2001 DODGE TOWN AND COUNTRY brake light

FASTENER IDENTIFICATION
DESCRIPTION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 10.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts.
FASTENER USAGE
DESCRIPTION - FASTENER USAGE
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
Figure art, specifications and torque references in
this Service Manual are identified in metric and SAE
format.
During any maintenance or repair procedures, it is
important to salvage all fasteners (nuts, bolts, etc.)
for reassembly. If the fastener is not salvageable, a
fastener of equivalent specification must be used.
International Symbols
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
RSINTRODUCTION5
INTERNATIONAL SYMBOLS (Continued)
ProCarManuals.com

FASTENER USAGE
DESCRIPTION
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
Figure art, specifications and torque references in
this Service Manual are identified in metric and SAE
format.
During any maintenance or repair procedures, it is
important to salvage all fasteners (nuts, bolts, etc.)
for reassembly. If the fastener is not salvageable, a
fastener of equivalent specification must be used.
THREADED HOLE REPAIR
DESCRIPTION
Most stripped threaded holes can be repaired using
a Helicoilt. Follow the vehicle or Helicoiltrecommen-
dations for application and repair procedures.
INTERNATIONAL VEHICLE
CONTROL & DISPLAY
SYMBOLS
DESCRIPTION
The graphic symbols illustrated in the following
International Control and Display Symbols Chart
(Fig. 4) are used to identify various instrument con-
trols. The symbols correspond to the controls and dis-
plays that are located on the instrument panel.
Fig. 4 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
RGINTRODUCTION5a
ProCarManuals.com

LUBRICANTS AND GREASES
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 7) on the label. At the bottom NLGI
symbol is the usage and quality identification letters.
Wheel bearing lubricant is identified by the letter
ªGº. Chassis lubricant is identified by the latter ªLº.
The letter following the usage letter indicates the
quality of the lubricant. The following symbols indi-
cate the highest quality.
OPERATION
The cooling system is designed around the coolant.
The coolant must accept heat from engine metal, in
the cylinder head area near the exhaust valves and
engine block. Then coolant carries the heat to the
radiator where the tube/fin radiator can transfer the
heat to the air.
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF
GLYCOL BASE COOLANT PROPERLY, CONTACT
YOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN
RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT.
FLUID FILL/CHECK
LOCATIONS
DESCRIPTION
The fluid check/fill points and lubrication locations
are located in each applicable Sections.
MAINTENANCE SCHEDULES
DESCRIPTION
There are two maintenance schedules that show
proper service for your vehicle.
First is Schedule ±A. It lists all the scheduled
maintenance to be performed under ªnormalº operat-
ing conditions.
Second is Schedule ±B. It is a schedule for vehi-
cles that are operated under the following conditions:
²Frequent short trip driving less than 10 miles
(16.2 km)
²Frequent driving in dusty conditions
²Frequent off-road or desert operation
²Frequent trailer towing
²Day and night temperatures are below freezing
²Frequent long periods of engine idling
²Frequent stop and go driving
²More than 50% of your driving is at sustained
high speeds during hot weather, above 90ÉF (32ÉC)*
²Taxi, police or delivery service
²If equipped for and operation with E-85
(ethanol) fuel.
DESCRIPTION
At Each Stop For Fuel
²Check engine oil level and add as required.
²Check windshield washer solvent and add as
required.
Once A Month
²Check tire pressure and look for unusual wear
or damage.
²Check fluid levels of coolant reservoir, brake
master cylinder, power steering and transmission.
Add fluid as required.
²Check all lights and all other electrical items for
correct operation.
At Each Oil Change
²Change oil filter
²Inspect the exhaust system.
²Inspect brake hoses.
²Inspect the CV joints and front suspension com-
ponent boots and seals.
²Rotate the tires at each oil change interval
shown on Schedule ± A (7,500 miles - 12 000 km) or
Fig. 7 NLGI Symbol
1 - WHEEL BEARINGS
2 - CHASSIS LUBRICATION
3 - CHASSIS AND WHEEL BEARINGS
RSLUBRICATION & MAINTENANCE0-7
FLUID TYPES (Continued)
ProCarManuals.com

FLUID FILL/CHECK
LOCATIONS
DESCRIPTION
The fluid check/fill points and lubrication locations
are located in each applicable service manual section.
MAINTENANCE SCHEDULES
MAINTENANCE SCHEDULES - DIESEL ENGINE
There are two maintenance schedules that show
proper service for the vehicle.
First is ScheduleªAº. It lists all the scheduled
maintenance to be performed under ªnormalº operat-
ing conditions.
Second is ScheduleªBº. It is a schedule for vehi-
cles that are operated under the conditions listed at
the beginning of the schedule.
Use the schedule that best describes the driving
conditions.
Where time and mileage are listed, follow the
interval that occurs first.
At Each Stop for Fuel
²Check the engine oil level, add as required.
²Check the windshield washer solvent and add if
required.
Once a Month
²Check the tire pressure and look for unusual
wear or damage.
²Inspect the battery and clean and tighten termi-
nals as required.
²Check the fluid levels of coolant reservoir, brake
master cylinder, power steering and transaxle and
add as needed.
²Check all lights and all other electrical items for
correct operation.
²Check the rubber seals on each side of the radi-
ator for proper fit.
At Each Oil Change
²Replace the engine oil filter at each oil change.
²Inspect exhaust system.
²Inspect brake hoses
²Inspect the CV joints and front suspension com-
ponents
²Rotate the tires at each oil change interval
shown on schedule ªAº 20 000 km or every other
interval shown on schedule ªBº 20 000 km.
²Check the coolant level, hoses, and clamps.
²Inspect brake linings, hoses and calipers.
²Inspect engine accessory drive belts.
²Inspect for presence of water in fuel filter/water
separator, drain if necessary.
SCHEDULE ªAº
20 000 km (12 000 miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Inspect air filter element. Replace as necessary.
40 000 km (24 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Replace air filter element.
²Replace fuel filter/water separator element. (2)
²Check alignment.
60 000 km (37 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Inspect air filter element. Replace as necessary.
80 000 km (49 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Replace air filter element.
²Replace fuel filter/water separator element. (2)
²Check alignment.
100 000 km (62 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Inspect air filter element. Replace as necessary.
120 000 km (75 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Replace air filter element.
²Replace fuel filter/water separator element. (2)
²Check alignment.
140 000 km (86 000 miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Inspect air filter element. Replace as necessary.
Fig. 6 Engine Oil Viscosity Recommendation ±
Diesel Engines
RGLUBRICATION & MAINTENANCE - RG - 2.5 L TURBO DIESEL0a-5
FLUID TYPES (Continued)
ProCarManuals.com

DIAGNOSIS AND TESTING - HUB AND
BEARING (FRONT)
The condition of the front hub and bearing assem-
bly is diagnosed using the inspection and testing pro-
cedure detailed below.
The bearing contained in the Unit III front hub/
bearing assembly will produce noise and vibration
when worn or damaged. The noise will generally
change when the bearings are loaded. A road test of
the vehicle is normally required to determine the
location of a worn or damaged bearing.
Find a smooth level road surface and bring the
vehicle up to a constant speed. When vehicle is at a
constant speed, swerve the vehicle back and forth
from the left and to the right. This will load and
unload the bearings and change the noise level.
Where axle bearing damage is slight, the noise is
usually not noticeable at speeds above 48 km/h (30
mph).
REMOVAL - HUB AND BEARING
NOTE: Replacement of the Unit III front hub/bearing
assembly can be normally done without having to
remove the steering knuckle from the vehicle. In the
event that the hub/bearing is frozen in the steering
knuckle and cannot be removed by hand, it will
have to be pressed out of the steering knuckle. The
steering knuckle will require removal from the vehi-
cle to allow the hub/bearing assembly to be
pressed out of the steering knuckle. (Refer to 2 -
SUSPENSION/FRONT/KNUCKLE - REMOVAL)
(1) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in Lubrication
and Maintenance.
(2) Remove wheel lug nuts, and front tire and
wheel assembly.
(3) Remove the cotter pin, nut lock and spring
washer from the stub axle (Fig. 4).
(4) With aid of a helper applying the brakes to
keep the front hub from turning, remove the hub nut
(Fig. 4).
(5) Remove disc brake caliper and adapter as an
assembly from knuckle as shown (Fig. 5). Hang
assembly out of the way using a bungee cord or wire.
Do not allow caliper hang by brake hose.
(6) Remove brake rotor from hub and bearing (Fig.
5).
(7) Push in on end of driveshaft stub shaft, push-
ing its splines out of the hub splines.(8) Remove the four hub and bearing mounting
bolts from the rear of steering knuckle (Fig. 6).Use
care not to come in contact with and damage
the ABS tone wheel on the driveshaft stub shaft
upon bolt removal.
(9) Remove the hub and bearing assembly from
the steering knuckle.
Fig. 4 Hub Nut
1 - HUB NUT
2 - NUT LOCK
3 - COTTER PIN
4 - WAVE WASHER
Fig. 5 Front Brake Mounting
1 - BRAKE ROTOR
2 - HUB AND BEARING
3 - STEERING KNUCKLE
4 - ADAPTER MOUNTING BOLTS
5 - BRAKE CALIPER
6 - ADAPTER
7 - CLIP
RSFRONT2-5
HUB / BEARING (Continued)
ProCarManuals.com

arately for each corner or side of the vehicle depend-
ing on optional equipment and type of vehicle
service. If the coil springs require replacement, be
sure that the springs are replaced with springs meet-
ing the correct load rating and spring rate for the
vehicle and its specific options.
OPERATION - STRUT ASSEMBLY
The strut assembly cushions the ride of the vehicle,
controlling vibration, along with jounce and rebound
of the suspension.
The coil spring controls ride quality and maintains
proper ride height.
The spring isolators isolate the coil spring at the
top and bottom from coming into metal-to-metal con-
tact with the upper seat and strut.
The jounce bumper limits suspension travel and
metal-to-metal contact under full jounce condition.
The strut dampens jounce and rebound motions of
the coil spring and suspension.
During steering maneuvers, the strut assembly
(through a pivot bearing in the upper strut mount)
and steering knuckle (through the lower ball joint)
turn as an assembly.
DIAGNOSIS AND TESTING - STRUT ASSEMBLY
(FRONT)
(1) Inspect for damaged or broken coil springs
(Fig. 39).
(2) Inspect for torn or damaged strut assembly
dust boots (Fig. 39).
(3) Inspect the coil spring isolator on the lower
spring seat for any signs of damage or deterioration.
(4) Lift dust boot (Fig. 40) and inspect strut
assembly for evidence of fluid running from the
upper end of fluid reservoir. (Actual leakage will be a
stream of fluid running down the side and dripping
off lower end of unit). A slight amount of seepage
between the strut rod and strut shaft seal is not
unusual and does not affect performance of the strut
assembly (Fig. 40). Also inspect jounce bumpers for
signs of damage or deterioration.
REMOVAL - STRUT ASSEMBLY
WARNING: DO NOT REMOVE THE NUT FROM THE
STRUT ROD WHILE STRUT ASSEMBLY IS
INSTALLED IN VEHICLE, OR BEFORE STRUT
ASSEMBLY SPRING IS COMPRESSED.
(1) Raise the vehicle. See Hoisting in Lubrication
and Maintenance.
(2) Remove the wheel and tire assembly from loca-
tion on front of vehicle requiring strut removal.(3) If both strut assemblies are to be removed,
mark the strut assemblies right or left according to
which side of the vehicle they were removed from.
(4) Remove the hydraulic brake hose routing
bracket and the speed sensor cable routing bracket
from the strut damper brackets (Fig. 41).
Fig. 40 Strut Assembly Leakage Inspection (Typical)
1 - DUST BOOT
2 - STRUT SHAFT
3 - STRUT FLUID RESERVOIR
4 - INSPECT THIS AREA FOR EVIDENCE OF EXCESSIVE FLUID
LEAKAGE
Fig. 41 Brake Hose And Speed Sensor Cable
Routing
1 - STRUT DAMPER
2 - WHEEL SPEED SENSOR CABLE
3 - ROUTING BRACKET
4 - HYDRAULIC BRAKE HOSE
5 - ATTACHING BOLT
6 - ROUTING BRACKET
2 - 20 FRONTRS
STRUT (Continued)
ProCarManuals.com

unload the bearings and change the noise level.
When bearing damage is slight, the noise is usually
not noticeable at speeds above 48 km/h (30 mph).
REMOVAL - HUB AND BEARING
FRONT-WHEEL-DRIVE VEHICLES
(1) Raise vehicle. See Hoisting in Lubrication and
Maintenance.
(2) Remove wheel and tire.
(3) Remove brake drum or disc brake caliper and
rotor from hub and bearing. Refer to Brakes.
(4) If equipped with antilock brakes, perform the
following:
(a) Remove secondary (yellow) retaining clip at
rear of wheel speed sensor head (Fig. 8).
(b) Push up on metal retaining clip (Fig. 8) until
it bottoms. This will release wheel speed sensor
head from hub and bearing.
(c) While holding metal clip up, pull back on
wheel speed sensor head removing it from hub and
bearing.
(5) Remove the 4 bolts attaching the hub and bear-
ing to the rear axle.
CAUTION: Corrosion may occur between the hub
and bearing, and the axle. If this occurs the hub
and bearing will be difficult to remove from the
axle. If the hub and bearing will not come out of the
axle by pulling on it by hand, do not pound on the
hub and bearing to remove it from the axle. Damage
will occur. Use the following procedure.(6) If hub and bearing cannot be removed from the
axle by hand, use Remover, Special Tool 8458 (Fig. 9)
and following procedure to press the hub and bearing
out of the axle.
(a) Thread Threaded Guide Pins into hub and
bearing mounting bolt holes.
(b) Remove the two outboard spring plate bolts.
(c) Using the spring plate bolts, install the
Screw Mount, Special Tool 8458±2, as shown (Fig.
9).
(d) Place Push Plate, Special Tool 8458±1, on
ends of Threaded Guide Pins
(e) Place a dab of grease in dimple of Push
Plate.
(f) Tighten the Forcing Screw, Special Tool
8458±3, up against dimple in Push Plate and press
hub and bearing out of axle by continuing to
tighten screw.
(g) Remove the tool.
(h) Reinstall the two outboard spring plate bolts.
Tighten the bolts to 102 N´m (75 ft. lbs.) torque.
(7) Remove the hub/bearing from the rear axle and
brake support plate.
ALL-WHEEL-DRIVE VEHICLES
(1) Set the parking brake.The parking brake is
set to keep the hub and bearing, and axle shaft
from rotating when loosening the hub nut.
Fig. 8 SENSOR CONNECTOR AT HUB AND
BEARING
1 - SECONDARY SENSOR RETAINING CLIP
2 - METAL SENSOR RETAINING CLIP
3 - HUB AND BEARING
Fig. 9 REMOVAL USING SPECIAL TOOL 8458
1 - THREADED GUIDE PINS 8458-4
2 - HUB AND BEARING
3 - LEAF SPRING PLATE
4 - FORCING SCREW 8458-3
5 - SCREW MOUNT 8458-2
6 - PUSH PLATE 8458-1
RSREAR2-31
HUB / BEARING (Continued)
ProCarManuals.com

(2) Raise vehicle. See Hoisting in Lubrication And
Maintenance.
(3) Remove the wheel/tire assembly.
(4) Remove the cotter pin and nut retainer (Fig.
19) from the stub shaft of the outer C/V joint.
(5) Remove the spring washer (Fig. 18) from the
stub shaft of the outer C/V joint.
(6) Remove the hub nut and washer (Fig. 16) from
the stub shaft of the outer C/V joint.
(7) Remove the 6 bolts (Fig. 17) mounting the
driveshaft inner joint to the output shaft of the rear
drive line module.
(8) Remove the rear wheel speed sensor (Fig. 20)
from the rear hub/bearing.
(9) Release the parking brake.
(10) Remove the disc brake caliper to adapter
guide pin bolts (Fig. 15).
(11) Remove rear caliper from adapter using the
following procedure. First rotate rear of caliper up
from the adapter. Then pull the front of the caliper
and the outboard brake shoe anti-rattle clip out from
under the front abutment on the adapter (Fig. 14).
(12) Support caliper to prevent the weight of the
caliper from damaging the flexible brake hose (Fig.
10).
(13) Remove the rotor from the hub/bearing.
(14) Remove driveshaft from rear drive line mod-
ule and hub/bearing. Driveshaft is removed by first
compressing the inner joint on the driveshaft and
removing it from the drive line module. Then, slide
the outer joint of the driveshaft out of the hub/bear-
ing.(15) Remove the hub/bearing to axle mounting
bolts (Fig. 13).
CAUTION: Corrosion may occur between the hub/
bearing and the axle. If this occurs the hub/bearing
will be difficult to remove from the axle. If the hub/
bearing will not come out of the axle by pulling on
it by hand, do not pound on the hub/bearing to
remove it from the axle. Pounding on the hub/bear-
ing to remove it from the axle will damage the hub/
bearing. This damage will result in noise or failure
of the hub/bearing. To remove a hub/bearing which
is corroded to the axle, lightly tap the disc brake
caliper adapter using a soft faced hammer. This will
remove both the disc brake caliper adapter and
hub/bearing from the axle. The hub/bearing will
then need to be removed from the caliper adapter.
(16) Remove the hub/bearing from the axle. (Fig.
12).
(17) If the disc brake caliper adapter and hub/
bearing were removed as an assembly from the axle
and the hub/bearing cannot be removed from the
adapter by hand, use the following procedure to
remove it from the adapter. With a helper supporting
the caliper adapter in his hands, position Remover,
Special Tool 8214-1 on the cast housing of hub/bear-
ing (Fig. 11).Do not position special tool on
inner race of hub/bearing.Lightly strike Remover,
Special Tool 8214-1 with a hammer to remove the
hub/bearing from the caliper adapter.
Fig. 10 Correctly Supported Caliper
1 - WIRE
2 - CALIPER
3 - ADAPTER
4 - ROTOR
5 - INNER FENDER
Fig. 11 Hub/Bearing Removal From Caliper Adapter
1 - SPECIAL TOOL 8214-1
2 - PARK BRAKE CABLE
3 - DISC BRAKE CALIPER ADAPTER
4 - HUB/BEARING
2 - 32 REARRS
HUB / BEARING (Continued)
ProCarManuals.com