Caravan, Town & Country 2006-2007

Struts (MacPherson Struts)

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Disassembly & Assembly



  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    For the disassembly and assembly of the strut assembly, use of Strut Spring Compressor tool 223-7400, or the equivalent, is recommended to compress the coil spring. Follow the manufacturer's instructions closely.


    CAUTION
    Do not remove the strut shaft nut before the coil spring is compressed. The coil spring is held under pressure and must be compressed, removing spring tension from the upper mount and pivot bearing, before the shaft nut is removed.

  2.  
  3. Position the strut assembly in the strut coil spring compressor following the manufacturer-s instructions. Position the lower hooks on the coil spring first. The strut clevis bracket should be positioned straight outward from the compressor.
  4.  
  5. Turn the upper mount of the strut assembly toward the inside of the compressor as shown to allow positioning of the compressor upper hooks. Position the upper hooks on top of the coil spring upper seat approximately 1 inch from outside diameter of seat. Do not allow hooks to be placed closer to edge. Place a clamp on the lower end of the coil spring, so the strut is held in place once the strut shaft nut is removed.
  6.  
  7. Compress the coil spring until all coil spring tension is removed from the upper mount.
  8.  
  9. Install Strut Nut Socket, Special Tool 6864, on the strut shaft retaining nut. Next, install a 10 mm socket on the hex on the end of the strut shaft. While holding the strut shaft from turning, remove the nut from the strut shaft.
  10.  
  11. Remove the upper mount from the strut shaft.
  12.  
  13. If the pivot bearing needs to be serviced, remove it from the top of the coil spring upper seat by pulling it straight up.
  14.  
  15. Remove the clamp from the bottom of the coil spring and remove the strut out through the bottom of the coil spring.
  16.  
  17. Release the tension from the coil spring by backing off the compressor drive fully. Push back the compressor upper hooks and remove the upper spring seat with upper spring isolator.
  18.  
  19. Remove the coil spring from the spring compressor.
  20.  
  21. Remove the dust shield and jounce bumper as an assembly from the strut shaft by pulling both straight up and off the strut shaft. The dust shield cannot be separated from the jounce bumper until after it is removed from strut shaft.
  22.  
  23. Remove the jounce bumper from the dust shield. The jounce bumper is removed from the dust shield by collapsing the dust shield until the jounce bumper can be pulled free from the dust boot.
  24.  
  25. Remove the spring isolator from the lower spring seat on the strut.
  26.  
  27. Inspect the strut assembly components for the following and replace as necessary:
    1. Inspect the strut for any condition of shaft binding over the full stroke of the shaft.
    2.  
    3. Check the upper mount for cracks and distortion and its retaining studs for any sign of damage.
    4.  
    5. Check the upper seat for stress cracks and wear.
    6.  
    7. Check the upper spring isolator for severe deterioration.
    8.  
    9. Check for binding of the strut assembly pivot bearing.
    10.  
    11. Inspect the dust shield for rips and deterioration.
    12.  
    13. Inspect the jounce bumper for cracks and signs of deterioration.
    14.  

  28.  

To assemble:

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Fig. Exploded view of the strut components



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Fig. Position the hooks (1) over the bearing (2) by 1 inch as shown



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Fig. Coil spring positioning on short wheelbase vehicles



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Fig. Coil spring positioning on long wheelbase vehicles


NOTE
Coil springs on this vehicle are side-oriented. Left and right springs must not be interchanged. On short wheel base vehicles the springs on the left side of the vehicle have a left-hand wind top-to-bottom while springs on the right side have a right-hand wind top-to-bottom. On long wheel base vehicles the springs on both the left side and right side of the vehicle have a left-hand wind top-to-bottom.

  1. Place the coil spring in the compressor lower hooks following the manufacturer-s instructions. Consider the following in terms of degrees when placing the coil spring in the compressor: From above, the compressor back is at the 180 degree position, and the operator, standing in the front of the compressor, is at the 0 degree position. On short-wheel-based vehicles, place the lower coil spring end at the 180 degree position for left springs and at the 180 degree position for right springs. On long-wheel-based vehicles, place the lower coil spring end at the 260 degree position (clockwise from 0 degrees) for left springs and at the 180 degree position for right springs.
  2.  
  3. Install the upper seat and upper isolator on top of the coil spring. Position the notch in the perimeter of the upper seat toward the front of the compressor (at 0 degree position).
  4.  
  5. Position the upper hooks on top of the coil spring upper seat so the upper hooks span approximately one inch past outside diameter of upper seat. This will allow proper clearance for upper mount installation without pinching the hooks in-between the two pieces.
    WARNING
    Do not allow hooks to be placed closer to edge.

  6.  
  7. Compress the coil spring far enough to allow strut installation.
  8.  
  9. If the pivot bearing has been removed from the upper seat, install the pivot bearing on the top of the upper spring seat. The bearing must be installed on upper seat with the smaller diameter side of the pivot bearing toward the spring seat. Be sure the pivot bearing is sitting flat on the spring seat once mounted.
  10.  
  11. Install the spring isolator on the lower spring seat of the strut.
  12.  
  13. Install the jounce bumper on the strut shaft. The jounce bumper is to be installed with the small end pointing downward.
  14.  
  15. Install the dust shield on the strut. Collapse and stretch the dust shield down over the top of the jounce bumper until the dust shield snaps into the slot on the jounce bumper. The jounce bumper will be at the top of the inner dust boot. Return the dust shield to its fully extended length.
    WARNING
    In the following step it most important to properly position the coil spring on the lower spring seat of the strut. Failure to do so will alter the geometry of the vehicle possibly causing a pull condition.

  16.  
  17. Install the strut through the bottom of the coil spring until the lower spring seat contacts the lower end of the coil spring. If the coil spring is properly aligned, the clevis bracket on the strut should point straight outward away from the compressor (toward operator at 0 degree position). If necessary, reposition the strut or coil spring in the compressor so the strut clevis bracket lines up with the lower coil spring end as indicated in the following:
    1. Short wheel base vehicles: Position the end of the lower coil approximately 180 degrees from the center of the clevis bracket.
    2.  
    3. Long wheel base vehicles: Position the end of the left side lower coil approximately 260 degrees clockwise from the center of the clevis bracket. Position the end of the right side lower coil approximately 180 degrees from the center of the clevis bracket.
    4.  

  18.  
  19. Install the clamp to hold the strut and coil spring together.
  20.  
  21. Install the strut mount over the strut shaft and onto the top of the pivot bearing and upper seat. Loosely install the retaining nut on the strut shaft.
  22.  
  23. Install Strut Nut Socket (on the end of a torque wrench), Special Tool 6864, on the strut shaft retaining nut. Next, install a 10 mm socket on the hex on the end of the strut shaft. While holding the strut shaft from turning, tighten the strut shaft retaining nut to 75 ft. lbs. (100 Nm).
  24.  
  25. Before releasing the tension the compressor has on the spring, make sure the upper spring seat and strut clevis bracket are lined up properly (within 5 degrees of one another).
  26.  
  27. Slowly release the tension from the coil spring by backing off the compressor drive fully. As the tension is relieved, make sure the upper mount, pivot bearing and upper seat are align properly. Remove the clamp from the lower end of the coil spring and strut. Push back the spring compressor upper and lower hooks, then remove the strut assembly from the spring compressor.
  28.  
  29. Install the strut assembly on the vehicle.
  30.  

Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Front wheel
     
    Brake hose bracket
     
    Wheel speed sensor harness bracket, if equipped
     
    Stabilizer bar link
     
    Steering knuckle bracket bolts
     
    Upper strut mount nuts
     
    Strut assembly
     

  4.  

To install:

  1. Install or connect the following:

    Strut assembly. Torque the upper strut mount nuts to 21 ft. lbs. (28 Nm).
     
    Steering knuckle bracket bolts. Torque the bolts to 60 ft. lbs. (81 Nm) plus 90 degrees.
     
    Stabilizer bar link. Torque the nut to 65 ft. lbs. (88 Nm).
     
    Wheel speed sensor harness bracket, if equipped. Torque the bolt to 10 ft. lbs. (13 Nm).
     
    Brake hose bracket. Tighten the bolt to 10 ft. lbs. (13 Nm).
     
    Front wheel
     

  2.  
  3. Check the wheel alignment and adjust as necessary.
  4.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Front wheel
     
    Brake hose bracket
     
    Wheel speed sensor harness bracket, if equipped
     
    Stabilizer bar link
     
    Steering knuckle bracket bolts
     
    Upper strut mount nuts
     
    Strut assembly
     

  4.  

To install:

  1. Install or connect the following:

    Strut assembly. Torque the upper strut mount nuts to 21 ft. lbs. (28 Nm).
     
    Steering knuckle bracket bolts. Torque the bolts to 60 ft. lbs. (81 Nm) plus 90 degrees.
     
    Stabilizer bar link. Torque the nut to 65 ft. lbs. (88 Nm).
     
    Wheel speed sensor harness bracket, if equipped. Torque the bolt to 10 ft. lbs. (13 Nm).
     
    Brake hose bracket. Tighten the bolt to 10 ft. lbs. (13 Nm).
     
    Front wheel
     

  2.  
  3. Check the wheel alignment and adjust as necessary.
  4.  

 
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