1984 Dodge Caravan

SUSPENSION - FRONT 1983-88 Front Suspension CHRYSLER MOTORS FWD

SUSPENSION - FRONT

1983-88 Front Suspension CHRYSLER MOTORS FWD

DESCRIPTION
The front suspension is an independent MacPherson strut type. The struts attach to upper fender reinforcements
and steering knuckle. Lower control arms attach inboard to crossmember and outboard to steering knuckle
through a ball joint.

Working through a pivot bearing in upper retainer, the upper strut and steering knuckle turn as an assembly
during steering maneuvers.

ADJUSTMENT & CHECKING

WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES

See WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in the WHEEL ALIGNMENT
Section.

WHEEL BEARING ADJUSTMENT

Front wheel bearings are permanently sealed requiring no lubrication or adjustment. Replace hub nuts, washers
and pins when removed. They are not reusable. With brakes applied, tighten new hub nuts to 180 ft. lbs. (244
N.m). Always install new bearings any time hub is removed.

BALL JOINT CHECKING

NOTE: The lower ball joint operates with no free play.

Lower Ball Joint

With weight of vehicle resting on wheels in normal driving position, grasp grease fitting and attempt to move it.
If fitting moves easily, ball joint is worn and should be replaced.

REMOVAL & INSTALLATION

LOWER BALL JOINT

NOTE: On some models, ball joints that are welded to the control arm must be serviced
by replacement of the complete control arm assembly.

Removal

1. Raise and support vehicle. Remove wheel and tire. Remove lower control arm. See LOWER
CONTROL ARM in this article. Pry off ball joint dust seal. Mount control arm assembly in hydraulic

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 1984 Dodge Caravan
SUSPENSION - FRONT 1983-88 Front Suspension CHRYSLER MOTORS FWD

press.
2. Position Receiving Cup (C-4699-2 ) to support lower control arm while removing ball joint. Install 1
1/16" deep socket over stud and against joint upper housing. Press to remove ball joint assembly from
arm.

Installation

1. Position ball joint housing in control arm cavity. Position assembly in press with Installer (C-4699-1 )
supporting control arm. Align and press assembly until ball joint housing ledge stops against control arm
cavity down flange.
2. Support ball joint housing with Receiving Cup (C-4699-2 ). Position new seal over stud, against housing.
Using a 1 1/2" socket, press seal onto joint housing with seat against control arm.

STRUT DAMPER

NOTE: When installing original strut and knuckle, mark cam adjusting bolt for proper
reassembly reference.

Removal

1. Raise and support vehicle. Remove wheel and tire. Remove cam adjusting bolt and knuckle bolt from
strut assembly. Remove brake hose-to-damper bracket retaining screw and position hose out of work area.
2. Remove strut damper-to-fender shield mounting nut washer assemblies. Remove strut assembly from
vehicle.

Disassembly

1. Compress the coil spring with Spring Compressor (C-4838 ). Place at least 5 spring coils between
compressor jaws. See Fig. 1.
2. Hold strut rod while loosening strut rod nut. Remove nut.Remove strut mount. Remove coil spring and
mark for reinstallation on same side of vehicle.

NOTE: Coil springs are rated separately for each side of vehicle depending on optional
equipment and type of service. If removed, ensure springs are marked for
installation in original positions.

Inspection

Inspect and replace all components showing signs of leakage, damage or excessive wear. If leakage is found,
replace strut damper as an assembly.

Reassembly

1. Install dust shield, jounce bumper, spacer and spring seat to top of spring. Install mount to strut rod,
ensuring lower washer is in position.
2. Position upper spring retainer alignment tab parallel to damper lower attaching bracket. See Fig. 1. Install

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 1984 Dodge Caravan
SUSPENSION - FRONT 1983-88 Front Suspension CHRYSLER MOTORS FWD

rebound retainer and rod nut.

3. Using Strut Rod Nut Holder (L-4558 ), tighten rod nut to 60 ft. lbs. (81 N.m) before releasing spring
compressor. Remove spring compressor.

Fig. 1: Spring Seat & Retainer Position

Installation

1. Install unit in fender reinforcement. Install retaining nuts and washers. Tighten nuts to 20 ft. lbs. (27
N.m). Position knuckle neck into strut. Position washer plate and install cam and knuckle bolts.
2. Attach brake hose retainer to damper. Tighten retainer bolt. Index cam bolt to original mark. Place a
4" (102 mm) "C" clamp on the strut and knuckle.
3. Tighten the clamp just enough to eliminate any looseness between the knuckle and the strut. Check
alignment of the index marks. Tighten the bolts to 75 ft. lbs. (102 N.m), plus 1/4 turn. Remove "C"
clamp.
4. Install wheel and tire. Adjust camber and toe settings as required.

LOWER CONTROL ARM

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 1984 Dodge Caravan
SUSPENSION - FRONT 1983-88 Front Suspension CHRYSLER MOTORS FWD

Removal

1. Raise and support vehicle. Remove front inner pivot through bolt. Remove rear stub strut nut, retainer and
bushings. Remove ball joint-to-steering knuckle clamp bolt. Separate ball joint from steering knuckle.

NOTE: Use care not to pull steering knuckle out from vehicle after release from
ball joint or the inner constant velocity joint will separate.

2. Remove sway bar-to-control arm end bushing retainer nuts and rotate control arm over sway bar. Remove
rear stub strut bushing, sleeve and retainer. Check lower control arm for distortion and bushings for
deterioration. Replace components as necessary.

Pivot Bushing Replacement

1. To replace pivot bushings, position Support (C-4700 ) between flanges of lower control arm and around
bushing to prevent control arm distortion. Install 1/2" x 2 1/2" bolt into bushing.
2. With Receiving Cup (C-4669-2 ) on press base, position control arm inner flange against cup wall to
support flange while pressing out bushing. Remove bushing by pressing against bolt head.
3. Place bushing inner sleeve and insulator into cavity of Receiving Cup (C-4699-2 ). Position assembly on
press base and align control arm to receive bushing.
4. Position Installer (C-4699-1 ) to support control arm outer flange while receiving bushing. Press bushing
into control arm until bushing flange seats against control arm.

Installation

To install, reverse removal procedure. Ensure control arm mount bolts are tightened with suspension supporting
vehicle. Refer to TORQUE SPECIFICATIONS table at end of article.

STEERING KNUCKLE

Removal

1. Remove cotter pin, nut lock and spring washer. Loosen hub nut with vehicle on ground and brakes
applied. Raise vehicle and remove wheel. Remove hub nut, making sure splined drive shaft is free to
separate from spline in hub. If necessary, driveshaft may be tapped lightly with soft brass punch. See Fig.
2.

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 1984 Dodge Caravan
SUSPENSION - FRONT 1983-88 Front Suspension CHRYSLER MOTORS FWD

Fig. 2: Typical Exploded View of Suspension & Strut Damper Assembly

2. Remove cotter pin and castellated nut from tie rod. Using Puller (C-3894-A ), disconnect tie rod from
steering knuckle. Remove brake hose retaining clamp from strut damper. Remove ball joint clamp stud
bolt. Remove caliper adapter bolts with washers. Remove caliper and support with wire. DO NOT hang
by brake flex hose. Remove rotor.

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 1984 Dodge Caravan
SUSPENSION - FRONT 1983-88 Front Suspension CHRYSLER MOTORS FWD

3. Mark camber position on upper cam adjusting bolt, then remove both bolts. Remove knuckle from strut
damper and off of ball joint stud. Be sure drive shaft is supported during removal of knuckle to prevent
damage to constant velocity joints.

Installation

To install, reverse removal procedure.

SWAY BAR

Removal

Raise and support vehicle. Remove nuts, bolts and retainers from lower control arms. Remove bolts at
crossmember clamps. Remove clamps and sway bar from vehicle. Inspect components for cracks, damage or
rubber deterioration.

Bushing Replacement

Inner bushing can be removed by opening split and removing bushing. Outer bushing must be cut or hammered
off. If replaced, outer bushing should be forced on until 1/2" of sway bar protrudes.

NOTE: The control arm retainers are symmetrical and bend slightly upon installation.

Installation

1. Position crossmember bushings on bar with curved surface up and split to front. Set lower clamps on
crossmember bushings, lift bar into crossmember and install lower bolts and clamps.
2. Position retainers at control arms, insert bolts and install nuts. With lower control arms raised to design
height, tighten bolts.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Ball Joint Clamp Bolt 70 (95)
Brake Caliper Adapter Bolt 160 (217)
Brake Hose-to-Strut Retainer Screw 10 (14)
Lower Control Arm Pivot Bolt 105 (142)
Strut Rod Nut 60 (81)
Strut-to-Steering Knuckle
Cam & Knuckle Bolts (1) 75 (102)

Stub Strut Nut 70 (95)

Sway Bar Bushing
Control Arm Retainer Bolt 25 (34)
Crossmember Retainer Bolt 25 (34)

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 1984 Dodge Caravan
SUSPENSION - FRONT 1983-88 Front Suspension CHRYSLER MOTORS FWD

Tie Rod End Nut 35 (47)

Wheel Hub Mount Nut 180 (244)
Wheel Nuts 95 (129)
(1) Tighten 1/4 turn beyond specified torque.

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