How to Replace the Springs in a Plymouth Voyager

The Plymouth Voyager is one of the minivans that helped change the fortunes of the Chrysler Corporation. The Voyager is one of the most popular minivan models ever sold and is known for its fine handling, due to the coil springs in MacPherson struts in front and leaf spring in the rear.

Instructions

Removing the Front Coil Spring

1

Raise the Voyager, block the wheels securely and remove the strut assembly as a single unit.

2

Mount the strut assembly in a large vise, but clamp it only at the strut clevis bracket.

3

Attach the spring compressor and compress the coil spring, Make sure the upper spring seat and second coil from the bottom are clamped into the compressor. This step can be dangerous if the spring slips from the compressor.

4

Remove the strut shaft nut by gripping the strut shaft with a wrench.

5

Take the upper strut mount away from the strut assembly and slowly remove the compressor tool from the spring, followed by the spring seat and pivot bearing assembly.

6

Remove the spring from the strut assembly and replace it with a new spring.

Reinstalling the Front Coil Spring

7

Clamp the strut assembly into the vise and replace the spring. Align the bottom of the spring with the clevis bracket

8

Place the upper spring seat onto the coil spring and align the spring seat notch (on top) with the strut clevis bracket.

9

Reinstall the compressor and compress the spring. Make sure the compressor is attached properly before compressing the spring.

10

Reinstall the pivot bearing onto the upper spring seat smaller side of the bearing facing the spring seat.

11

Attach the strut mount onto the upper spring seat before hand tightening the strut shaft nut.

12

Tighten the strut shaft nut and be sure the spring is seated correctly before proceeding to remove the compressor tool.

13

Lower the vehicle and perform a safety check before taking the Voyager out on the road.

Replacing the Rear Leaf Springs

14

Raise and securely support the Voyager on jack stands and raise the rear axle in order to relieve the pressure on the leaf springs.

15

Unfasten the lower ends of the shock absorbers before removing the axle plate bolts from the leaf springs.

16

Lower the rear axle to free the rear springs. Support the spring while removing the mounting bolts from the spring hanger at the front and take off the rear spring shackle nuts and plate.

17

Slip the leaf spring from its shackle and remove the leaf spring assembly along with the front leaf spring mount pivot bolt.

18

Reattach the leaf spring, mounting plate and reinstall the leaf spring to the shackle plate. Position the lower leaf spring isolator.

19

Lift the axle assembly in order to align the leaf spring post. Reinstall the rear axle plate bolts and torque to manufacturer's specifications. Reattach the rear shock absorbers to the lower brackets.

20

Lower the vehicle and tighten the front pivot bolt, shackle nuts and shock absorber bolts to the manufacturer's specified levels.