Rear Shock Absorber - Rattles on Bumps

NO: 02-09-98

GROUP: Suspension

DATE: Aug. 28, 1998

SUBJECT:
Load Leveling Shock
Bushing Service

MODELS:
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1996 - 1998 (GS) Chrysler Voyager (International Market)

NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH LOAD LEVELING SHOCKS (SALES CODE SER).

SYMPTOM/CONDITION:

Rattle noise from rear of the vehicle when driving over road bumps.

DIAGNOSIS:

Check all rear shock bolts for proper torque, 101 Nm (75 ft. lbs.). Check upper shock bushing for wear, rubber debris around bushing or holes and voids in rubber. If the bushing has evidence of wear, perform the Repair Procedure.

PARTS REQUIRED:

2 05013474AA Bushing, Upper Load Leveling

REPAIR PROCEDURE:

This bulletin involves replacing the upper load leveling shock bushings

1. Using the procedure outlined in group 2 of the appropriate service manual, remove the rear shocks.





2. Secure ball joint press, special tool C-4212F, in a bench vise. Install the receiver, special tool 8526-1, into the cup of C-4212F, and tighten the set screw. Install the driver, special tool 8526-2, on the tip of the C-4212F screw drive, (Figure 1).





3. Place the shock absorber upper mounting eye in the receiver so the notch in the receiver clears the shock absorber body (Figure 2).

4. Tighten the screw drive until the driver contacts the outer circumference of the bushing evenly. Continue to tighten the screw drive until the bushing is pressed completely out of the shock absorber eye and into the receiver.

5. Back off the screw drive and remove the bushing from the receiver.





6. Install the driver, special tool 8526-2, on the tip of the ball joint press screw drive as shown in Figure 3. Position the driver this way to seat the bushing to its correct depth.





7. Place the shock absorber upper mounting eye in the receiver so the notch in the receiver clears the shock absorber body (Figure 4).

8. Position the bushing between the shock absorber eye and the driver. Tighten the screw drive until the driver, bushing, and shock absorber eye are touching and squarely aligned.

9. Press the bushing into the shock absorber eye until the driver bottoms against the face of the eye. Back off the ball Joint press screw drive and remove the shock absorber from the press.

10. Repeat steps 2 through 9 for the other shock.

11. Using the procedure outline in section 2 of the appropriate service manual, install the rear shocks.

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: 02-15-15-90 0.9 Hrs.

FAILURE CODE: P8 - New Part