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TSB 02-004-03

Muffled Rattle Sound From Front Suspension

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Date: October 3, 2003

Models:

2004             (CS) Pacifica
2003 - 2004 (RS) Town & Country/Caravan/Voyager

NOTE: This bulletin applies to vehicles built on or before August 15, 2003 (MDH 0815XX).

Overview:
This bulletin involves installing new front sway bar link assemblies.

Symptom/Condition:
The vehicle may exhibit a muffled rattle sound which may be heard during low speed driving on road surfaces with minor fluctuations (such as a parking lot) and may also occur during turning maneuvers.

Diagnosis:
If the vehicle exhibits the Symptom/Condition, perform the Repair Procedure.

Parts Required: Not available

Special Tools/Equipment Required: Not available

Repair Procedure:  1. Raise the vehicle on a suitable hoist. Refer to the service information available in TechCONNECT or the appropriate service manual, Section 0, Lubrication & Maintenance, Hoisting.

2. Remove both front wheel and tire assemblies.

3. Remove the upper and lower sway bar link nuts and remove the sway bar link.

CAUTION: When installing the nuts to the studs of the sway bar links, do not allow the stud to rotate in its socket. Hold the stud from rotating by placing an open-end wrench on flat machined surface on the stud.

4. Install the new sway bar link. Install the sway bar link nuts and torque to 88 Nm (65 ft. lbs.).

5. Perform steps 3 and 4 on the other side of the vehicle

6. Install both front wheel and tire assemblies. Refer to the service information available in TechCONNECT or the appropriate service manual, Section 22, Tires/Wheels, Installation.

7. Lower the vehicle.

Policy:    Reimbursable within the provisions of the warranty.

Time Allowance: Not available

Failure Code: Not available

This page was edited on: May 3, 2004