Chrysler Voyager 2001-2003 Body Panel & Frame Bolt Torque Specifications
Chrysler Voyager 2001-2003

Chrysler Voyager 2001-2003 Body & Frame Bolt Torque Specifications

Detailed torque specifications for various body bolts on the 2001-2003 Chrysler Voyager, including locations and recommended torque values.

Updated

Important Information

Safety guidelines and reference information for proper torque application

Quick Reference Guide
ft-lbs → Nm
× 1.356
ft-lbs → kg-m
× 0.138
Nm → ft-lbs
× 0.738
in-lbs → ft-lbs
× 0.083

Common Torque Patterns

Star Pattern

Used for wheels and other circular bolt patterns

Star Pattern torque pattern diagram showing proper bolt tightening sequence
Cross Pattern

Used for gaskets and cover plates

Cross Pattern torque pattern diagram showing proper bolt tightening sequence
Sequential Pattern

Used for head bolts and other critical components

Sequential Pattern torque pattern diagram showing proper bolt tightening sequence

Common Mistakes to Avoid

Over-tightening

Exceeding the specified torque value can stretch or break fasteners, damage threads, or crack components.

Prevention:

Always use a calibrated torque wrench and follow specifications exactly.

Incorrect Torque Sequence

Tightening bolts in the wrong order can cause uneven pressure distribution and potential leaks or damage.

Prevention:

Follow the manufacturer's specified torque sequence pattern.

Dirty Threads

Dirt, rust, or old thread locker can affect torque readings and proper fastener tension.

Prevention:

Clean and inspect all threads before assembly. Use new thread locker if specified.

Reusing TTY Bolts

Torque-to-yield bolts are designed to stretch and must not be reused.

Prevention:

Always replace TTY bolts with new ones. They are single-use only.

Dry vs. Lubricated

Not accounting for whether torque specs are for dry or lubricated fasteners can lead to incorrect tension.

Prevention:

Check if specs are for dry or lubricated threads. Use specified lubricant when required.

Recommended Tools

Torque Wrench (1/4" Drive)

Range: 2-25 ft-lbs
Small fasteners, delicate components

Torque Wrench (3/8" Drive)

Range: 10-100 ft-lbs
Most common automotive fasteners

Torque Wrench (1/2" Drive)

Range: 30-250 ft-lbs
Large fasteners, wheels

Angle Gauge

Torque-to-yield (TTY) bolts

Torque Wrench Care

  • Calibrate annually or after 5,000 clicks
  • Store at lowest setting
  • Keep clean and lubricated

Search Specifications

Search by component name, bolt size, or description

Torque Calculator

Convert between different torque units

Fuel System

Torque specifications for components related to the vehicle's fuel system.

1

Fuel Tank Strap Bolts

M10 x 1.5
Torque Value
30 ft-lbs (41 N·m)
Important Notes
Ensure straps are properly aligned before tightening. Over-tightening may damage the straps.
2

Fuel Filler Neck Bolts

M8 x 1.25
Torque Value
50 ft-lbs (68 N·m)
Important Notes
Ensure the filler neck is properly seated against the body. A damaged filler neck can lead to fuel leaks.

Body Panels

Torque specifications for bolts securing various body panels.

1

Bumper Mounting Bolts

M8 x 1.25
Torque Value
28 ft-lbs (38 N·m)
Important Notes
Estimated value for M8 bolts. If larger bolts (M10) are used, increase torque to 55 ft-lbs (75 N·m). Always verify the bolt size.
2

Fender Mounting Bolts

M8 x 1.25
Torque Value
22 ft-lbs (30 N·m)
Important Notes
Estimated value for M8 bolts. If smaller M6 bolts are used, reduce the torque to 18 ft-lbs (24 N·m)

Hinges And Latches

Torque specifications for hinges, latches and related components.

1

Hood Hinge Bolts

M8 x 1.25
Torque Value
20 ft-lbs (27 N·m)
Important Notes
Ensure hood is aligned before tightening. Over-tightening can cause binding. Estimated value.
2

Door Hinge Bolts

M10 x 1.5
Torque Value
45 ft-lbs (61 N·m)
Important Notes
Ensure door is properly aligned before tightening. Use a support to hold door during installation, as doors are heavy. Estimated value for M10 bolts. If M8, use 28 ft-lbs (38 N·m)
3

Door Latch and Striker Bolts

M6 x 1.0
Torque Value
13 ft-lbs (18 N·m)
Important Notes
Ensure door closes securely and aligns properly with the striker. Estimated value.
4

Tailgate or Liftgate Hinge Bolts

M8 x 1.25
Torque Value
23 ft-lbs (31 N·m)
Important Notes
Ensure the tailgate or liftgate is aligned before tightening. Estimated value for M8 bolts.

Seats And Restraints

Torque specifications for seat and restraint system components.

1

Seat Mounting Bolts

M10 x 1.5
Torque Value
28 ft-lbs (38 N·m)
Important Notes
Ensure the seat is properly aligned. A loose seat can be very dangerous.
2

Seatbelt Mounting Bolts

M10 x 1.5
Torque Value
33 ft-lbs (45 N·m)
Important Notes
Ensure the seatbelt is properly aligned before tightening. Always replace bolts that are removed. This is a very important safety item.

Lighting And Mirrors

Torque specifications for lighting and mirror components.

1

Tail Light Mounting Bolts

M6 x 1.0
Torque Value
9 ft-lbs (12 N·m)
Important Notes
Do not over-tighten, as this can damage plastic housings.
2

Headlight Mounting Bolts

M6 x 1.0
Torque Value
9 ft-lbs (12 N·m)
Important Notes
Do not over-tighten, as this can damage plastic housings. Ensure beam alignment after installation.
3

Side Mirror Mounting Bolts

M8 x 1.25
Torque Value
18 ft-lbs (24 N·m)
Important Notes
Ensure the mirror is properly positioned before tightening. Estimated value.

Interior Trim

Torque specifications for interior trim and dashboard components.

1

Interior Trim Panel Bolts and Screws

Various (M4-M6)
Torque Value
6 ft-lbs (8 N·m)
Important Notes
Primarily hand-tighten plastic trim screws. Use low torque, as these can easily be over-tightened. Estimated Value.
2

Dashboard Mounting Bolts/Fasteners

M6 x 1.0
Torque Value
11 ft-lbs (15 N·m)
Important Notes
Ensure all electrical connectors are plugged in before final tightening. Estimated Value.

Troubleshooting Guide

Common issues, diagnostic steps, and prevention guidelines

Common Issues

Bolt stretching, stripped threads, uneven torque patterns

Loose Components

Symptoms:
  • Rattling or vibration noises
  • Visible movement in components
  • Uneven panel gaps
Solutions:
  • Clean threads and mounting surfaces
  • Replace damaged fasteners
  • Apply proper torque in sequence
  • Use thread locker if specified

Stripped Fasteners

Symptoms:
  • Unable to achieve proper torque
  • Fastener spins freely
  • Visible thread damage
Solutions:
  • Use thread repair kit if appropriate
  • Install thread insert (HeliCoil)
  • Replace component if threaded hole is damaged
  • Upgrade to higher grade fastener if recommended

Overtightened Components

Symptoms:
  • Cracked or deformed parts
  • Broken fasteners
  • Compressed gaskets or seals
Solutions:
  • Replace damaged components
  • Use new fasteners
  • Follow proper torque sequence
  • Verify correct torque specifications

Diagnostic Steps

Visual inspection, torque verification, thread assessment

1

Visual Inspection

Inspect the affected area for any visible signs of damage or wear

  • Check for cracks or deformation
  • Look for signs of excessive wear
  • Verify proper fastener installation
2

Torque Verification

Verify the torque applied to the fasteners

  • Check the torque wrench calibration
  • Verify the torque specification
  • Compare the applied torque to the specification
3

Thread Assessment

Assess the condition of the threads

  • Check for signs of thread damage
  • Verify the thread type and size
  • Check for proper thread engagement

Prevention Guidelines

Best practices, maintenance tips, tool care

Best Practices

  • Always follow the recommended torque specification
  • Use the correct type and size of fasteners
  • Verify the torque wrench calibration regularly

Maintenance Tips

  • Regularly inspect the affected area for signs of wear or damage
  • Replace damaged or worn-out components promptly
  • Keep the work area clean and organized

Tool Care

  • Regularly clean and maintain the torque wrench
  • Store the torque wrench in a dry and secure location
  • Verify the torque wrench calibration before each use

Frequently Asked Questions

Find answers to common questions about torque specifications

Q1

Why is it important to use the correct torque specifications for body bolts?

Using the correct torque specification is crucial to ensure proper body panel alignment and prevent damage. Under-tightening can lead to panels coming loose or rattling, while over-tightening can strip threads or cause the panels to deform, potentially compromising safety and causing leaks. Imagine a door panel becoming loose and rattling due to improperly tightened bolts; this creates an annoyance and could become a safety issue if it shifts unexpectedly while driving. Likewise over-tightening an outer fender can crush the mount point and deform the panel. Correct torque ensures consistent clamping force.

Q2

What happens if I over-torque a body bolt?

Over-torquing a body bolt can damage the bolt itself (stretching, breaking), strip the threads in the receiving metal, or damage the body panel. This could lead to the need for expensive repairs and may require the use of thread repair kits or even replacement of the affected panels. For example, over-tightening the bolts securing the front bumper fascia can crack the plastic around the bolt holes requiring an expensive repair.

Q3

What happens if I under-torque a body bolt?

Under-torquing a body bolt will lead to loose connections. This can cause rattling, vibration, and potential separation of the body panels during vehicle operation. Furthermore, it can also lead to increased wear of the components. Imagine the hood bolts being under-tightened. During normal driving, especially at higher speeds, the hood could vibrate and potentially become completely unlatched.

Q4

Do I need to use threadlocker on body bolts?

Generally, threadlocker is not required for most body bolts on a 2001-2003 Chrysler Voyager, unless specifically specified in the repair manual. However, for bolts that are subject to vibration or may be prone to loosening, a small amount of medium-strength threadlocker (like Loctite 242) can provide additional security. Specifically, bolts used to mount items that vibrate such as the door hinges or hatch hinges might benefit from thread locker. Always refer to the manufacturer's specific recommendations or service manual for your specific circumstance.

Q5

Should I replace body bolts when removing body panels?

While not always required, it is a good practice to inspect body bolts for damage, corrosion, or excessive stretching when they are removed. If any such issues are found, replacement is recommended. Reusing damaged bolts can lead to improper torque and reduced structural integrity. Often, re-using old bolts could also damage the bolt heads requiring drilling and replacement. In addition, always replace any self-tapping or plastic bolts. Bolts that have been deformed or stretched should always be replaced.

Environmental Considerations

Temperature, humidity, and seasonal effects on torque specifications

Temperature Effects

Includes: High Heat, Cold Weather, Thermal Cycling

Temperature can significantly impact torque values and fastener behavior

Cold Weather

Effects:
  • Increased material brittleness
  • Higher torque required due to thread contraction
  • Reduced thread lubricant effectiveness
Recommendations:
  • Allow components to warm to room temperature when possible
  • Consider using winter-grade thread lubricants
  • Check torque values more frequently during winter months

Hot Weather

Effects:
  • Thermal expansion of components
  • Decreased friction in threads
  • Accelerated lubricant breakdown
Recommendations:
  • Check torque when components are at normal operating temperature
  • Use temperature-resistant thread lockers
  • Consider re-torquing after heat cycles

Humidity and Corrosion

Covers: Rust Prevention, Salt Exposure, Moisture Control

Moisture and corrosion can affect fastener integrity and torque values

High Humidity

Effects:
  • Accelerated corrosion formation
  • Reduced friction coefficient
  • Potential thread seizing
Prevention:
  • Use corrosion-resistant fasteners
  • Apply appropriate anti-seize compounds
  • Maintain proper protective coatings

Salt Exposure

Effects:
  • Rapid corrosion development
  • Thread damage
  • Seized fasteners
Prevention:
  • Regular underbody washing
  • Use of sacrificial anodes where appropriate
  • Application of protective coatings

Seasonal Maintenance

Spring, Summer, Fall, and Winter maintenance schedules

Spring

  • Inspect for winter damage
  • Clean and protect exposed fasteners
  • Check torque on critical components

Summer

  • Monitor heat-affected components
  • Check expansion-related loosening
  • Inspect cooling system mounts

Fall

  • Prepare for winter conditions
  • Apply corrosion protection
  • Verify all fasteners are properly torqued

Winter

  • More frequent inspection of critical fasteners
  • Check for salt damage
  • Monitor suspension component torque

Related Resources

Tools, service procedures, and technical bulletins

Recommended Tools

Torque Wrench (1/2-inch Drive)

A 1/2-inch drive torque wrench is essential for applying accurate torque to body bolts. Ensure it covers the necessary torque range.

  • Wide torque range (e.g., 20-150 ft-lbs)
  • Calibration accuracy
  • Durable construction
Learn more

Torque Wrench (3/8-inch Drive)

A 3/8-inch drive torque wrench is suitable for lower torque applications on smaller body fasteners.

  • Moderate torque range (e.g., 5-80 ft-lbs)
  • Easy to handle
  • Calibration accuracy
Learn more

Socket Set (Metric)

A comprehensive metric socket set with various sizes is required to fit the different body bolts on the vehicle.

  • Deep and shallow sockets
  • Impact rated options
  • Common sizes (e.g., 10mm, 13mm, 15mm, 16mm, 18mm)
Learn more

Socket Extensions

Socket extensions of varying lengths will aid in reaching recessed or difficult to access fasteners.

  • Various lengths (e.g., 3, 6, 10 inch)
  • Durable construction
  • Secure attachment
Learn more

Universal Joint

A universal joint may be needed when a fastener is positioned at an awkward angle.

  • Durable construction
  • Strong articulation
Learn more
Service Procedures

Front Bumper Cover Removal and Installation

This procedure outlines the removal and reinstallation of the front bumper cover, including applicable torque specifications.

  • Disconnect any electrical connections to the bumper cover (if applicable).
  • Remove all fasteners securing the bumper cover to the fender and support structure.
  • Carefully remove the bumper cover.
  • Align the bumper cover to the vehicle.
  • Install all fasteners and torque to the manufacturer's specification of 100 inch pounds.
  • Reconnect any electrical connections.
View full procedure

Rear Bumper Cover Removal and Installation

This procedure details the removal and installation of the rear bumper cover, including torque specs.

  • Open the rear hatch and disconnect any wiring harness connectors.
  • Remove the fasteners securing the rear bumper cover to the quarter panels and rear body.
  • Carefully remove the rear bumper cover.
  • Align the bumper cover to the vehicle.
  • Install all fasteners and torque to the manufacturer's specification of 100 inch pounds.
  • Reconnect any electrical connections.
View full procedure

Body Panel Bolt Torque Specification Verification

This procedure is a general guide to verifying torque on body bolts.

  • Locate the specific body panel joint you're working on.
  • Consult the torque specification chart for the vehicle and location.
  • Use the correct socket and torque wrench combination.
  • Set the torque wrench to the specified torque value.
  • Apply the torque to the fastener, ensuring the wrench 'clicks' or beeps upon reaching the specified value.
  • Repeat on all bolts in the area as required.
View full procedure
Technical Service Bulletins

Corrosion Issues on Bumper Mounting Brackets

2004-05-15

This bulletin addresses premature corrosion issues found on the front and rear bumper mounting brackets, which may cause improper bumper fitment.

2001-2003 Chrysler Voyager

Resolution: Inspect bumper mounting brackets for excessive corrosion. Replace affected brackets and apply anti-corrosion protectant during reassembly. Torque fasteners to 100 inch pounds.

Loose or Missing Body Panel Fasteners

2002-11-20

This bulletin reports issues of loose or missing body panel fasteners, particularly around wheel wells and door frames.

2001-2003 Chrysler Voyager

Resolution: Inspect all body panel fasteners for tightness and proper seating. Replace any missing or damaged fasteners. Torque to manufacturer's specification, typically 100 inch pounds.

About the Author

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Alan Montanye - Automotive Technical Specialist
ASE

Alan Montanye

Automotive Technical Specialist

ASE Master Certified Technician with over a decade of hands-on experience in automotive repair and diagnostics.

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