'Pop' goes the Chrysler minivan
SUBJECT VEHICLE: 2003 Chrysler Town & Country, Dodge Caravan, Chrysler Voyager.
COMPLAINT: A squeak, creak, pop and/or clicking sound coming from the rear of the vehicle when driving over bumps or while turning.
CAUSE/SOLUTION: Original rear spring hanger brackets generate noise under stress. To correct the condition, replace both brackets.
Chrysler or Dodge minivan drivers may complain of a squeak, creak, pop and/or clicking sound coming from the rear of the vehicle when driving over bumps or while turning. This repair involves replacing both rear spring hanger brackets. To correct the condition, follow these steps. NOTE: This repair applies to all-wheel drive (AWD) and front-wheel drive (FWD) minivans built between Sept. 16, 2002 (MDH 0916XX), and Sept. 28, 2002 (MDH 0928XX).
Two Mopar P/N 05006089AA brackets will be required.
NOTE: This entire procedure should be completed on one side of the vehicle before it is started on the other side of the vehicle. This will prevent resetting rear thrust angle and/or front toe for steering wheel centering.
1. Raise the vehicle on a suitable hoist in accordance with factory and/or industry standard approved practices.
2. Remove the nuts from the upper and lower shackle pins (Figure 1).
3. Remove both shackle stiffener bolts (Figure 1) item 5 (AWD only).
4. Place a jackstand under the side of the axle having the hanger bracket replaced. Using the jackstand, support the weight of the axle and leaf spring.
5. Remove the lower mounting bolt from the shock absorber on the side of the axle having the hanger bracket replaced.
6. Remove the four bolts attaching the hanger bracket to the body.
CAUTION: Do not stretch the rubber brake hose.
[PAGEBREAK]7. Lower the jackstand and the rear of the leaf spring.
8. Remove the shackle plate and hanger bracket as follows:
a. Remove the inboard shackle plate.
b. Slide the outboard shackle plate outward toward the facia as far as possible.
c. Remove the hanger bracket by sliding the bracket toward the center of the vehicle.
9. Loosely assemble the shackle plates to the new hanger bracket and leaf spring. The shackle pin nuts should be on the inboard side of the spring.
NOTE: Do not tighten shackle nuts at this time.
10. Raise the axle and rear of the leaf spring and support with the jackstand.
11. Install the four bolts attaching the hanger bracket to the body and tighten to 61 Nm (45 ft.-lb.).
12. Loosely install the lower shock mounting bolt.
NOTE: Do not tighten the bolt at this time.
13. Repeat steps 2 through 12 on the other side of the vehicle.
14. Remove the jackstand and lower the vehicle so the full vehicle weight is on the rear wheels.
15. Tighten the lower shock mounting bolt to 102 Nm (75 ft.-lb.).
16. Tighten the upper and lower shackle pin nuts to 61 Nm (45 ft.-lb.).
17. Tighten both shackle stiffener bolts (AWD only) to 61 Nm (45 ft.-lb.).
NOTE: The AWD shackle stiffener bolts must be torqued after the shackle pin nuts to avoid bending the shackle plates.
18. Repeat steps 15 through 17 on the other side of the vehicle. ■
Eric Seifert is a technical editor for ALLDATA LLC. Seifert is an ASE-certified Master Technician and Engine Machinist. He is a graduate of the De Anza College Automotive Technology Program, with 20 years of independent shop and parts store experience.
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