Chrysler Caravan/Voyager/Town and Country 1996-1999

Struts

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5 and 6



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Fig. Fig. 1: Unbolting the brake hose and ABS speed sensor bracket from the strut



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Fig. Fig. 2: Removing the sway bar link

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the front wheel.
  4.  
  5. If equipped, remove the brake hose routing bracket and ABS speed sensor cable routing bracket from the strut damper brackets.
  6.  



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Fig. Fig. 3: The strut is attached to the steering knuckle with two bolts. Hold the bolts stationary while removing the nuts

  1. If equipped, remove the sway bar attaching link from the mounting bracket on the strut assembly. Hold the sway bar attaching link stud using a 6mm hex bit while removing the retaining nut with a box wrench.
  2.  



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Fig. Fig. 4: Some models may be fitted with an eccentric bolt; make sure to mark its position before removal to retain the alignment settings


WARNING
The steering knuckle-to-strut assembly attaching bolts are of the serrated type and, therefore, cannot be turned during the removal procedure. Hold the bolts stationary in the steering knuckle while removing the nuts.

  1. Remove the steering knuckle-to-strut assembly attaching bolts.
  2.  
  3. Remove the three nuts securing the strut assembly upper mount to the strut tower. Remove the strut assembly from the vehicle.
  4.  



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Fig. Fig. 5: After the strut is detached from the steering knuckle, remove the three bolts that secure the upper strut to the strut tower



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Fig. Fig. 6: Now the strut can be removed from the vehicle

To install:
  1. Position the strut assembly into the strut tower and loosely install the upper washers and nuts. Tighten the three attaching upper mount nuts to 21 ft. lbs. (28 Nm).
  2.  
  3. Position the lower mount over the steering knuckle and loosely install the attaching bolts and nuts. If one of the attaching bolts is a cam bolt, the cam bolt must be installed in the lower slotted hole of the strut clevis bracket. Be sure that the attaching nuts face the front of the vehicle. Tighten the attaching nuts to 65 ft. lbs. (88 Nm) plus an additional 1 / 4 turn.
  4.  
  5. If equipped, install the sway bar attaching link to the bracket on the strut assembly. Using a 6mm hex bit and crowfoot, tighten the sway bar link bracket attaching nut to 65 ft. lbs. (88 Nm).
  6.  
  7. If equipped, install the brake hose retaining bracket and ABS speed sensor cable routing bracket onto the strut assembly bracket. Tighten the mounting bolts to 10 ft. lbs. (13 Nm).
  8.  
  9. Install the front wheels and lug nuts. Tighten the lug nuts, in a star pattern sequence, to 95 ft. lbs. (129 Nm). Lower the vehicle and check the wheel alignment. Adjust, if necessary.
  10.  

OVERHAUL



See Figures 7, 8, 9, 10, 11 and 12



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Fig. Fig. 7: A spring compressor is required to disassemble the strut



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Fig. Fig. 8: With the spring compressed, remove the strut shaft retaining nut with the special tool



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Fig. Fig. 9: Pivot bearing installation

  1. Remove the strut assembly from the vehicle.
  2.  
  3. Secure the strut assembly into a bench vise. Mount the strut assembly in the vertical position, clamping the strut assembly at the strut clevis bracket ONLY.
  4.  
  5. Using a coil spring compressor, compress the coil spring. It is required that the upper spring seat and second spring coil from the bottom be secured within the jaws of the spring compressor tool.
  6.  
  7. Using a wrench, hold the end of the strut shaft from rotating and remove the strut shaft nut.
  8.  



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Fig. Fig. 10: If a strut cartridge is being replaced, be sure to install the jounce bumper and dust boot to keep the strut from being damaged

  1. Remove the upper strut mount from the strut assembly. Carefully remove the coil spring compressor tool from the coil spring.
  2.  
  3. Remove the upper spring seat and pivot bearing assembly from the coil spring.
  4.  
  5. Remove the coil spring from the strut. If the coil spring is being reused, mark the coil spring for correct reinstallation position.
  6.  



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Fig. Fig. 11: When installing the springs, make sure they are positioned correctly on the lower spring seats



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Fig. Fig. 12: The notch on the upper spring seat should line up with the end of the bottom coil

To install:
  1. With the strut assembly mounted firmly in the bench vise, install the coil spring on the strut assembly. Be sure the end of the coil spring's bottom coil aligns with the strut clevis bracket.
  2.  
  3. Install the upper spring seat onto the coil spring. Position the notch on the top of the spring seat in alignment with the strut clevis bracket.
  4.  
  5. Install the compressor tool onto the coil spring, and compress the spring.
  6.  
  7. Install the pivot bearing onto the top of the upper spring seat with the smaller diameter side of the bearing facing toward the spring seat.
  8.  
  9. Install the strut mount on the upper spring seat of the strut assembly. Loosely install the strut shaft nut.
  10.  
  11. Tighten the strut shaft nut to 70 ft. lbs. (94 Nm). This step is performed with the spring compressor tool still installed on the spring.
  12.  
  13. Check that the top of the coil spring is seated correctly against the upper spring seat. Carefully remove the spring compressor tool.
  14.  

 
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