Suspension System: Specifications Dodge Caravan IV

FRONT SUSPENSION FASTENER TORQUE

FRONT SUSPENSION FASTENER TORQUE

Scheme 1

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

1. Raise Vehicle. Refer to «HOISTING»(ref-248903-S15913609192007022700000).
2. Remove the 2 bolts fastening the emission leak detection pump to the cradle crossmember reinforcement.
3. Move the leak detection pump to the side allowing access to the stabilizer bar cushion retainers.
4. Remove the nut and bolt securing each stabilizer bar cushion retainer to the cradle crossmember and remove the retainers. (Scheme 7) 1 - STEERING GEAR 2 - STABILIZER BAR 3 - RAISED BEAD 4 - FRONT CRADLE CROSSMEMBER 5 - RETAINERS
5. Remove each stabilizer bar cushion from the stabilizer bar by opening the slit in the cushion and peeling it off the stabilizer bar.

Scheme 8

1. Install each new cushion on stabilizer bar by spreading cushion at slit and forcing it onto stabilizer bar. NOTE: Cushions must be installed on stabilizer bar so the square corner of the bushing will be down and slit in cushion will be facing the rear of the vehicle when the stabilizer bar is installed. (Scheme 8) 1 - SLIT IN SWAY BAR BUSHING. 2 - SQUARE CORNER 3 - SWAY BAR 4 - SWAY BAR ISOLATOR BUSHING
2. Place stabilizer bar into mounted position with cushions properly aligned.
3. Hook each retainer into cradle crossmember mounting hole and over cushion.
4. Install each mounting bolt from rear of cradle crossmember through retainer. Install the two nuts and tighten to 68 N.m (50 ft. lbs.) torque.
5. Reattach emission leak detection pump to cradle crossmember reinforcement with two mounting bolts.
6. Lower the vehicle.

REAR SUSPENSION FASTENER TORQUE

REAR SUSPENSION FASTENER TORQUE

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

1. Raise vehicle on frame-contact hoist as follows: Position the hoist arm supporting the corner of the vehicle to be serviced against a block of wood placed on the body sill as shown. (Scheme 12) Position the remaining hoist arms at each corner of the vehicle in the normal fashion. «(Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)»(ref-248903-S02249938992007022700000) Raise the vehicle to a comfortable working level. 1 - BODY SILL AREA 2 - MOUNTING BOLTS 3 - SPRING MOUNTING BRACKET 4 - LEAF SPRING 5 - HOIST LIFT ARM 6 - WOODEN BLOCK
2. Position an under-hoist utility jack or transmission jack under rear axle toward the side needing bushing replacement. Jack pad should just contact axle.
3. Remove shock absorber lower mounting bolt. NOTE: If shock absorber bolt deflects upward during removal, raise axle by adjusting support jack. If shock absorber bolt deflects downward during removal, lower axle by adjusting support jack (or by pulling on axle).
4. Remove four bolts securing leaf spring front mounting bracket to the body. (Scheme 12)
5. Using jack, slowly lower rear axle, permitting the forward end of rear spring to hang down. Lower it enough to allow access to spring pivot bolt. It may be necessary to place a wooden block between the spring and vehicle to hold forward end of the spring in place.
6. Remove leaf spring forward pivot bolt, then remove mounting bracket.
7. Straighten the retainer tabs on the bushing. (Scheme 13) 1 - SPRING EYE 2 - RETAINING TABS
8. Place Remover/Installer, Special Tool 8459 on leaf spring and bushing as shown and tighten Set Screw securing Remover Plate to tool threaded shaft. (Scheme 14) 1 - BUSHING 2 - BEARING 3 - WASHER 4 - NUT 5 - BODY (8459-1) 6 - PIN 7 - REMOVER PLATE (8459-2) 8 - SET SCREW
9. Tighten nut, removing bushing from spring eye. (Scheme 14)
10. Remove the tool from spring, then remove bushing from tool.

Scheme 15

1. Install by hand NEW bushing in left side of leaf spring eye.
2. Place Remover/Installer, Special Tool 8459 on leaf spring and bushing as shown and tighten Set Screw securing Installer Plate (8459-3) to tool threaded shaft. (Scheme 15) 1 - NUT 2 - WASHER 3 - BEARING 4 - LEAF SPRING EYE 5 - BUSHING 6 - INSTALLER PLATE (8459-3) 7 - PIN 8 - BODY (8459-1)
3. Tighten nut, installing bushing in spring eye. Tighten nut until there is approximately a 1 mm gap between the bushing flange and the spring eye. (Scheme 15) Do not bottom the flange against the spring eye.
4. Remove Remover/Installer from the bushing and leaf spring.
5. Bend the retainer tabs on bushing outward against spring eye.
6. Position spring mounting bracket over spring eye and install pivot bolt through center of bushing from the outboard side. NOTE: The pivot bolt must be installed from the outboard side to allow proper bracket to body mounting.
7. Install the nut on the pivot bolt and lightly tighten. Do not fully tighten bolt at this time.
8. Raise the under-hoist utility jack or transmission jack, guiding the forward mounting bracket into place against the body. It may help to use a drift punch placed through the hole centered between the mounting bolt holes in the bracket and the pilot hole in the body of the vehicle as a guide. When the four mounting bolt holes line up with their threads in the body, Install the mounting bolts. (Scheme 12) Tighten the four mounting bolts to 61 N.m (45 ft. lbs.) torque.
9. Raise or lower the jack until shock absorber lower eye aligns with threads in axle housing. Install shock absorber lower mounting bolt. Do not fully tighten bolt at this time.
10. Lower the vehicle and remove hoist arms and block of wood from under vehicle.
11. Tighten the spring front pivot bolt to 156 N.m (115 ft. lbs.) torque.
12. Tighten the lower shock absorber mounting bolt to 88 N.m (65 ft. lbs.) torque.