Suspension - Rear Suspension Creak/Pop/Click Noises
NUMBER: 02-005-02GROUP: Suspension
DATE: November 11, 2002
SUBJECT:
Squeak, Creak, Pop, and/or Clicking Sound From Rear of Vehicle.
OVERVIEW:
This bulletin involves replacing both rear spring rear hanger brackets.
MODELS:
2003 (RS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO ALL WHEEL DRIVE (AWD) AND FRONT WHEEL DRIVE (FWD) VEHICLES BUILT BETWEEN SEPTEMBER 16, 2002 (MDH 0916XX) AND SEPTEMBER 28, 2002 (MDH 0928XX).
SYMPTOM/CONDITION:
Customer 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.
DIAGNOSIS:
If the customer describes the Symptom/Condition, perform the Repair Procedure.
PARTS REQUIRED
REPAIR PROCEDURE:
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.
2. Remove the nuts from the upper and lower shackle pins (Fig. 1) or (Fig. 2).
3. Remove both shackle stiffener bolts (Fig. 2) 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 having the hanger bracket replaced.
6. Remove the four bolts attaching the hanger bracket to the body (Fig. 3).
CAUTION:
DO NOT TO STRETCH THE RUBBER BRAKE HOSE.
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 new the 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.
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 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.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE
FAILURE CODE