged view

      Fig. Strut assembly components-Upper mounting nut (1), Upper mount (2), Bearing (3), Isolator (4), Coil spring (5), Jounce bumper (6), Lower spring isolator (7), Strut (8).

    18.  

    To assemble:

    1. Place the coil spring in the spring compressor following the manufacturer's instructions. Before compressing the spring, rotate the spring so the end of the bottom coil is at approximately the 9 o'clock position as viewed from above (or to where the spring was when removed from the compressor). This action will allow the strut (damper) clevis bracket to be positioned outward, away from the compressor once installed.
    2.  
    3. Slowly compress the coil spring until enough room is available for strut assembly reassembly.
    4.  
    5. Install the upper spring seat and isolator on top of the coil spring.
    6.  
    7. Install the bearing and upper mount on top of the upper spring seat and isolator.
    8.  
    9. Install the lower spring isolator on the spring seat on the strut.
    10.  
    11. Slide the dust shield and jounce bumper onto the strut rod.
    12.  
    13. Install the strut up through the bottom of the coil spring and upper spring seat, mount, and bearing until the lower spring seat contacts the lower end of the coil spring. Rotate the strut as necessary until the end of the bottom coil comes in contact with the stop built into the lower spring isolator.

      Click image to see an enlarged view

      Fig. Rotate the strut until the end of the bottom coil (2) comes in contact with the stop (1).

    14.  
    15. While holding the strut in position, install the nut on the end of the strut rod.
    16.  
    17. Install Special Tool 9632 Strut Nut Wrench on the strut rod nut.
    18.  
    19. Install Special Tool 9894 Strut Shaft Socket on the end of the strut rod. While holding the strut rod from turning, tighten the strut rod nut to 44 ft. lbs. (60 Nm) using a torque wrench on the end of Special Tool 9362.
    20.  
    21. Slowly release the tension from the coil spring by backing off the compressor drive completely. As the tension is relieved, make sure the upper mount and bearing align properly. Verify the upper mount does not bind when rotated.
    22.  
    23. Remove the strut assembly from the spring compressor.
    24.  
    25. Install the strut assembly on the vehicle.
    26.  

    Removal & Installation



    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Install or connect the following:
      WARNING
      The steering knuckle-to-strut assembly attaching bolts are serrated and must not be turned during removal.



      The negative battery cable
       
      The front wheels
       
      Mark each strut assembly (right or left), as applicable, if both struts are being removed
       
      The ground strap from the rear of the strut
       
      The Anti-lock Brake System (ABS) wheel speed sensor from the strut, if equipped
       



      The steering knuckle nuts while holding the bolts stationary
       
      The 3 upper strut mount-to-strut tower nuts
       
      The strut assembly

      Click image to see an enlarged view

      Fig. Exploded view of the front suspension

       

    4.  

    To install:

    1. Install or connect the following:
      WARNING
      The steering knuckle-to-strut assembly attaching bolts are serrated and must not be turned during installation.


      NOTE
      The bolts should be installed with the nuts facing the front of the vehicle.



      The strut assembly into the strut tower by aligning the 3 upper strut mount studs with the shock tower holes. Torque the 3 upper strut mount nut/washer assemblies to 25 ft. lbs. (34 Nm).
       



      The steering knuckle nuts while holding the bolts stationary
       
      The steering knuckle arm and position it into the strut assembly by aligning the strut assembly-to-steering knuckle holes
       
      Both strut-to-steering knuckle bolts. Torque both bolts to 120 ft. lbs. (163 Nm).
       



      The ABS wheel sensor to the rear of the strut and torque the screw to 120 inch lbs. (13 Nm)
       
      The ground strap to the rear of the strut and torque the screw to 120 inch lbs. (13 Nm)
       
      The front wheel
       
      The negative battery cable
       

    2.  

     
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