Chrysler Caravan/Voyager/Town and Country 1996-1999

Lower Ball Joint

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INSPECTION



Inspect the ball joint dust cover for cracks and damage by pushing on it with your finger. If the dust cover is cracked or damaged, the component must be replaced, or damage to the ball joint will result.

  1. With the weight of the vehicle resting on the road wheels, grasp the ball joint grease fitting.
  2.  
  3. If the ball joint is worn, the grease fitting will rotate easily.
  4.  
  5. Replace the lower control arm ball joint if movement is evident.
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REMOVAL & INSTALLATION



See Figures 1, 2 and 3



Click image to see an enlarged view

Fig. Fig. 1: Using the special tools or equivalent size sockets, press the ball joint from the lower control arm-1996-99 models

Special Chrysler Tools 6758, 6908-4 and 6919 or equivalents, are required to remove and install the lower ball joint. An arbor press is also required to remove and install the ball joint.

  1. Raise and safely support the vehicle. Remove the front wheel.
  2.  
  3. Remove the lower control arm. Using a flat blade tool, pry off the seal from the ball joint.
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  5. Position a receiving cup, special tool 6758 or its equivalent, to support the lower control arm.
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  7. Install remover, special tool 6919 or its equivalent, over the stud and against the joint upper housing.
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  9. Using an arbor press, press the joint assembly from the lower control arm.
  10.  

To install:
  1. Position the ball joint housing into the control arm cavity. Be sure the ball joint is not cocked in the control arm bore, or this will cause the ball joint to bind. The notch in the ball joint stud must face inward to the control arm to allow for clearance of the ball joint-to-steering knuckle clamp bolt.
  2.  



Click image to see an enlarged view

Fig. Fig. 2: Using a press and the correct adapters, carefully press the new ball joint into the lower control arm-1996-99 models

  1. Position the assembly in a press with special tool 6758 or its equivalent, supporting the control arm.
  2.  
  3. Position the ball joint installer special tool 6908-4 or its equivalent, on the bottom of the ball joint.
  4.  
  5. Carefully align the ball joint assembly. Using a press, apply pressure against the control arm assembly until the housing ledge of the ball joint assembly seats completely against the lower control arm surface and there is no gap between the lower control arm and ball joint. Be careful not to apply excessive force on the ball joint or the control arm.
  6.  
  7. Install a new seal boot as far as it will go on the ball joint by hand, first making sure the shield of the ball joint seal is facing outward from the end of the control arm.
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  9. Grease the ball joint using MOPAR® Multi-Mile grease, or equivalent. Do NOT over grease the ball joint or this will prevent the seal boot from being properly installed.
  10.  
  11. To install the new seal, place special tool 6758 or equivalent, over the seal boot and align it squarely with the bottom edge of the seal boot. Apply hand pressure only, until the new seal boot is against the top surface of the control arm.
  12.  



Click image to see an enlarged view

Fig. Fig. 3: Install a new boot on the ball joint using tool No. 6758 or an equivalent socket-1996-99 models

  1. Install the control arm in the vehicle.
  2.  
  3. Install the front wheel and lug nuts. Tighten the lug nuts to 95 ft. lbs. (129 Nm).
  4.  
  5. Lower the vehicle. Check the wheel alignment.
  6.  
  7. Road test the vehicle.
  8.  

 
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