I80 and I39/90 has 2 toll sections, a brief one in the south were it joins I294, and in the north, Rockford to the border.
The only way around the south one is to take I94 north/south to the city center.
Coming south from Door Cty, the direct route is around/through Milwaukee, on I94. But I94 north of Chicago is toll. US41, Skokie Hwy, lets you bypass this toll section. It's divided, but has surface intersections in the north.
Years ago when living in Chicago and vacationing in Door Cty, we took mostly surface hwys along the shore north of Milwaukee. Now I43 runs south from Greenbay. And it continues SW from Milwaukee to I90, if you want to take advantage of I39. Otherwise you'd have take I41 to Fondulac, and something else to Janesville.
Sunday afternoon traffic back into Chicago will be heavy. But if you get to Illinois by noon, the drive through the city should be reasonable.