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Chrysler Town, Dodge Caravan. Manual - part 21

(6) Install the shock absorber on the vehicle. Refer

to REMOVAL AND INSTALLATION in this section
for the procedure.

INSTALLATION - SHOCK ABSORBER

(1) While

holding

shock

absorber

position

against the frame rail, install the shock absorber
upper mounting bolt.

(2) Install the shock absorber lower mounting bolt

securing the lower end of the shock absorber to the
axle.

(3) Remove the support jack.
(4) Lower the vehicle to the ground so the full curb

weight of the vehicle is supported by the suspension.

(5) Tighten the upper and lower shock absorber

mounting bolt to a torque of 88 N·m (65 ft. lbs.).

SPRING - AWD

REMOVAL - AWD

(1) Raise vehicle on frame-contact hoist as follows:

(a) 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 (Fig. 26).

(b) Position the remaining hoist arms at each

corner of the vehicle in the normal fashion. (Refer
to LUBRICATION & MAINTENANCE/HOISTING
- STANDARD PROCEDURE)

level.

(2) Position an under-hoist utility jack or transmis-

sion jack under rear axle toward the side needing
spring replacement. Jack pad should just contact
axle.

NOTE: If shock absorber bolt deflects upward dur-
ing 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).

(3) Begin removal of the shock absorber lower

mounting bolt (Fig. 27).

(4) Using 2 jack stands positioned under the outer

ends of the axle, raise the axle enough to remove the
weight of the axle from the rear springs.

(5) Loosen and remove the axle plate bolts from

the rear axle (Fig. 28).

(6) Using the jack stands slowly lower the rear

axle, permitting the rear springs to hang free.

(7) Loosen and remove the 4 bolts at the front

mount of the rear leaf spring (Fig. 26).

(8) Loosen and remove the 2 bolts and the 2 pin

nuts from the spring shackle for the rear leaf spring
(Fig. 29). Then remove the inner half of the spring
shackle from the outer half hanger of the spring
hanger and the spring.

(9) Remove the rear leaf spring from the outer half

of the spring shackle.

(10) Remove the leaf spring from the vehicle.
(11) Loosen and remove the pivot bolt from the

front mount of the rear leaf spring. (Fig. 30).

Fig. 26 LIFTING POINT AND SPRING MOUNT

1 - BODY SILL AREA
2 - MOUNTING BOLTS
3 - SPRING MOUNTING BRACKET
4 - LEAF SPRING
5 - HOIST LIFT ARM
6 - WOODEN BLOCK

Fig. 27 Rear Shock Absorber Mounting Bolt

1 - SHOCK BOLT

2 - 38

REAR SUSPENSION

SHOCK ABSORBER (Continued)

INSTALLATION - AWD

CAUTION: Pivot bolt must face inboard to prevent
structural damage during installation of spring.

(1) Install the front eyelet of the rear leaf spring

into the spring mount. Install the pivot bolt and nut.
Do not tighten the pivot bolt at this time.

(2) Position the front spring mount for the rear

leaf spring against the floor pan of the vehicle.
Install the 4 mounting bolts for the front spring
mount (Fig. 26). Tighten the 4 mounting bolts to a
torque of 61 N·m (45 ft. lbs.).

(3) Install the rear of the leaf spring onto the outer

half of the rear shackle. Install the inner half of the
rear hanger. Install the pin nuts and bolts on the
rear shackle, but do not tighten at this time.

(4) Raise axle assembly into correct position with

axle centered under spring locator post.

(5) Install axle plate bolts (Fig. 28). Tighten bolts

to 95 N·m (70 ft. lbs.) torque.

(6) Install shock absorber bolts. Do not tighten

at this time.

(7) Lower the vehicle and remove hoist arms and

block of wood from under vehicle.

CAUTION: The following sequence must be fol-
lowed when tightening the pin nuts on the rear
hanger for the rear leaf spring. First the hanger pin
nuts must be tightened to the specified torque
shown below. Then tighten the retaining bolts for
the inner to outer half of the spring hanger to the
torque specification listed below. This sequence
must be followed to properly seat the bushings into
the springs and to avoid bending the spring hanger.

(8) Tighten the spring front pivot bolt to 156 N·m

(115 ft. lbs.) torque.

(9) Tighten rear spring shackle pin nuts to 61 N·m

(45 ft. lbs.) torque.

(10) Tighten rear spring shackle inner to outer

half retaining bolts to 61 N·m (45 ft. lbs.) torque.

(11) Tighten the lower shock absorber mounting

bolt to 102 N·m (75 ft. lbs.) torque.

Fig. 28 Axle Plate Bolts

1 - LEAF SPRING
2 - AXLE PLATE BOLTS (4)
3 - AXLE PLATE
4 - AXLE

Fig. 29 All-Wheel-Drive Rear Suspension

1 - SHACKLE
2 - REAR MOUNT (HANGER)
3 - LEAF SPRING (MULTI-LEAF)
4 - AWD REAR AXLE

Fig. 30 Leaf Spring Front Mount (Typical)

1 - LEAF SPRING
2 - SPRING MOUNT

REAR SUSPENSION

2 - 39

SPRING - AWD (Continued)

SPRING - FWD

REMOVAL - FWD

(1) Raise vehicle on frame-contact hoist as follows:

(a) 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 (Fig. 31).

(b) Position the remaining hoist arms at each

corner of the vehicle in the normal fashion. (Refer
to LUBRICATION & MAINTENANCE/HOISTING
- STANDARD PROCEDURE)

level.

(2) Position an under-hoist utility jack or transmis-

sion jack under rear axle toward the side needing
spring replacement. Jack pad should just contact
axle.

(3) Remove the shock absorber lower mounting

bolt (Fig. 32).

(4) Using 2 jack stands positioned under the outer

ends of the axle, raise the axle enough to remove the
weight of the axle from the rear springs.

(5) Loosen and remove the spring plate bolts from

the rear axle (Fig. 33).

(6) Remove the spring plate from the rear axle and

the leaf spring (Fig. 34).

(7) Using the jack stands slowly lower the rear

axle, permitting the rear springs to hang free.

(8) Loosen and remove the 4 bolts securing the

front mount of the leaf spring to the vehicle (Fig. 31).

(9) Loosen and remove the nuts from the spring

hanger (Fig. 35) for the rear leaf spring. Then
remove the hanger plate from the hanger and remove
the spring from the spring hanger (Fig. 35).

(10) Remove the leaf spring from the vehicle.
(11) Loosen and remove the pivot bolt from the

front mount of the rear leaf spring. Remove mount.

Fig. 31 LIFTING POINT AND SPRING MOUNT

1 - BODY SILL AREA
2 - MOUNTING BOLTS
3 - SPRING MOUNTING BRACKET
4 - LEAF SPRING
5 - HOIST LIFT ARM
6 - WOODEN BLOCK

Fig. 32 Rear Shock Mounting Bolt

1 - SHOCK BOLT

Fig. 33 Spring Plate Bolts

1 - SPRING PLATE

2 - 40

REAR SUSPENSION

INSTALLATION - FWD

(1) Assemble front spring mount to front of spring

eye and install pivot bolt and nut. Do not tighten
at this time.

CAUTION: Pivot bolt must face inboard to prevent
structural damage during installation of spring.

(2) Raise front of spring and install four mounting

bolts (Fig. 31). Tighten bolts to 61 N·m (45 ft. lbs.)
torque.

(3) Install rear of spring onto rear spring shackle.

Install shackle plate. Do not tighten.

(4) Verify lower leaf spring isolator is in position.

(5) Raise axle into correct position on leaf spring

with axle centered under spring locator post (Fig.
36).

(6) Verify that the leaf spring isolator is correctly

positioned in the spring plate.

(7) Install spring plate in position on the spring

(Fig. 33).

(8) Install spring plate bolts (Fig. 33). Tighten

bolts to 95 N·m (70 ft. lbs.) torque.

(9) Install lower shock absorber bolt. Do not

tighten at this time.

(10) Remove jack under axle.
(11) Lower the vehicle and remove hoist arms and

block of wood from under vehicle.

(12) Tighten the spring front pivot bolt to 156 N·m

(115 ft. lbs.) torque.

(13) Tighten rear spring shackle pin nuts to 61

N·m (45 ft. lbs.) torque.

(14) Tighten rear spring shackle inner to outer

half retaining bolts to 61 N·m (45 ft. lbs.) torque.

(15) Tighten the lower shock absorber mounting

bolt to 102 N·m (75 ft. lbs.) torque.

Fig. 34 Spring Plate

1 - SPRING PLATE

Fig. 35 Rear Spring Hanger

1 - SHACKLE PLATE
2 - SPRING HANGER

Fig. 36 Leaf Spring Locator Post

1 - LEAF SPRING ISOLATOR
2 - LEAF SPRING
3 - LOCATOR POST

REAR SUSPENSION

2 - 41

SPRING - FWD (Continued)

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