2002 CHRYSLER CARAVAN automatic transmission fluid

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phone lights compression ratio battery location radiator cap mirror controls

Page 1032 of 2399

CHRYSLER CARAVAN 2002 Service Manual 8W-80 CONNECTOR PIN-OUTS
Component Page
A/C Compressor Clutch................ 8W-80-6
A/C Pressure Sensor.................. 8W-80-6
A/C-Heater Control C1 (MTC)........... 8W-80-6
A/C-Heater Control C2

8W-80 CONNECTOR PIN-OUTS
Component Page
A/C Compressor Clutch................ 8W-80-6
A/C Pressure Sensor.................. 8W-80-6
A/C-Heater Control C1 (MTC)........... 8W-80-6
A/C-Heater Control C2 (MTC)........... 8W-80-7
Accelerator Pedal Position Sensor
(Diesel).......................... 8W-80-7
Adjustable Pedals Module
(Except Built-Up-Export)............ 8W-80-7
Adjustable Pedals Switch
(Except Built-Up-Export)............ 8W-80-7
Airbag Control Module (ORC)........... 8W-80-8
Ambient Temp Sensor (Except Base)..... 8W-80-8
ATC Remote Sensor (ATC)............. 8W-80-8
Auto Temp Control C1................ 8W-80-9
Auto Temp Control C2................ 8W-80-9
Auto Temp Control C3................ 8W-80-9
Automatic Day/Night Mirror
(Premium/Luxury)................. 8W-80-9
Autostick Switch (Except
Built-Up-Export).................. 8W-80-10
Back-Up Lamp Switch (MTX).......... 8W-80-10
Battery Temperature Sensor (Diesel).... 8W-80-10
Blower Motor Resistor C1 (MTC)....... 8W-80-10
Blower Motor Resistor C2 (MTC)....... 8W-80-10
Body Control Module C1.............. 8W-80-11
Body Control Module C2.............. 8W-80-11
Body Control Module C3.............. 8W-80-12
Body Control Module C4.............. 8W-80-13
Body Control Module C5.............. 8W-80-14
Boost Pressure Sensor (Diesel)......... 8W-80-14
Brake Fluid Level Switch............. 8W-80-14
Brake Lamp Switch................. 8W-80-15
Brake Transmission Shift Interlock Solenoid
(EATX) ......................... 8W-80-15
C100............................. 8W-80-15
C100............................. 8W-80-16
C101............................. 8W-80-16
C101............................. 8W-80-16
C102 (2.4L)........................ 8W-80-17
C102 (2.4L)........................ 8W-80-17
C102 (3.3L/3.8L).................... 8W-80-17
C102 (3.3L/3.8L).................... 8W-80-18
C103 (Diesel)....................... 8W-80-18
C103 (Diesel)....................... 8W-80-18
C106 (Built-Up-Export)............... 8W-80-18
C106 (Built-Up-Export)............... 8W-80-19
C107 (Built-Up-Export)............... 8W-80-19
C107 (Built-Up-Export)............... 8W-80-19
C200............................. 8W-80-20
C200............................. 8W-80-22
C201............................. 8W-80-23
C201............................. 8W-80-24Component Page
C202............................. 8W-80-24
C202............................. 8W-80-24
C203 (United Kingdom).............. 8W-80-24
C203 (United Kingdom).............. 8W-80-25
C300 (LHD)........................ 8W-80-25
C300 (LHD)........................ 8W-80-25
C300 (RHD)....................... 8W-80-26
C300 (RHD)....................... 8W-80-26
C301............................. 8W-80-26
C301............................. 8W-80-26
C302............................. 8W-80-27
C302............................. 8W-80-27
C303 (LHD)........................ 8W-80-27
C303 (LHD)........................ 8W-80-28
C303 (RHD)....................... 8W-80-28
C303 (RHD)....................... 8W-80-28
C304............................. 8W-80-29
C304............................. 8W-80-29
C305............................. 8W-80-29
C305............................. 8W-80-29
C306............................. 8W-80-30
C306............................. 8W-80-30
C307............................. 8W-80-30
C307............................. 8W-80-30
C308............................. 8W-80-31
C308............................. 8W-80-31
C309............................. 8W-80-31
C309............................. 8W-80-32
C310 (Front Console)................ 8W-80-32
C310 (Front Console)................ 8W-80-32
C311 ............................. 8W-80-32
C311 ............................. 8W-80-33
C312............................. 8W-80-33
C312............................. 8W-80-34
C313 (Rear Console)................. 8W-80-34
C313 (Rear Console)................. 8W-80-34
C314 (High Line)................... 8W-80-35
C314 (High Line)................... 8W-80-35
C315 (High Line)................... 8W-80-35
C315 (High Line)................... 8W-80-36
C316 (Power Sliding Door)............ 8W-80-36
C316 (Power Sliding Door)............ 8W-80-36
C317 (Power Sliding Door)............ 8W-80-36
C317 (Power Sliding Door)............ 8W-80-37
C318 (Trailer Tow).................. 8W-80-37
C318 (Trailer Tow).................. 8W-80-37
C319 (Except Built-Up-Export/Low Line) . 8W-80-37
C319 (Except Built-Up-Export/Low Line) . 8W-80-38
C320............................. 8W-80-38
C320............................. 8W-80-38
C321............................. 8W-80-38
C321............................. 8W-80-38
RS8W-80 CONNECTOR PIN-OUTS8W-80-1
ProCarManuals.com

Page 1101 of 2399

CHRYSLER CARAVAN 2002 Service Manual INTEGRATED POWER MODULE C7 - BLACK/RED 20 WAY
CAV CIRCUIT FUNCTION
1 C16 20DB/GY (EXCEPT
BUILT-UP-EXPORT)FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
1 C16 18DB/GY (BUILT-UP-EXPORT) FUSED REAR WINDOW DEFOG

Page 1212 of 2399

CHRYSLER CARAVAN 2002 Service Manual CAUTION: Squirt approximately one teaspoon of oil
into the cylinders, rotate engine to lubricate the cyl-
inder walls to prevent damage on restart.
(8) Install new spark plugs.
(9) Drain engine oil an

CAUTION: Squirt approximately one teaspoon of oil
into the cylinders, rotate engine to lubricate the cyl-
inder walls to prevent damage on restart.
(8) Install new spark plugs.
(9) Drain engine oil and remove oil filter.
(10) Install a new oil filter.
(11) Fill engine with specified amount of approved
oil.
(12) Connect negative battery cable.
(13) Start engine and check for any leaks.
STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS AND SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results.Do not use form-in-
place gasket material unless specified.Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
Engine RTV GEN II, MopartATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPARtENGINE RTV GEN IIis used to seal
components exposed to engine oil. This material is a
specially designed black silicone rubber RTV that
retains adhesion and sealing properties when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Always
inspect the package for the expiration date before
use.
MOPARtATF RTVis a specifically designed
black silicone rubber RTV that retains adhesion and
sealing properties to seal components exposed to
automatic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
MOPARtGASKET MAKERis an anaerobic type
gasket material. The material cures in the absence of
air when squeezed between two metallic surfaces. It
will not cure if left in the uncovered tube. The
anaerobic material is for use between two machined
surfaces. Do not use on flexible metal flanges.
MOPARtBED PLATE SEALANTis a unique
(green-in-color) anaerobic type gasket material that
is specially made to seal the area between the bed-plate and cylinder block without disturbing the bear-
ing clearance or alignment of these components. The
material cures slowly in the absence of air when
torqued between two metallic surfaces, and will rap-
idly cure when heat is applied.
MOPARtGASKET SEALANTis a slow drying,
permanently soft sealer. This material is recom-
mended for sealing threaded fittings and gaskets
against leakage of oil and coolant. Can be used on
threaded and machined parts under all tempera-
tures. This material is used on engines with multi-
layer steel (MLS) cylinder head gaskets. This
material also will prevent corrosion. MopartGasket
Sealant is available in a 13 oz. aerosol can or 4oz./16
oz. can w/applicator.
SEALER APPLICATION
MopartGasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location.
MopartEngine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to
prevent smearing material off the location.
MopartGasket Sealant in an aerosol can should be
applied using a thin, even coat sprayed completely
over both surfaces to be joined, and both sides of a
gasket. Then proceed with assembly. Material in a
can w/applicator can be brushed on evenly over the
sealing surfaces. Material in an aerosol can should be
used on engines with multi-layer steel gaskets.
STANDARD PROCEDURE - ENGINE GASKET
SURFACE PREPARATION
To ensure engine gasket sealing, proper surface
preparation must be performed, especially with the
use of aluminum engine components and multi-layer
steel cylinder head gaskets.
Neveruse the following to clean gasket surfaces:
²Metal scraper
²Abrasive pad or paper to clean cylinder block
and head
²High speed power tool with an abrasive pad or a
wire brush (Fig. 3)
RSENGINE 2.4L9-11
ENGINE 2.4L (Continued)
ProCarManuals.com

Page 1285 of 2399

CHRYSLER CARAVAN 2002 Service Manual Calibrate the tester according to the manufactur-
ers instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum, with 552 kPa (80 psi) rec-
o

Calibrate the tester according to the manufactur-
er's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum, with 552 kPa (80 psi) rec-
ommended.
Perform the test procedures on each cylinder
according to the tester manufacturer's instructions.
While testing, listen for pressurized air escaping
through the throttle body, tailpipe and oil filler cap
opening. Check for bubbles in the coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage per cylinder.
FOR EXAMPLE:At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder.
STANDARD PROCEDURE
STANDARD PROCEDURE - MEASURING
BEARING CLEARANCE USING PLASTIGAGE
Engine crankshaft bearing clearances can be deter-
mined by use of Plastigage or equivalent. The follow-
ing is the recommended procedure for the use of
Plastigage:
(1) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(2) Place a piece of Plastigage across the entire
width of the bearing shell in the cap approximately
6.35 mm (1/4 in.) off center and away from the oil
holes (Fig. 3). (In addition, suspected areas can be
checked by placing the Plastigage in the suspected
area). Torque the bearing cap bolts of the bearing
being checked to the proper specifications.(3) Remove the bearing cap and compare the
width of the flattened Plastigage with the metric
scale provided on the package. Locate the band clos-
est to the same width. This band shows the amount
of clearance in thousandths of a millimeter. Differ-
ences in readings between the ends indicate the
amount of taper present. Record all readings taken.
Compare clearance measurements to specs found in
engine specifications (Refer to 9 - ENGINE - SPECI-
FICATIONS).Plastigage generally is accompa-
nied by two scales. One scale is in inches, the
other is a metric scale.
NOTE: Plastigage is available in a variety of clear-
ance ranges. Use the most appropriate range for
the specifications you are checking.
(4) Install the proper crankshaft bearings to
achieve the specified bearing clearances.
STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS AND SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results.Do not use form-in-
place gasket material unless specified.Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
Engine RTV GEN II, MopartATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPARtENGINE RTV GEN IIis used to seal
components exposed to engine oil. This material is a
specially designed black silicone rubber RTV that
retains adhesion and sealing properties when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Always
inspect the package for the expiration date before
use.
MOPARtATF RTVis a specifically designed
black silicone rubber RTV that retains adhesion and
sealing properties to seal components exposed to
automatic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
Fig. 3 Plastigage Placed in Lower ShellÐTypical
1 - PLASTIGAGE
9 - 84 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)
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Page 1547 of 2399

CHRYSLER CARAVAN 2002 Service Manual NOTE: Before installing power steering pressure
hose on power steering pump, inspect the O-ring
on the power steering pressure hose for damage
and replace if required.
(4) Install the power steering f

NOTE: Before installing power steering pressure
hose on power steering pump, inspect the O-ring
on the power steering pressure hose for damage
and replace if required.
(4) Install the power steering fluid pressure hose
fitting into the pressure port of the power steering
pump (Fig. 12). Tighten the pressure line to pump
fitting tube nut to a torque of 31 N´m (275 in. lbs.).
(5) Install the power steering fluid supply hose on
the power steering pump supply fitting (Fig. 12).Be
sure hose clamp is properly reinstalled.
(6) Install the accessary drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(7) Install the splash shields below the engine
compartment.
(8) Lower the vehicle.
(9) Connect the negative (-) battery cable on the
negative battery post.
(10) Fill and bleed the power steering system
using the Power Steering Pump Initial Operation
Procedure (Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE).
(11) Inspect for leaks.
SPECIAL TOOLS
POWER STEERING PUMP
FLUID
STANDARD PROCEDURE - POWER STEERING
FLUID LEVEL CHECKING
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH THE ENGINE OFF TO PREVENT INJURY
FROM MOVING PARTS AND TO ENSURE ACCU-
RATE FLUID LEVEL READING.
The fluid level can be read on the exterior of the
power steering fluid reservoir. The fluid level should
be within the ªFILL RANGEº when the fluid is at
normal ambient temperature, approximately 21ÉC to
27ÉC (70ÉF to 80ÉF) (Fig. 17).
Before removing the power steering filler cap, wipe
the reservoir filler cap free of dirt and debris. Do not
overfill the power steering system.Use only
MopartATF+4 Automatic Transmission Fluid
(MS-9602) in the power steering system.For
additional information on Automatic Transmission
Fluid, (Refer to LUBRICATION & MAINTENANCE/
FLUID TYPES - DESCRIPTION).
CAUTION: Use only MoparTATF+4 Automatic Trans-
mission Fluid (MS-9602). Use of other MoparT
power steering fluids (MS5931 and MS9933) should
be avoided to ensure peak performance of the
power steering system under all operating condi-
tions.
Installer C-4063B
Puller C-4333
Fig. 17 Power Steering Fluid Reservoir
19 - 44 PUMPRS
PUMP (Continued)
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Page 1558 of 2399

CHRYSLER CARAVAN 2002 Service Manual TRANSMISSION/TRANSAXLE
TABLE OF CONTENTS
page page
POWER TRANSFER UNIT..................1
31TH AUTOMATIC TRANSAXLE.............2141TE AUTOMATIC TRANSAXLE............161
T850 MANUAL TRANSAXLE..........

TRANSMISSION/TRANSAXLE
TABLE OF CONTENTS
page page
POWER TRANSFER UNIT..................1
31TH AUTOMATIC TRANSAXLE.............2141TE AUTOMATIC TRANSAXLE............161
T850 MANUAL TRANSAXLE...............308
POWER TRANSFER UNIT
TABLE OF CONTENTS
page page
POWER TRANSFER UNIT
DESCRIPTION..........................1
OPERATION............................3
DIAGNOSIS AND TESTING
SEAL IDENTIFICATION..................3
FLUID LEAK DIAGNOSIS................4
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
INSPECTION..........................5
STANDARD PROCEDURE - PTU FLUID
CHANGE.............................5
REMOVAL.............................6
INSTALLATION..........................7
ADJUSTMENTS
OUTPUT FLANGE SHIM SELECTION.......7
SPECIFICATIONS
TORQUE.............................8
SPECIAL TOOLS
SDP POWER TRANSFER UNIT............8
DIFFERENTIAL CARRIER SEAL
REMOVAL.............................9
INSTALLATION..........................9
END COVER BALL BEARING
REMOVAL.............................9INSTALLATION.........................10
END COVER SEAL
REMOVAL.............................11
INSTALLATION.........................11
HALF SHAFT INNER SEAL
REMOVAL.............................12
INSTALLATION.........................13
INPUT SHAFT COVER SEAL
REMOVAL.............................13
INSTALLATION.........................14
INPUT SHAFT END SEAL
REMOVAL.............................16
INSTALLATION.........................16
INPUT SHAFT SEAL
REMOVAL.............................17
INSTALLATION.........................18
OUTER HALF SHAFT SEAL
REMOVAL.............................19
INSTALLATION.........................19
REAR COVER O-RING
REMOVAL.............................19
INSTALLATION.........................20
POWER TRANSFER UNIT
DESCRIPTION
The Power Transfer Unit (P.T.U.) is attached to a
modified automatic transaxle case where the right
half shaft extension housing would normally be
located.
The Power Transfer Unit is sealed from the trans-
axle and has its own oil sump. The Unit uses MopartSAE 80W-90 Gear and Axle Lubricant (MS-9020) and
holds 1.15 liters (1.22 quarts).
Service of the Power Transfer Unit is limited to:
²Fluid Change
²Seals
²Gaskets
²One ball bearing
²Output flange
If the ring gear and pinion, any tapered roller
bearings, case, covers, or pinion carrier fail the entire
unit must be replaced.
RSTRANSMISSION/TRANSAXLE21-1
ProCarManuals.com

Page 1579 of 2399

CHRYSLER CARAVAN 2002 Service Manual ASSEMBLY...........................115
SHIFT INTERLOCK SOLENOID
DESCRIPTION........................115
OPERATION..........................115
DIAGNOSIS AND TESTING - BRAKE/
TRANSMISSION SHIFT INTERLOC

ASSEMBLY...........................115
SHIFT INTERLOCK SOLENOID
DESCRIPTION........................115
OPERATION..........................115
DIAGNOSIS AND TESTING - BRAKE/
TRANSMISSION SHIFT INTERLOCK
SOLENOID..........................117
REMOVAL............................117
INSTALLATION........................118
SOLENOID - TCC
DESCRIPTION........................119
OPERATION..........................119
REMOVAL............................119
INSTALLATION........................120
THROTTLE VALVE CABLE
REMOVAL............................120
INSTALLATION........................121
ADJUSTMENTS
THROTTLE VALVE LINKAGE
ADJUSTMENT.......................122
TORQUE CONVERTER
DESCRIPTION........................122
OPERATION..........................126
REMOVAL............................127
INSTALLATION........................127
TRANSFER SYSTEM - OUTPUT SHAFT/GEAR/
BEARING
REMOVAL............................128INSTALLATION........................131
ADJUSTMENTS
ADJUSTMENT - OUTPUT SHAFT BEARING . 135
TRANSFER SYSTEM - TRANSFER SHAFT/
GEAR/BEARING
REMOVAL............................137
INSTALLATION........................141
ADJUSTMENTS
ADJUSTMENT - TRANSFER SHAFT
BEARING...........................145
VALVE BODY
REMOVAL............................146
DISASSEMBLY........................148
CLEANING...........................154
INSPECTION.........................155
ASSEMBLY...........................155
INSTALLATION........................158
ADJUSTMENTS
HYDRAULIC CONTROL PRESSURE
ADJUSTMENTS......................160
VEHICLE SPEED SENSOR/PINION GEAR
REMOVAL............................160
INSTALLATION........................160
31TH AUTOMATIC
TRANSAXLE
DESCRIPTION
This transaxle combines torque converter, three
speed transmission, final drive gearing, and differen-
tial into a front wheel drive system.
Within this transaxle, there are three primary
areas:
(1) Main center line plus valve body.
(2) Transfer shaft center line (includes governor
and parking sprag).
(3) Differential center line.
Center distances between the main rotating parts
in these three areas are held precise to maintain a
low noise level.
The torque converter, transaxle area, and differen-
tial are housed in an integral aluminum die casting.
The differential oil sump is common with the
transaxle sump. Separate filling of the differen-
tial is NOT necessary.
The torque converter is attached to the crankshaft
through a flexible driving plate. Cooling of the con-
verter is accomplished by circulating the transaxle
fluid through a remote cooler. There are two types of
coolers used. An oil-to-water type cooler located in
the radiator side tank and/or an oil-to-air heatexchanger. The torque converter assembly is a sealed
unit that cannot be disassembled.
The transaxle fluid is filtered by an internal filter
attached to the lower side of the valve body assembly.
Engine torque is transmitted to the torque con-
verter and then through the input shaft to multiple-
disc clutches in the transaxle. The power flow
depends on the application of the clutches and bands.
Refer to Elements in Use Chart in Diagnosis and
Tests section.
The transaxle consists of:
²Two multiple-disc clutches
²An overrunning clutch
²Two servos
²A hydraulic accumulator
²Two bands
²Two planetary gear sets
This provides three forward ratios and a reverse
ratio. The common sun gear of the planetary gear
sets is connected to the front clutch by a driving
shell. The driving shell is splined to the sun gear and
front clutch retainer. The hydraulic system consists
of an oil pump and a single valve body which con-
tains all of the valves except the governor valves.
The transaxle sump and differential sump are both
vented through the dipstick. Output torque from the
main center line is delivered through helical gears to
the transfer shaft. This gear set is a factor in the
transaxle final drive (axle) ratio. The shaft also car-
21 - 22 31TH AUTOMATIC TRANSAXLERS
ProCarManuals.com

Page 1581 of 2399

CHRYSLER CARAVAN 2002 Service Manual ries the governor and parking sprag. An integral heli-
cal gear on the transfer shaft drives the differential
ring gear.
OPERATION
Transmission output is directed to an integral dif-
ferential by a tr

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