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Home >> Chrysler >> 2007 >> PT Cruiser Base, 2D Convertible, Automatic >> Repair and Diagnosis >> Suspension >> Wheel Alignment >> Suspension System >> Rear Suspension >> Axle-Rear >> Installation >> Axle - Rear Disc Brake Vehicles

Axle - Rear Disc Brake Vehicles

Fig 1: Rear Axle Trailing Arm & Mounting Brackets
GC0043360Courtesy of CHRYSLER LLC
  1. If removed, install the trailing arm forward brackets (2) on each side of the axle in the following way:
    • From above the axle (4), place the bracket (2) down over the axle trailing arm bushing aligning the hole in the bracket with the center hole in the bushing.
    • From the outboard side of the axle and bracket, push the thru-bolt (1) through the bracket and bushing. The trailing arm bracket thru-bolts must be installed from the outside, in toward the center of the axle assembly, otherwise the bolt threaded ends will come in contact with the body of the vehicle upon axle installation on vehicle. 
    • Install the nut (3) on the inboard end of the bolt. Tighten the nut until the bracket has resistance when turned, but still moves independent of the axle bushing. Do not tighten at this time; it must be fully tightened with the vehicle at curb height. 
  2. Center the axle beam on a transmission jack standing at axle removal height.
    Fig 2: Trailing Arm Mounting To Body
    GC0043365Courtesy of CHRYSLER LLC
  3. Swing the axle trailing arms up aligning the brackets (3) with the scribed marks made upon removal.
  4. Install all eight (four per side) axle bracket-to-body mounting bolts (4). Thread the bolts in, but do not fully tighten at this time. 
  5. Tap the brackets (3) as necessary to align the brackets with the scribed marks, then tighten all the bolts to 54 N.m (40 ft. lbs.).
    Fig 3: Isolator Properly Installed
    GC0021778Courtesy of CHRYSLER LLC
    1 - ISOLATOR ABUTMENT
    2 - FINGERS
  6. Install a rubber isolator on each end of the coil springs wrapping the rubber fingers around the coil (2). Turn each isolator until the rubber abutment (1) butts up against the flat end of the spring coil.
    Fig 4: Rear Coil Springs
    GC0043364Courtesy of CHRYSLER LLC
    NOTE: Both ends of the coil spring are identical. Either end of the spring can be the top or bottom.
  7. Place the coil springs (2) on top of the axle spring perches (5).
    Fig 5: Coil Spring Orientation
    GC0021779Courtesy of CHRYSLER LLC
    1 - IMAGINARY LINE
    NOTE: The coil springs require proper orientation to the body when installed.
  8. Rotate the coil springs (along with the rubber isolators) until the flat end of each upper spring coil lines up with an imaginary line (1) running parallel with the axle beam as shown. Also, make sure that each upper coil ends near the outboard sides of the vehicle (as shown) and not 180 degrees of that location.
    Fig 6: Rear Coil Springs
    GC0043364Courtesy of CHRYSLER LLC
  9. Raise the transmission jack guiding the coil springs (2) into the spring mounting brackets (4) on the body of the vehicle. Raise the jack until the shock absorber lower mounting bolts can be installed though the axle brackets and shock absorber lower mounting eyes.
    Fig 7: Rear Shock & Trailing Arm Mounting
    GC0043363Courtesy of CHRYSLER LLC
  10. Continue to raise the jack until the shock absorber (2) lower mounting bolts (5) can be inserted though the axle brackets and shock absorber lower mounting eyes.
  11. Install the washer (6) and nut (7) on the end of each shock absorber lower mounting bolt. Tighten the mounting bolts to 88 N.m (65 ft. lbs.).
  12. Remove the jack.
    Fig 8: Stabilizer Bar Mounting To Axle
    GC0043362Courtesy of CHRYSLER LLC
  13. If equipped with a rear stabilizer bar, hook the lower ends of both stabilizer bar cushion retainers (1) into the slots in the rear of the axle (2), then rotate the opposite end of the retainers upward so the mounting bolts (3) can be installed. Install the mounting bolts and tighten each to 61 N.m (45 ft. lbs.).
    Fig 9: Watts Links Bell Crank
    GC0021780Courtesy of CHRYSLER LLC
    1 - INSTALLATION DIRECTION
    CAUTION: When installing the watts links and bell crank to the axle, make sure the bell crank is right-side-up. When mounted properly, the words "BACK UP" (1) should be able to be read from the rear over the top of the axle.
    Fig 10: Exploded View Of Watts Linkage System
    GC0043361Courtesy of CHRYSLER LLC
  14. Install the bolt (7) from the front securing the watts link bell crank (9) to the center of the axle (11). Place the washer (2) and nut (1) on the end of the mounting bolt and tighten it to 149 N.m (110 ft. lbs.).
    NOTE: Perform step  15 through step  32 on each side of the vehicle.
    Fig 11: Rear Disc Brakes, Hub And Spindle Components
    GC0041084Courtesy of CHRYSLER LLC
  15. Position the spindle (6), seal (5) and disc brake adapter (3) on the end of the axle.
  16. Clean the threads of the bolts used to mount the disc brake adapter and spindle to the axle, then apply Mopar® Stud & Bearing Mount Adhesive or equivalent to the bolt threads or replace with new mounting bolts.
  17. Install the four bolts (7) securing the disc brake adapter and spindle to the axle. Tighten the mounting bolts to 95 N.m (70 ft. lbs.).
    Fig 12: Rear Wheel Speed Sensor Mounting
    GC0041119Courtesy of CHRYSLER LLC
  18. On vehicles equipped with antilock brakes, install the wheel speed sensor head in the disc brake adapter.
  19. On vehicles equipped with antilock brakes, install the mounting screw (3) securing the wheel speed sensor in place. Tighten the mounting screw to 12 N.m (105 in. lbs.).
    Fig 13: Rear Wheel Speed Sensor Routing
    GC0041243Courtesy of CHRYSLER LLC
  20. On vehicles equipped with antilock brakes, install the routing clips (2) securing the wheel speed sensor to the axle (1) and its trailing arm (3).
    Fig 14: Cable Routing And Bracket Fasteners
    GC0021775Courtesy of CHRYSLER LLC
    1 - CABLE
    2 - ARM
    3 - FASTENERS
  21. Guide the end of each parking brake cable (1) through hole in the trailing arm (2) towards the wheel brake.
  22. Align the cable routing brackets with their mounts on the trailing arm. Install the two bolts (3) securing the cable and routing brackets to the trailing arm (2). Tighten the mounting bolts to 11 N.m (100 in. lbs.).
    Fig 15: Parking Brake Actuator Lever
    GC0019734Courtesy of CHRYSLER LLC
    1 - SHOE ACTUATOR LEVER
    2 - SHIELD MOUNTING SCREWS
    3 - REAR PARKING BRAKE CABLE
  23. Install the parking brake cable into the disc brake adapter. Be sure the locking fingers on the cable retainer (3) are expanded once the cable is pushed all the way into the brake adapter hole to ensure the cable is securely held in place.
  24. Install the parking brake shoe actuator lever (1) on the parking brake cable.
    Fig 16: Parking Brake Shoes
    GC0019730Courtesy of CHRYSLER LLC
    1 - UPPER RETURN SPRING
    2 - SHOE HOLD DOWN CLIPS
    3 - ADJUSTER
    4 - LOWER REAR SPRING
    5 - DISC BRAKE ADAPTER
  25. Install the parking brake shoe assembly on the disc brake adapter (5).
  26. Install both shoe hold-down clips (2) and the upper return spring (1).
    Fig 17: Rear Disc Brakes, Hub And Spindle Components
    GC0041084Courtesy of CHRYSLER LLC
  27. Slide the hub and bearing (2) on the spindle (6).
  28. Install a NEW hub nut (11) on the spindle. Tighten the nut to 217 N.m (160 ft. lbs.).
  29. Install the hub and bearing dust cap (10).
  30. Install the brake rotor (8) and caliper (1). Install and tighten the caliper guide pin bolts (4) to 22 N.m (192 in. lbs.). Refer to INSTALLATION .
  31. Install the bolt securing the disc brake flex hose to the axle.
    Fig 18: Tire & Wheel Mounting Method
    GC0041085Courtesy of CHRYSLER LLC
  32. Install tire and wheel assembly (1). Refer to INSTALLATION . Install and tighten wheel mounting nuts (3) to 135 N.m (100 ft. lbs.).
  33. Lower the vehicle to a point where the rear wheels just clear the floor.
    Fig 19: Parking Brake Cables At Equalizer
    GC0019738Courtesy of CHRYSLER LLC
    1 - LEVER OUTPUT CABLE
    2 - EQUALIZER
    3 - REAR PARKING BRAKE CABLES
  34. Install the rear parking brake cables (3) into the equalizer (2) on the parking brake lever output cable (1).
    WARNING: The automatic adjusting feature of this parking brake lever contains a clockspring loaded to approximately 19 pounds. Do not release the automatic adjuster lockout device unless the rear parking brake cables and equalizer are connected to the lever output cable. Keep hands out of automatic adjuster sector and pawl area. Failure to observe caution in handling this mechanism could lead to serious injury.
    NOTE: The parking brake lever can only be in the released position when releasing the automatic adjuster.
    Fig 20: Installing Pin Punch
    GC0021773Courtesy of CHRYSLER LLC
    1 - PARKING BRAKE LEVER
    2 - OUTPUT CABLE
    3 - PIN PUNCH
  35. Ensure that the parking brake cables are correctly installed on the equalizer and aligned with the cable track on the parking brake lever (1).
  36. Keeping hands clear of the automatic adjuster sector and pawl area, firmly grasp the pin punch (3) (drill bit or locking pin) installed in the parking brake lever (1), then quickly remove it from the lever mechanism. This will allow the parking brake lever mechanism to automatically adjust the parking brake cables.
  37. Cycle the parking brake lever once to position the parking brake cables, then return the parking brake lever its released position.
  38. Check the rear wheels of the vehicle. They should rotate freely without excessive dragging with the lever in the released position.
  39. Lower the vehicle.
    Fig 21: Center Console - Typical
    GC0041123Courtesy of CHRYSLER LLC
    1 - CENTER CONSOLE
  40. Install the center console. Refer to INSTALLATION .
  41. Apply the parking brake.
  42. Remove the blocks from the tires and wheels.
    Fig 22: Battery Cables
    GC0041103Courtesy of CHRYSLER LLC
  43. Connect the battery negative cable (1) to its post on the battery (4).
    Fig 23: Air Cleaner Cover
    GC0021569Courtesy of CHRYSLER LLC
  44. Install the air cleaner cover.
  45. Pump the brake pedal several times to ensure the vehicle has a firm brake pedal before moving the vehicle.
  46. Place the vehicle on an alignment rack or drive-on hoist.
    Fig 24: Rear Axle Trailing Arm & Mounting Brackets
    GC0043360Courtesy of CHRYSLER LLC
  47. With the vehicle at curb height, tighten both trailing arm to mounting bracket pivot thru-bolts (1) to 122 N.m (90 ft. lbs.).
    Fig 25: Trailing Arm Mounting To Body
    GC0043365Courtesy of CHRYSLER LLC
  48. Perform a rear wheel alignment. See STANDARD PROCEDURE . If necessary, thrust angle may be adjusted by loosening the axle trailing arm bracket bolts (4) and shifting the axle (1) forward or rearward, then retightening the bolts to 54 N.m (40 ft. lbs.).
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