2002 CHRYSLER CARAVAN Service Manual

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Page 1561 of 2399

CHRYSLER CARAVAN 2002 Service Manual FLUID LEAK DIAGNOSIS
When diagnosing fluid leaks on the Power Transfer
Unit two weep holes are provided to diagnose certain
seal leaks. These holes are located on the bottom side
of the assembly (Fig.

Page 1562 of 2399

CHRYSLER CARAVAN 2002 Service Manual STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
INSPECTION
(1) Raise vehicle on hoist.
(2) Remove PTU inspection plug (Fig. 6).
(3) Fluid level should be within 3/16º from bottom
of inspection ho

Page 1563 of 2399

CHRYSLER CARAVAN 2002 Service Manual (4) Add 1.15 liters (1.22 quarts) of MopartGear
and Axle Lubricant 80W-90 with suction gun (Fig. 9).
(5) Install inspection plug and torque to 20 N´m
(180 in. lbs.) torque.
(6) Lower vehicle.
REMOVAL

Page 1564 of 2399

CHRYSLER CARAVAN 2002 Service Manual (8) Remove the four mounting bolts for the P.T.U.
(Fig. 13)and (Fig. 14).
(9) Remove P.T.U. assembly from vehicle.
INSTALLATION
(1) To install, reverse removal procedure. Check
transaxle fluid and P.T

(8) Remove the four mounting bolts for the P.T.U.
(Fig. 13)and (Fig. 14).
(9) Remove P.T.U. assembly from vehicle.
INSTALLATION
(1) To install, reverse removal procedure. Check
transaxle fluid and P.T.U. fluid and fill to level.
(2) Refer to the Specifications section for the
proper torque specifications.
ADJUSTMENTS
OUTPUT FLANGE SHIM SELECTION
This procedure is used when the output flange is
replaced. Replacement of the output flange requires
installation of the correct size shim to maintain bearingpreload.The shim must protrude from the new out-
put flange the same distance that the original
shim protruded from the original flange.
(1) Stand the original output flange on end with
shim side pointing up.
(2) Place original shim into groove in top of flange.
(3) Place a straight edge across the shim.
(4) Using feeler gauge, measure the distance
between the straight edge and the top of the flange
(Fig. 15). Record this measurement.
(5) Repeat steps Step 1 through Step 4using the
new flange and the original shim.Record this
measurement.
(6) If measurements are not equal, use a new shim
that protrudes from new output flange. Make sure it
protrudes the same amount.
(7) For Example: The original shim protrudes
0.075 inch from the original output flange. Place the
original shiminto the new output flange. The pro-
trusion of the shim in the new flange is 0.085 inch.
This indicates that a 0.010 inch thinner shim is
required to maintain the original protrusion.
(8) Install output flange and torque flange nut to
244 N´m (180 ft. lbs.).
(9) Check the turning torque of the pinion before
installing the rear cover into the P.T.U. The turning
torque should be between 2.0 N´m and 2.5 N´m (17
in. lbs. and 22 in. lbs.).
Fig. 13 P.T.U. Lower Mounting Bolts
1 - P.T.U.
2 - P.T.U. MOUNTING BOLTS
Fig. 14 P.T.U. Upper Mounting Bolts
1 - P.T.U. UPPER MOUNTING BOLTS
2 - P.T.U.
Fig. 15 Output Flange Shim Measurement
1 - MEASURE THIS DIMENSION
2 - SHIM
3 - O-RING
4 - OUTPUT FLANGE
RSPOWER TRANSFER UNIT21-7
POWER TRANSFER UNIT (Continued)
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Page 1565 of 2399

CHRYSLER CARAVAN 2002 Service Manual SPECIFICATIONS
TORQUE
DESCRIPTION...................TORQUE
End Cover................ 28N´m(250 in. lbs.)
Fill Plug.................. 27N´m(240 in. lbs.)
Flange Nut............... 162N´m(120 ft. lbs

Page 1566 of 2399

CHRYSLER CARAVAN 2002 Service Manual DIFFERENTIAL CARRIER SEAL
REMOVAL
The Power Transfer Unit must be removed from
the vehicle to replace this seal.
(1) Remove P.T.U. from vehicle.
(2) Use a pry bar to remove seal from retainer
plate (F

Page 1567 of 2399

CHRYSLER CARAVAN 2002 Service Manual (4) Remove bearing retaining snap ring (Fig. 18).
(5) Use bearing puller MD998346 to remove bear-
ing (Fig. 19).
INSTALLATION
The end cover ball bearing can be removed and
installed without removing t

Page 1568 of 2399

CHRYSLER CARAVAN 2002 Service Manual END COVER SEAL
REMOVAL
The Power Transfer Unit must be removed from
the vehicle to perform this operation. (Refer to 21 -
TRANSMISSION/TRANSAXLE/POWER TRANSFER
UNIT - REMOVAL)
(1) Remove P.T.U. end co

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