PT Cruiser, 2001 - 2005

Rear Suspension

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Shock Absorbers



Removal & Installation
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the rear wheel and position a transmission jack under the center of the axle. Raise the jack enough to support the axle.
  4.  
  5. Remove or disconnect the following:

    Shock absorber lower mounting bolt from the axle
     
    Upper mounting bolt
     
    Shock absorber

    Click image to see an enlarged view

    Fig. Shock absorber mounting bolts

     

  6.  

To install:

  1. Install or connect the following:

    Shock absorber eye to the body bracket. Hand tighten the upper mounting bolt.
     
    Lower the jack and install the lower mounting bolt through the axle flange and shock absorber. Torque the bolt to 65 ft. lbs. (88 Nm) on 2001-04 models or 65 ft. lbs. (88 Nm) on 2005 models. Torque the upper mounting bolt to 73 ft. lbs. (99 Nm).
     
    Rear wheel
     
    Negative battery cable
     

  2.  

Testing

Inspect the shock absorber for damage and evidence of fluid running from the upper end of the fluid reservoir. (Actual leakage will be a stream of fluid running down the side of the reservoir tube and dripping off lower end of unit). A slight amount of seepage between the shaft and shaft seal is not unusual and does not affect performance of the shock absorber.

Upper Control Arms



Removal & Installation
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Both rear wheels
     
    Watts link bell crank from the center of the axle
     
    Sway bar cushion retainers
     
    Sway bar from the rear axle and place a jack under the rear axle
     
    Shock absorber and lower the jack
     
    Coil springs and rubber isolators

    Click image to see an enlarged view

    Fig. Exploded view of the rear suspension

     

  4.  

To install:

  1. Install or connect the following:

    Rubber isolator on each end of the coil spring and wrap the finger around the coil
     
    Coil springs on top of the axle spring perches and make certain that the upper coils end near the outboard sides of the vehicle and not at 180 degrees of that location
     
    Coil springs into the spring mounting brackets
     
    Washer and nut on the lower mounting bolts and torque the bolts to 65 ft. lbs. (88 Nm) on 2002-04 models or 65 ft. lbs. (88 Nm) on 2005-06 models.
     
    Lower end of the sway bar retainers in the slots at the back of the axle
     
    Mounting bolt through the cushion retainer and torque to 40 ft. lbs. (54 Nm) on 2002-04 models or 45 ft. lbs. (61 Nm) on 2005-06 models
     
    Watts link bell crank to the center of the axle and torque the bolts to 90 ft. lbs. (122 Nm) on 2002-04 models or 110 ft. lbs. (149 Nm) on 2005-06 models
     
    Rear wheels
     

  2.  

Watts Link



Removal & Installation
  1. Raise the vehicle.
  2.  
  3. If the lower watts link is being removed, perform the following first, otherwise proceed to the next step.

    Remove the nut securing the bell crank pivot bolt in the center of the axle.
     
    With the bolt still installed, slide the bell crank away from the axle just enough to remove the nut securing the lower link to the bell crank.
     

  4.  
  5. Remove the nut securing the ball joint to the bell crank.
  6.  
  7. Install the Remover, Special Tool MB991113, on the link ball joint at the bell crank and release ball joint from the bell crank.
  8.  
  9. Remove the bolt securing the link to the bracket on the body of the vehicle. Remove the link.
  10.  

To install:

Click image to see an enlarged view

Fig. Location of the Watts link in relation to the rear suspension


CAUTION
When installing the link, DO NOT attempt to turn the ball joint end of the link independently.

  1. Making sure the ball joint end is positioned properly for mounting to the bell crank, install the link into the bracket on the body of the vehicle.
  2.  
  3. Install the bolt (and flag nut for upper link) securing the link to the bracket, but do not fully tighten it at this time. It must be tightened when the vehicle is at curb height.
    NOTE
    The upper link extends from the right side of the vehicle to the upper end of the bell crank while the lower link extends from the left side of the vehicle to the lower end of the bell crank.

  4.  
  5. Install the upper or lower link to the bell crank. Install the nut on the ball joint stud and tighten it to a torque of 10 ft. lbs. (14 Nm) plus an additional 180° turn after torque is met.
  6.  
  7. If the lower link is the link being installed, perform the following, otherwise proceed to the next step.
    CAUTION
    Although both ends of the bell crank appear to be the same, they are not. When installing the watts links or bell crank, make sure the bell crank is properly positioned.



    Slide the bell crank pivot bolt all the way through the axle.
     
    Place the washer and nut on the end of the pivot bolt and tighten it to a torque of 110 ft. lbs. (149 Nm).
     

  8.  
  9. When mounted properly, the words -BACK UP- should be able to be read from the rear over the top of the axle.
  10.  
  11. Verify the words -BACK UP- can be read on the bell crank from the rear over the top of the axle. If they cannot be read at this position, the link or bell crank is not installed properly and must be removed and reinstalled so that the words -BACK UP- can be read on the upper rear of the bell crank once installed.
  12.  
  13. Lower the vehicle to the ground.
  14.  
  15. Place the vehicle on an alignment rack or drive-on hoist.
  16.  
  17. With the suspension at curb height, tighten the link mounting bolt at the body bracket to a torque of 68 ft. lbs. (92 Nm).
  18.  

Wheel Bearings



Adjustment

The PT Cruiser is equipped with a sealed hub and bearing assemblies. The hub and bearing assembly is non-serviceable. If the assembly is damaged, the complete unit must be replaced.

Removal & Installation
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    WARNING
    DO NOT allow the caliper to hang by the brake hose.


    NOTE
    Discard the hub nut and replace with a new one during installation.



    Wheel
     
    Rear brake drum, if equipped
     
    Caliper (suspend on a wire) and the rotor, if equipped with rear disc brakes
     



    Dust cap from the rear hub/bearing
     
    Hub/bearing assembly-to-knuckle/spindle nut
     



    Hub/bearing from the spindle by pulling it off the end of the spindle by hand
     

  4.  

To install:


WARNING
The hub/bearing nut must be tightened to, but NOT over, its specified torque value. The proper specification is crucial to the life of the hub bearing.

  1. Position the hub/bearing assembly on the rear spindle/knuckle. Install a NEW hub nut and tighten to 160 ft. lbs. (217 Nm)
  2.  
  3. Install or connect the following:

    Dust cap and seat it using a soft face hammer to carefully tap it into place
     
    Brake drum, if equipped
     
    Rotor, if equipped
     
    Caliper and 2 guide pin bolts, if equipped with disc brakes. Torque the bolts to 16 ft. lbs. (22 Nm).
     

  4.  

 
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