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Dan
Dan, Technician
Category: Chrysler
Satisfied Customers: 21399
Experience:  Independent Shop Experience, 2 Year Automotive Diploma, & Access to Information Database
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I want to replace the struts on a 2004 Chrysler Pacifica.

Resolved Question:

I want to replace the struts on a 2004 Chrysler Pacifica. How would you go about removing the strut nut that is located beneath the surface of the strut mount?   Is there a special tool used?
Submitted: 5 years ago.
Category: Chrysler
Expert:  Dan replied 5 years ago.

Here are instructions to replace. Make sure you pring off instructions or save to your computer asap because picture expire and will not be available. Let me know if you have questions. Thanks

 

Service and Repair
Notes

STRUT ASSEMBLY

REMOVAL

WARNING: DO NOT REMOVE NUT FROM STRUT ROD WHILE STRUT ASSEMBLY IS INSTALLED IN VEHICLE OR BEFORE STRUT ASSEMBLY SPRING IS COMPRESSED.

  1. Raise and support vehicle.
  2. Remove wheel and tire assembly.
  3. If both strut assemblies are to be removed, mark strut assemblies right or left according to which side of vehicle they were removed from.

  1. Remove screw fastening wheel speed sensor routing bracket to strut assembly (Fig. 24).



CAUTION: When removing nut from stud of stabilizer bar link, do not allow stud to rotate in it's socket. Hold stud from rotating by placing an open end wrench on flat machined into stud (Fig. 25).

  1. Remove stabilizer bar link from bracket on strut assembly (Fig. 25). To do so, place an open-end wrench on flat machined into link's mounting stud, then remove nut while holding wrench in place. Push stud out of bracket. CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during removal. Remove nuts while holding bolts stationary in steering knuckles.


  1. Remove two bolts and nuts attaching strut clevis to steering knuckle (Fig. 26) (Fig. 27).
  2. If servicing left strut assembly, remove nuts fastening coolant recovery bottle in place and reposition bottle with hoses attached out of way.

  1. Remove three nuts attaching strut assembly upper mount to strut tower (Fig. 28), then remove strut assembly from vehicle.
  2. To disassemble strut assembly, Refer to STRUT - DISASSEMBLY.

DISASSEMBLY
The strut assembly must be removed from vehicle for it to be disassembled and assembled.
For disassembly and assembly of strut assembly, use of Strut Spring Compressor, Pentastar Service Equipment (PSE) tool W-7200, or equivalent, is recommended to compress coil spring. Follow manufacturer's instructions closely.

WARNING: DO NOT REMOVE STRUT SHAFT NUT BEFORE COIL SPRING IS COMPRESSED. COIL SPRING IS HELD UNDER PRESSURE AND MUST BE COMPRESSED, REMOVING SPRING TENSION FROM UPPER MOUNT AND PIVOT BEARING, BEFORE SHAFT NUT IS REMOVED.

  1. Position strut assembly in strut coil spring compressor following manufacturers instructions (Fig. 29). Position lower hooks on coil spring first, then uppers.
  2. Compress coil spring until all coil spring tension is removed from upper mount.

  1. Install Strut Nut Wrench, Special Tool 6864, on strut shaft retaining nut (Fig. 30). Next, install a 10 mm socket onto hex located on end of strut shaft. While holding strut shaft from turning, remove nut from strut shaft.

  1. Remove upper mount from strut shaft (Fig. 22).

  1. If pivot bearing needs to be serviced, remove it from top of upper seat by pulling it up off seat (Fig. 31).
  2. If upper spring seat or isolator need to be serviced, remove them from top of coil spring pulling both up off spring, then removing isolator from seat.
  3. Remove clamp from bottom of coil spring and remove strut out through bottom of coil spring. NOTE: If coil spring needs to be serviced, proceed with next step, otherwise, proceed with step 10.
  4. If not previously removed, lift pivot bearing, upper spring seat or isolator off coil spring (Fig. 22). NOTE: Prior to removing spring from compressor, note location of lower spring coil end in relationship to compressor to ease assembly of components later.
  5. Release tension from coil spring by backing off compressor drive fully. Push back compressor upper hooks and remove coil spring from spring compressor.
  6. Remove dust shield and jounce bumper as an assembly from strut shaft by pulling both straight up and off strut shaft (Fig. 22). Dust shield cannot be separated from jounce bumper until after it is removed from strut shaft.
  7. Remove jounce bumper from dust shield. Jounce bumper is removed from dust shield by collapsing dust shield until jounce bumper can be pulled free from dust boot.
  8. Remove spring isolator from lower spring seat on strut (Fig. 22).
  9. Inspect strut assembly components for following and replace as necessary:
    • Inspect strut for any condition of shaft binding over full stroke of shaft.
    • Check upper mount for cracks and distortion and its retaining studs for any sign of damage.
    • Check upper seat for stress cracks and wear.
    • Check upper spring isolator for severe deterioration.
    • Check for binding of strut assembly pivot bearing.
    • Inspect dust shield for rips and deterioration.
    • Inspect jounce bumper for cracks and signs of deterioration.

ASSEMBLY

CAUTION: Use care not to damage coil spring coating during spring assembly. Damage to coating will jeopardize its corrosion protection.

NOTE: Left and right springs must not be interchanged.

NOTE: If coil spring has been removed from spring compressor, proceed with next step, otherwise, proceed with step 4.

  1. Place coil spring (part number tag end downward) in compressor lower hooks following manufacturers instructions. To ease strut reassembly, rotate coil spring around until lower coil end is in same location as it was upon disassembly. Proper orientation of spring to strut (once installed) is necessary.
  2. Position compressor upper hooks over coil spring following manufacturers instructions.
  3. Compress coil spring far enough to allow strut installation.

  1. If separated, install isolator onto upper seat (Fig. 22). Be sure to match master notches built into each up to one another (Fig. 32).
  2. Install upper isolator and upper seat on top of coil spring if previously removed (Fig. 22).
  3. If pivot bearing has been removed from upper seat, install pivot bearing on top of upper spring seat (Fig. 31). Bearing must be installed on upper seat with smaller diameter side of pivot bearing toward spring seat. Be sure pivot bearing is sitting flat on spring seat once mounted.
  4. Install spring lower isolator on lower spring seat of strut matching isolator alignment pin with hole in strut (Fig. 22).
  5. Install jounce bumper on strut shaft with small end pointing downward (Fig. 22).
  6. Install dust shield on strut shaft. Collapse and stretch dust shield down over top of jounce bumper until dust shield snaps into slot on jounce bumper. jounce bumper will be at top of inner dust boot. Return dust shield to its fully extended length.
  7. Install strut through bottom of coil spring until lower spring seat contacts lower end of coil spring. Match step built into strut lower seat and isolator to lower coil end, then install clamp to hold strut and coil spring together.
  8. Install strut mount over strut shaft and onto top of pivot bearing and upper seat (Fig. 22). Loosely install retaining nut on strut shaft.
  9. Install Strut Nut Wrench (on end of a torque wrench), Special Tool 6864, on strut shaft retaining nut (Fig. 30). Next, install a 10 mm socket onto hex on end of strut shaft. While holding strut shaft from turning, tighten strut shaft retaining nut to a torque of 115 Nm (85 ft. lbs.) . NOTE: Before releasing tension compressor has on spring, using following figure as reference (Fig. 32), rotate upper spring seat and upper isolator (notches in each) to line up with hole in strut and clevis bracket (within 5°of one another).
  10. Slowly release tension from coil spring by backing off compressor drive fully. As tension is relieved, make sure upper mount, pivot bearing and upper seat are align properly.
  11. Remove clamp from lower end of coil spring and strut. Push back spring compressor upper and lower hooks, then remove strut assembly from spring compressor.
  12. Install strut assembly on vehicle.

INSTALLATION

CAUTION: When installing a strut assembly, make sure strut being installed has correct coil spring for that side of vehicle. Do not interchange two sides.

  1. Install strut assembly into strut tower, aligning and installing three studs on upper strut mount into holes in tower. Install three mounting nut/washer assemblies (Fig. 28). Tighten nuts to 28 Nm (250 inch lbs.) torque.
  2. If servicing left strut assembly, place coolant recovery bottle in its normal mounted position and install nuts fastening it in place. CAUTION: Steering knuckle to strut assembly attaching bolts are serrated and must not be turned during installation. Install nuts while holding bolts stationary in steering knuckle.



CAUTION: If strut being serviced is equipped with a slotted lower clevis bracket mounting hole and eccentric cam strut attaching bolt, eccentric cam bolt must be installed in lower (slotted) hole in strut clevis bracket (Fig. 33).

NOTE: Strut clevis-to-steering knuckle bolts are installed differently on each side. Left hand side bolts are to be installed from vehicle rear to front (Fig. 26). Right side bolts are to be installed from vehicle front to rear (Fig. 27).

  1. Align steering knuckle in clevis bracket of strut. Install strut clevis-to-steering knuckle attaching bolts (Fig. 26) (Fig. 27). Install nuts on ends of bolts and tighten to 81 Nm (60 ft. lbs.) torque. Then, tighten nuts an additional 1/4 (90°) turn after that torque is met.
  2. Install stabilizer bar link mounting stud through rearmost hole in bracket on strut assembly. CAUTION: When installing nut on mounting stud of stabilizer bar link, do not allow stud to rotate in it's socket. Hold stud from rotating by placing an open end wrench on flat machined into stud (Fig. 25).
  3. Hand thread nut on end of stabilizer bar link stud. Hold stud from turning by placing an open-end wrench on flat machined into link's mounting stud, then tighten nut while holding wrench in place (Fig. 25). Tighten nut to 88 Nm (65 ft. lbs.) torque.
  4. Attach wheel speed sensor routing bracket to strut assembly (Fig. 24). Tighten screw to 13 Nm (115 inch lbs.) torque.
  5. Install tire and wheel assembly. Tighten wheel mounting nuts to a torque of 135 Nm (100 ft. lbs.) .
  6. Lower vehicle.
  7. Perform wheel alignment as necessary.
Dan, Technician
Category: Chrysler
Satisfied Customers: 21399
Experience: Independent Shop Experience, 2 Year Automotive Diploma, & Access to Information Database
Dan and 7 other Chrysler Specialists are ready to help you
Expert:  Dan replied 5 years ago.

Here are instructions to replace. Make sure you print off instructions or save to your computer asap because picture expire and will not be available. Let me know if you have questions. Thanks

 

Service and Repair
Notes

STRUT ASSEMBLY

REMOVAL

WARNING: DO NOT REMOVE NUT FROM STRUT ROD WHILE STRUT ASSEMBLY IS INSTALLED IN VEHICLE OR BEFORE STRUT ASSEMBLY SPRING IS COMPRESSED.

  1. Raise and support vehicle.
  2. Remove wheel and tire assembly.
  3. If both strut assemblies are to be removed, mark strut assemblies right or left according to which side of vehicle they were removed from.

  1. Remove screw fastening wheel speed sensor routing bracket to strut assembly (Fig. 24).



CAUTION: When removing nut from stud of stabilizer bar link, do not allow stud to rotate in it's socket. Hold stud from rotating by placing an open end wrench on flat machined into stud (Fig. 25).

  1. Remove stabilizer bar link from bracket on strut assembly (Fig. 25). To do so, place an open-end wrench on flat machined into link's mounting stud, then remove nut while holding wrench in place. Push stud out of bracket. CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during removal. Remove nuts while holding bolts stationary in steering knuckles.


  1. Remove two bolts and nuts attaching strut clevis to steering knuckle (Fig. 26) (Fig. 27).
  2. If servicing left strut assembly, remove nuts fastening coolant recovery bottle in place and reposition bottle with hoses attached out of way.

  1. Remove three nuts attaching strut assembly upper mount to strut tower (Fig. 28), then remove strut assembly from vehicle.
  2. To disassemble strut assembly, Refer to STRUT - DISASSEMBLY.

DISASSEMBLY
The strut assembly must be removed from vehicle for it to be disassembled and assembled.
For disassembly and assembly of strut assembly, use of Strut Spring Compressor, Pentastar Service Equipment (PSE) tool W-7200, or equivalent, is recommended to compress coil spring. Follow manufacturer's instructions closely.

WARNING: DO NOT REMOVE STRUT SHAFT NUT BEFORE COIL SPRING IS COMPRESSED. COIL SPRING IS HELD UNDER PRESSURE AND MUST BE COMPRESSED, REMOVING SPRING TENSION FROM UPPER MOUNT AND PIVOT BEARING, BEFORE SHAFT NUT IS REMOVED.

  1. Position strut assembly in strut coil spring compressor following manufacturers instructions (Fig. 29). Position lower hooks on coil spring first, then uppers.
  2. Compress coil spring until all coil spring tension is removed from upper mount.

  1. Install Strut Nut Wrench, Special Tool 6864, on strut shaft retaining nut (Fig. 30). Next, install a 10 mm socket onto hex located on end of strut shaft. While holding strut shaft from turning, remove nut from strut shaft.

  1. Remove upper mount from strut shaft (Fig. 22).

  1. If pivot bearing needs to be serviced, remove it from top of upper seat by pulling it up off seat (Fig. 31).
  2. If upper spring seat or isolator need to be serviced, remove them from top of coil spring pulling both up off spring, then removing isolator from seat.
  3. Remove clamp from bottom of coil spring and remove strut out through bottom of coil spring. NOTE: If coil spring needs to be serviced, proceed with next step, otherwise, proceed with step 10.
  4. If not previously removed, lift pivot bearing, upper spring seat or isolator off coil spring (Fig. 22). NOTE: Prior to removing spring from compressor, note location of lower spring coil end in relationship to compressor to ease assembly of components later.
  5. Release tension from coil spring by backing off compressor drive fully. Push back compressor upper hooks and remove coil spring from spring compressor.
  6. Remove dust shield and jounce bumper as an assembly from strut shaft by pulling both straight up and off strut shaft (Fig. 22). Dust shield cannot be separated from jounce bumper until after it is removed from strut shaft.
  7. Remove jounce bumper from dust shield. Jounce bumper is removed from dust shield by collapsing dust shield until jounce bumper can be pulled free from dust boot.
  8. Remove spring isolator from lower spring seat on strut (Fig. 22).
  9. Inspect strut assembly components for following and replace as necessary:
    • Inspect strut for any condition of shaft binding over full stroke of shaft.
    • Check upper mount for cracks and distortion and its retaining studs for any sign of damage.
    • Check upper seat for stress cracks and wear.
    • Check upper spring isolator for severe deterioration.
    • Check for binding of strut assembly pivot bearing.
    • Inspect dust shield for rips and deterioration.
    • Inspect jounce bumper for cracks and signs of deterioration.

ASSEMBLY

CAUTION: Use care not to damage coil spring coating during spring assembly. Damage to coating will jeopardize its corrosion protection.

NOTE: Left and right springs must not be interchanged.

NOTE: If coil spring has been removed from spring compressor, proceed with next step, otherwise, proceed with step 4.

  1. Place coil spring (part number tag end downward) in compressor lower hooks following manufacturers instructions. To ease strut reassembly, rotate coil spring around until lower coil end is in same location as it was upon disassembly. Proper orientation of spring to strut (once installed) is necessary.
  2. Position compressor upper hooks over coil spring following manufacturers instructions.
  3. Compress coil spring far enough to allow strut installation.

  1. If separated, install isolator onto upper seat (Fig. 22). Be sure to match master notches built into each up to one another (Fig. 32).
  2. Install upper isolator and upper seat on top of coil spring if previously removed (Fig. 22).
  3. If pivot bearing has been removed from upper seat, install pivot bearing on top of upper spring seat (Fig. 31). Bearing must be installed on upper seat with smaller diameter side of pivot bearing toward spring seat. Be sure pivot bearing is sitting flat on spring seat once mounted.
  4. Install spring lower isolator on lower spring seat of strut matching isolator alignment pin with hole in strut (Fig. 22).
  5. Install jounce bumper on strut shaft with small end pointing downward (Fig. 22).
  6. Install dust shield on strut shaft. Collapse and stretch dust shield down over top of jounce bumper until dust shield snaps into slot on jounce bumper. jounce bumper will be at top of inner dust boot. Return dust shield to its fully extended length.
  7. Install strut through bottom of coil spring until lower spring seat contacts lower end of coil spring. Match step built into strut lower seat and isolator to lower coil end, then install clamp to hold strut and coil spring together.
  8. Install strut mount over strut shaft and onto top of pivot bearing and upper seat (Fig. 22). Loosely install retaining nut on strut shaft.
  9. Install Strut Nut Wrench (on end of a torque wrench), Special Tool 6864, on strut shaft retaining nut (Fig. 30). Next, install a 10 mm socket onto hex on end of strut shaft. While holding strut shaft from turning, tighten strut shaft retaining nut to a torque of 115 Nm (85 ft. lbs.) . NOTE: Before releasing tension compressor has on spring, using following figure as reference (Fig. 32), rotate upper spring seat and upper isolator (notches in each) to line up with hole in strut and clevis bracket (within 5°of one another).
  10. Slowly release tension from coil spring by backing off compressor drive fully. As tension is relieved, make sure upper mount, pivot bearing and upper seat are align properly.
  11. Remove clamp from lower end of coil spring and strut. Push back spring compressor upper and lower hooks, then remove strut assembly from spring compressor.
  12. Install strut assembly on vehicle.

INSTALLATION

CAUTION: When installing a strut assembly, make sure strut being installed has correct coil spring for that side of vehicle. Do not interchange two sides.

  1. Install strut assembly into strut tower, aligning and installing three studs on upper strut mount into holes in tower. Install three mounting nut/washer assemblies (Fig. 28). Tighten nuts to 28 Nm (250 inch lbs.) torque.
  2. If servicing left strut assembly, place coolant recovery bottle in its normal mounted position and install nuts fastening it in place. CAUTION: Steering knuckle to strut assembly attaching bolts are serrated and must not be turned during installation. Install nuts while holding bolts stationary in steering knuckle.



CAUTION: If strut being serviced is equipped with a slotted lower clevis bracket mounting hole and eccentric cam strut attaching bolt, eccentric cam bolt must be installed in lower (slotted) hole in strut clevis bracket (Fig. 33).

NOTE: Strut clevis-to-steering knuckle bolts are installed differently on each side. Left hand side bolts are to be installed from vehicle rear to front (Fig. 26). Right side bolts are to be installed from vehicle front to rear (Fig. 27).

  1. Align steering knuckle in clevis bracket of strut. Install strut clevis-to-steering knuckle attaching bolts (Fig. 26) (Fig. 27). Install nuts on ends of bolts and tighten to 81 Nm (60 ft. lbs.) torque. Then, tighten nuts an additional 1/4 (90°) turn after that torque is met.
  2. Install stabilizer bar link mounting stud through rearmost hole in bracket on strut assembly. CAUTION: When installing nut on mounting stud of stabilizer bar link, do not allow stud to rotate in it's socket. Hold stud from rotating by placing an open end wrench on flat machined into stud (Fig. 25).
  3. Hand thread nut on end of stabilizer bar link stud. Hold stud from turning by placing an open-end wrench on flat machined into link's mounting stud, then tighten nut while holding wrench in place (Fig. 25). Tighten nut to 88 Nm (65 ft. lbs.) torque.
  4. Attach wheel speed sensor routing bracket to strut assembly (Fig. 24). Tighten screw to 13 Nm (115 inch lbs.) torque.
  5. Install tire and wheel assembly. Tighten wheel mounting nuts to a torque of 135 Nm (100 ft. lbs.) .
  6. Lower vehicle.
  7. Perform wheel alignment as necessary.

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