2002 CHRYSLER CARAVAN manual transmission

INSTALLATION - UPSTREAM 1/1 - 3.3/3.8L
The engines uses two heated oxygen sensors.
(1) After removing the sensor, the exhaust mani-
fold threads must be cleaned with an 18 mm X 1.5 +
6E tap. If reusing the original sensor, coat the sensor
threads with an anti-seize compound such as Loctite
771- 64 or equivalent. New sensors have compound
on the threads and do not require an additional coat-
ing.
(2) Install sensor and tighten to 27 N´m (20 ft.
lbs.).
(3) Connect the electrical connector for the O2 sen-
sor and install onto bracket.
(4) Connect the electrical connector for the speed
control servo.
(5) Install the speed control servo and bracket
refer to the Speed Control Servo for more informa-
tion.
(6) Connect the speed control vacuum harness to
servo.
(7) Install the battery tray, refer to the Battery
section for more information.
(8) Install battery, refer to the Battery section for
more information.
INSTALLATION DOWNSTREAM 2/1 -
2.4/3.3/3.8L
The O2S is located on the side of the catalytic con-
verter.
Threads of new oxygen sensors are factory coated
with anti-seize compound to aid in removal.DONOT add any additional anti-seize compound to
the threads of a new oxygen sensor.
(1) Install sensor and tighten to 27 N´m (20 ft.
lbs.).
(2) Connect the electrical connector.
(3) Lower vehicle.
(4) Install the negative battery cable.
THROTTLE BODY
DESCRIPTION
The throttle body is located on the intake manifold
(Fig. 26) or (Fig. 27). Fuel does not enter the intake
manifold through the throttle body. Fuel is sprayed
into the manifold by the fuel injectors.
OPERATION
Filtered air from the air cleaner enters the intake
manifold through the throttle body. The throttle body
contains an air control passage controlled by an Idle
Air Control (IAC) motor. The air control passage is
used to supply air for idle conditions. A throttle valve
(plate) is used to supply air for above idle conditions.
Certain sensors are attached to the throttle body.
The accelerator pedal cable, speed control cable and
transmission control cable (when equipped) are con-
nected to the throttle body linkage arm.
A (factory adjusted) set screw is used to mechani-
cally limit the position of the throttle body throttle
plate.Never attempt to adjust the engine idle
speed using this screw.All idle speed functions are
controlled by the PCM.
Fig. 25 DOWNSTREAM 2/1 O2 SENSOR
Fig. 26 IAC MOTOR 2.4L
1 - Idle Air Control Motor
2 - Throttle Position Sensor
RSFUEL INJECTION14-33
O2 SENSOR (Continued)
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(3) Carefully install the ignition switch. The
switch will snap over the retaining tabs (Fig. 16) .
Install mounting screw (Fig. 12).
(4) Install upper and lower shrouds.
(5) Install key cylinder (cylinder retaining tab will
depress only in the RUN position).
(6) Connect negative cable to battery.(7) Check for proper operation of ignition switch
and key-in warning switch.
LOCK CYLINDER HOUSING
DESCRIPTION - IGNITION INTERLOCK
All vehicles equipped with automatic transaxles
have an interlock system. The system prevents shift-
ing the vehicle out of Park unless the ignition lock
cylinder is in the Unlock, Run or Start position. In
addition, the operator cannot rotate the key to the
lock position unless the shifter is in the park posi-
tion. On vehicles equipped with floor shift refer to
the - Transaxle for Automatic Transmission Shifter/
Ignition Interlock.
REMOVAL
(1) Disconnect negative (ground) cable from the
battery and isolate cable from battery terminal.
(2) Remove the screws attaching the lower steer-
ing column cover to the instrument panel (Fig. 17),
then remove the cover from the lower instrument
panel.
Fig. 15 Ignition Switch Connectors
1 - KEY IN SWITCH
2 - PRNDL SWITCH
3 - IGNITION SWITCH
Fig. 16 Ignition Switch Installation
1 - IGNITION SWITCH
2 - ACTUATOR SHAFT
3 - RETAINING TABS
Fig. 17 Lower Steering Column Cover Attachment
1 - PARK BRAKE RELEASE HANDLE
2 - STEERING COLUMN COVER
3 - STEERING COLUMN
4 - ATTACHING CLIP
5 - ATTACHING SCREWS
6 - HOOD RELEASE LEVER
7 - ATTACHING SCREWS
RSCOLUMN19-17
IGNITION SWITCH (Continued)
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(10) On both sides of vehicle, remove nut attaching
outer tie rod end to steering knuckle (Fig. 4).
Remove nut by holding tie rod end stud with a
socket while loosening and removing nut with
wrench.
(11) Remove bolts fastening leak detection pump to
cradle crossmember reinforcement. (Refer to 25 -EMISSIONS CONTROL/EVAPORATIVE EMIS-
SIONS/LEAK DETECTION PUMP - REMOVAL)
(12) Remove both outer tie rods from steering
knuckles, using Puller, Special Tool C-3894±A (Fig.
5).
(13) Remove the lower control arm rear bushing
retainer bolts located on each side of each lower con-
trol arm rear bushing.
NOTE: The bolts fastening the cradle crossmember
reinforcement are of two different thread sizes. Note
the location of the various sizes.
(14) Remove the bolts attaching the cradle cross-
member reinforcement to the front suspension cradle
crossmember (Fig. 6). Remove the 2 bolts fastening
the reinforcement and rear of cradle crossmember to
the body of the vehicle. Remove lower rear bushings,
then the reinforcement.
(15) If the vehicle is equipped with All-Wheel-
Drive, remove the power transfer unit (Refer to 21 -
TRANSMISSION/TRANSAXLE/POWER TRANSFER
UNIT - REMOVAL).
(16) Remove tube nuts and power steering pres-
sure and return hoses from the power steering gear
(Fig. 7).
Fig. 3 Power Steering Cooler
1 - CRADLE CROSSMEMBER REINFORCEMENT
2 - POWER STEERING COOLER
Fig. 4 Removing/Installing Tie Rod End Attaching
Nut
1 - TIE ROD END
2 - STEERING KNUCKLE
3 - WRENCH
4 - SOCKET
5 - TIE ROD END STUD
Fig. 5 Tie Rod Removal With Tool C-3894-A
1 - OUTER TIE ROD
2 - SPECIAL TOOL C-3894-A
3 - STEERING KNUCKLE
19 - 28 GEARRS
GEAR (Continued)
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(17) Remove the 3 bolts and nuts mounting the
steering gear to the front suspension cradle (Fig. 8).
NOTE: The next step must be done to allow the
removal of the steering gear from the front suspen-
sion cradle. The steering gear can not be removed
from the vehicle with the intermediate coupler
attached to the steering gear.
(18) Lower steering gear from suspension cradle
enough to allow access to the intermediate coupler
roll pin (Fig. 9). Install Remover/Installer Special
Tool 6831A through the center of the roll pin, secur-
ing with the knurled nut (Fig. 9). Hold threaded rod
stationary while turning nut, this will pull the roll
pin out of the intermediate coupler.
(19) Separate the coupler from the shaft of the
steering gear.(20) Remove the power steering gear from the
vehicle.
REMOVAL - RHD GEAR
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much fluid as
possible from the power steering fluid reservoir.
CAUTION: Locking the steering column in the
straight-ahead position will prevent the clockspring
from being accidentally over-extended when the
steering column is disconnected from the interme-
diate steering coupler.
(3) Position the steering wheel in the STRAIGHT-
AHEAD position. Lock the steering wheel in place
using a steering wheel holding tool.
(4) With the ignition key in the locked position
turn the steering wheel to the left until the steering
wheel is in the locked position.
(5) With the vehicle on the ground, disconnect the
steering column shaft coupler from the steering gear
intermediate coupler (Fig. 2).
(6) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(7) Remove front wheel and tire assemblies.
(8) If power steering cooler equipped, remove a
hose at power steering cooler and allow fluid to
drain.
(9) Remove 2 bolts attaching power steering cooler
to cradle crossmember reinforcement (Fig. 3).
(10) On both sides of vehicle, remove nut attaching
outer tie rod end to steering knuckle (Fig. 4).
Remove nut by holding tie rod end stud with a
socket while loosening and removing nut with
wrench.
(11) Remove both tie rod ends from steering
knuckles using Puller, Special Tool C-3894±A (Fig. 5).
(12) Remove the lower control arm rear bushing
retainer bolts located on each side of each lower con-
trol arm rear bushing.
NOTE: The bolts fastening the cradle crossmember
reinforcement are of two different thread sizes. Note
the location of the various sizes.
(13) Remove the bolts attaching the cradle cross-
member reinforcement to the front suspension cradle
crossmember (Fig. 6). Remove the 2 bolts fastening
the reinforcement and rear of cradle crossmember to
the body of the vehicle. Remove the reinforcement.
(14) If the vehicle is equipped with All-Wheel-
Drive, remove the power transfer unit (Refer to 21 -
TRANSMISSION/TRANSAXLE/POWER TRANSFER
UNIT - REMOVAL).
Fig. 6 Cradle Crossmember Reinforcement
Attachment
1 - STEERING GEAR
2 - RIGHT LOWER CONTROL ARM
3 - LEFT LOWER CONTROL ARM
4 - CRADLE CROSSMEMBER REINFORCEMENT
5 - REAR CRADLE CROSSMEMBER ISOLATOR BUSHING
6 - STABILIZER BAR
7 - CRADLE CROSSMEMBER
RSGEAR19-29
GEAR (Continued)
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(12) Install the power steering fluid cooler on the
cradle crossmember reinforcement (Fig. 3). Install
the mounting bolts and tighten to 11 N´m (100 in.
lbs.). When installing mounting bolts, include pres-
sure hose routing clamp.
(13) Reconnect previously disconnected hose at
power steering cooler and install clamp.
(14) Install the front tire and wheel assemblies on
vehicle. Install the wheel lug nuts and torque to 135
N´m (100 ft. lbs.).
(15) Install front emissions vapor canister. (Refer
to 25 - EMISSIONS CONTROL/EVAPORATIVE
EMISSIONS/VAPOR CANISTER - INSTALLATION)
(16) Lower the vehicle to a level where the interior
of vehicle is accessible.
(17) With the wheels pointed approximately
STRAIGHT-AHEAD, align the intermediate shaft
with the steering column coupler. Assemble the steer-
ing column shaft coupler onto the steering gear inter-
mediate coupler (Fig. 2). Install steering column
coupler to intermediate shaft retaining pinch bolt.
Tighten the pinch bolt nut to a torque of 28 N´m (250
in. lbs.).
(18) Remove the steering wheel holding tool.
(19) Fill and bleed the power steering system
using the Power Steering Pump Initial Operation
Procedure. (Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE)
(20) Inspect system for leaks.
(21) Adjust front toe (Refer to 2 - SUSPENSION/
WHEEL ALIGNMENT - STANDARD PROCEDURE).
INSTALLATION - RHD GEAR
(1) Install the steering gear up in the front sus-
pension cradle crossmember, leaving room to install
intermediate coupler.
(2) Start the roll pin into the intermediate coupler
before installing coupler on steering gear shaft. Start
roll pin into coupler, using a hammer and tapping it
into the coupler. Then install the intermediate cou-
pler on the shaft of the steering gear.
(3) Install Remover/Installer Special Tool 6831A
through the center of the roll pin, securing it with
the knurled nut (Fig. 12). Hold threaded rod station-
ary while turning nut. This will pull the roll pin into
the intermediate coupler.
(4) Install power steering gear on the front suspen-
sion cradle. Install the 2 steering gear mounting
bolts and nuts. Tighten the M-14 size steering gear
to suspension cradle mounting bolt to a torque of 183
N´m (135 ft. lbs.). Tighten the M-12 size steering
gear to suspension cradle mounting bolt to a torque
of 95 N´m (70 ft. lbs.).CAUTION: Proper torque on the steering gear to
suspension cradle mounting bolts is very impor-
tant.
(5) Install the heat shield on the steering gear
(Fig. 10).
(6) Attach the power steering fluid pressure and
return hoses to the proper fittings on the steering
gear (Fig. 10). Do not fully tighten the fittings at this
time.
(7) Install the routing clamp with the bolt securing
the power steering fluid hoses to the rear of the cra-
dle crossmember (Fig. 11).
(8) Using a crowfoot wrench on a torque wrench,
tighten the power steering fluid hose tube nuts at the
gear to a torque of 31 N´m (275 in. lbs.).
(9) Install tie rod end into steering knuckle. Start
tie rod end to steering knuckle attaching nut onto
stud of tie rod end. While holding stud of tie rod end
stationary using a socket (Fig. 4), tighten tie rod end
to steering knuckle attaching nut. Then using a
crowfoot and socket (Fig. 13), tighten the tie rod end
attaching nut to a torque of 75 N´m (55 ft. lbs.).
(10) If the vehicle is equipped with All-Wheel-
Drive, install the power transfer unit (Refer to 21 -
TRANSMISSION/TRANSAXLE/POWER TRANSFER
UNIT - INSTALLATION).
CAUTION: Proper torque on the cradle reinforce-
ment to suspension cradle mounting bolts is very
important.
(11) Install the reinforcement on the front suspen-
sion cradle crossmember and install the bolts attach-
ing the reinforcement to the cradle crossmember
(Fig. 6). Tighten the M-14 size bolts to a torque of
163 N´m (120 ft. lbs.). Tighten the M-12 size bolts to
a torque of 108 N´m (80 ft. lbs.).
(12) Install the lower control arm rear bushing
retainer bolts through reinforcement on each side of
each lower control arm rear bushing. Tighten bolts to
a torque of 61 N´m (45 ft. lbs.).
(13) Install the two bolts and bushings attaching
the reinforcement and rear of cradle crossmember to
body of vehicle (Fig. 6). Tighten bolts to a torque of
163 N´m (120 ft. lbs.).
(14) If power steering cooler equipped, install the
previously disconnected power steering cooler hose on
the cooler. Install the clamp.
(15) If power steering cooler equipped, install the
power steering fluid cooler on the cradle crossmem-
ber reinforcement (Fig. 3). Install the mounting bolts
and tighten to 11 N´m (100 in. lbs.).
(16) Install the front tire and wheel assemblies on
vehicle. Install the wheel mounting lug nuts and
tighten to a torque to 135 N´m (100 ft. lbs.).
RSGEAR19-33
GEAR (Continued)
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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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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
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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. 5).
If fluid leak is detected from either weep hole, seal
replacement is necessary.Do not attempt to repair
the leak by sealing weep holes,they must be kept
clear of sealants for proper seal operation.
If fluid is leaking from weep hole A (Fig. 5) the
type of fluid leaking will determine which seal needs
to be replaced. If the fluid leaking is red in color(transmission fluid) this indicates that the Transmis-
sion differential carrier seal should be replaced. If
the fluid leaking is light brown (gear lube) this indi-
cates that the Power Transfer Unit input seal should
be replaced. For replacement of these seals refer to
Power Transfer Unit Service Procedures.
If fluid is leaking from weep hole B (Fig. 5) the
type of fluid leaking will determine which seal is
leaking. If the fluid leaking is red in color (transmis-
sion fluid) this indicates that the input shaft end seal
should be replaced. If the fluid leaking is light brown
(gear lube) this indicates that the half shaft inner
seal and P.T.U. input shaft cover seal should be
replaced. For replacement of these seals refer to
Power Transfer Unit Service Procedures.
Before condemning any seal or gasket be sure that
the rear rocker arm cover on the engine is not the
cause of the oil leak. Oil leaking from the rocker arm
cover is easily mistaken for a leaking Power Transfer
Unit.
Fig. 3 Seal Location
1 - INPUT SHAFT
2 - OUTPUT SHAFT
3 - REAR COVER
4 - P.T.U. CASE
5 - INPUT SHAFT SEAL
Fig. 4 Seal Location
1 - P.T.U. INPUT SHAFT COVER SEAL
2 - HALF SHAFT INNER SEAL
3 - INSIDE VIEW OF P.T.U. END COVER
Fig. 5 Weep Hole Locations
1 - ENGINE OIL PAN
2 - WEEP HOLE ªAº
3 - TRANSAXLE CASE
4 - P.T.U.
5 - WEEP HOLE ªBº
21 - 4 POWER TRANSFER UNITRS
POWER TRANSFER UNIT (Continued)
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