Unity® Replacement Front Right Complete Strut
Contents
1. Dy BRACKET AN i m do not allow stud to rotate Hold stud from rotating by inserting Ee i a a Torx Plus 401P bit in the end of the stud 3 7 Remove lower strut mounting bolts G4 The lower strut assembly attaching bolts 5 are serrated j and must not be turned during removal Remove nuts while holding bolts stationary in the steering knuckles 8 Remove upper strut mounting nuts 6 9 Remove strut assembly from vehicle installation is the reverse of removal Care should be taken while installing the new complete strut assembly not to chip or scratch the strut assembly coil spring Damage to the coating may cause premature failure 1041 2 Chrysler Caravan Town amp Country Unity Automotive Due to an unusal amount of complaints of noise from this unit we have identified multiple Technical Sevice Bulletins from the manufacturer that deal with suspension noise We have provided you with these bulletins so you may familiarize yourself with common problems and causes of noise from suspension related noise NUMBER 02 004 01 GROUP Suspension DATE July 6 2001 SUBJECT Knock S quawk Sound From Front Suspension OVERVIEW This bulletin involves installing new front sway bar link assemblies MODELS 1996 2000 NS Town amp Country Caravan V oyager 1996 2000 GS Chrysler Voyager International Markets 2001 RS Town amp Country Caravan V oyager 2001 RG Chrysler Voyager Internati2. for your protection Be sure to follow the instructions in the order that they are given The instructions are in a certain order for a reason and improper installation could lead to damage to your vehicle or the parts Keep in mind that if you damage the parts during installation you will be responsible for the replacement parts Minimum Tools Needed For This Installation Product Photos TL Hand Tools Sockets Wrenches AS Jackstands Jack and 1041 2 Chrysler Caravan Town amp Country Unity Automotive ee Vehicle is equipped with a gas pressurized Do not use a suspension style lift nor use a front shock absorber which will extend floor jack on any suspension parts Failure to unassisted Do not apply heat or flame to follow these instructions will result in the the front shock absorber during removal inability to remove and install the complete Failure to follow these instructions may strut assemblies Use a jack point or the pinch result in personal injury weld to lift the car 1 Removal my 1 Loosen lug nuts on front wheels 2 Raise vehicle and support with suitable jack stands 3 Remove wheels b Remove the hydraulic brake hose routing bracket and the speed sensor cable routing bracket from the strut damper brackets G1 6 Remove the stabilizer bar attaching link from the bracket on the strut assembly 2 ff a eTRUT When removing nut from stud of stabilizer bar attaching link
3. Complete Strut Assembly Installation Instructions 11 4 ni A STRUT ASSEMBLY 00 Chrysler Voyager Grand Voyager 95 00 Chrysler Town amp Country These complete strut assemblies have been designed and extensively tested to provide the same ride quality and height as the O E M system Please note that the car will sit approximately 1 2 3 4 immediately following installation This is normal and the car will settle into its O E M ride height as the coil spring adjusts to the weight of the vehicle This settle period is approximately 500 miles as a reference tool only If you are uncomfortable with any step within these instructions f i These instructions are not meant to replace a certified mechanic Please use these instructions please consult an A S E cerfified mechanic General Precautions When servicing any vehicle be sure to follow all safety procedures First make sure that when lifting the vehicle that you are using the appropriate jack for the weight of the vehicle Make sure before going underneath any vehicle that it is properly supported with sturdy jack stands and on level ground so that the vehicle doesn t fall or slide off of the jack and onto you As with any automotive repair make sure you have the appropriate tools to do the job so you don t damage any parts on the vehicle There is a list of tools needed included in these instructions Safety glasses and mechanic gloves should also be worn
4. ROCEDURE 1 Raise the vehicle on a frame contact hoist See Hoisting in the Lubrication and Maintenance section of the appropriate service manual if you are unfamiliar with the procedure 2 Remove both front wheels CAUTION WHEN REMOVING THE NUTS FROM THE STUDS OF THE STABILIZER LINKS DO NOT ALLOW THE STUD TO ROTATE IN ITS SOCKET HOLD THE STUD FROM ROTATING BY INSERTING A TORX PLUS 40 IP BIT IN THE END OF THE STUD USE OF A NON PLUS IP BIT MAY RESULT IN ROUNDING OUT THE END OF THE STUD 3 Remove each stabilizer link retaining nut washer while holding the stabilizer link stud with a Torx Plus 40 IP bit do not allow the stud to rotate in its socket 4 Install revised nut washer p n 06505291AA and tighten to 88 Nm 65 ft Ibs 5 Repeat steps 3 and 4 for the other three nut washers 6 Install both front wheels use a criss cross pattern to tighten the lug nuts to 70 Nm 50 ft Ibs and then use a criss cross pattern again to tighten to a final torque of 135 Nm 100 ft Ibs 7 Lower the vehicle POLICY Reimbursable within the provisions of the warranty TIME ALLOWANCE Labor Operation No 02 20 10 96 0 7 Hrs FAILURE CODE P8 New Part UNITY AUTOMOTIVE SYSTEMS SUSPENSION SYSTEMS
5. onal Markets SYMPTOM CONDITION 1 A squawk creak groan sound is heard when turning the steering wheel at a stop or during a low speed turn such as a parking lot maneuver 2 A Knocking clunking sound is heard from the front suspension while driving over rough bumpy roads DIAGNOSIS 1 With a helper in the vehicle apply the parking brake start the engine and turn the steering wheel in both directions Reach between the top of the front tire and the wheel well lip and grasp the sway bar link Listen or feel for the condition described above while the wheel is being turned If the condition is present perform the Repair Procedure 2 Drive the vehicle over rough bumpy roads to verify condition Raise the vehicle on an appropriate hoist and perform a visual inspection of the front suspension Repair or replace any loose damaged or worn components and test drive vehicle It the condition is still present perform the Repair P rocedure Description 2 0474345404 Link Sway Bar PARTS REQUIRED REPAIR PROCEDURE 1 Raise the vehicle on a frame contact hoist 2 Remove both front wheels 3 Remove the upper and lower sway bar link nuts and remove the sway bar link CAUTION WHEN INSTALLING THE NUTS TO THE STUDS OF THE SWAY BAR LINKS DO NOT ALLOW THE STUD TO ROTATE IN ITS SOCKET HOLD THE STUD FROM ROTATING BY INSERTING A 40 TORX BIT INTO THE END OF THE STUD 4 Install the new sway bar link Install the sway bar link nuts and tor
6. que to 88 N m 65 ft Ibs 5 Perform steps 3 and 4 for the other sway bar link 6 Install both front wheels use a criss cross pattern to tighten the lug nuts to 70 N m 50 ft Ibs and then use a criss cross pattern again to tighten to a final torque of 135 N m 100 ft Ibs 7 Lower vehicle POLICY Reimbursable within the provisions of the warranty Labor Operation No 02 20 10 90 _ TIME ALLOWANCE Pae New Part FAILURE CODE NUMBER 02 03 00 GROUP Front Suspension DATE Feb 25 2000 MODELS 1999 2000 NS Town amp Country Caravan V oyager 1999 2000 GS Chrysler Voyager International Market SUBJ ECT knock Clunk Sound From Front Strut Area OVERVIEW This bulletin involves installing revised front sway bar link retaining nut washer assemblies SYMP TOM CONDITION A knocking clunking sound coming from the front sway bar link is heard inside and outside the vehicle when driving over rough roads DIAGNOSIS Grasp and attempt to shake each front sway bar link If either sway bar link feels loose check the upper attachments at the strut to determine if either washer is missing If both upper washers are present raise the vehicle to check the presence of both lower washers at the sway bar attachment If any of the four washers are missing perform the following Repair Procedure to replace all four nut amp washer assemblies PARTS REQUIRED 4 06505291AA Assembly Nut W asher REPAIR P
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