2002 CHRYSLER CARAVAN Service Manual

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Page 1889 of 2399

CHRYSLER CARAVAN 2002 Service Manual (10) Install reverse idler gear bearing (Fig. 54). (11) Install reverse idler gear with hub down as shown in (Fig. 55).(12) Install flat washer (Fig. 56). (13) Install wave washer (Fig. 57). Fig. 54 I

Page 1890 of 2399

CHRYSLER CARAVAN 2002 Service Manual (14) Install input shaft sealed roller bearing using installer 8482 (Fig. 58). (15) Installnewinput shaft bearing snap ring (Fig. 59).(16) Install shift rail bushing to end cover using installer 8475

Page 1891 of 2399

CHRYSLER CARAVAN 2002 Service Manual (18) Install lifting bar 8489 to geartrain. (19) Lift up on bar (input shaft side) and install input shaft bearing snap ring (Fig. 64). (20) Lift up on bar (intermediate shaft side) and install interm

Page 1892 of 2399

CHRYSLER CARAVAN 2002 Service Manual (23) Install back up lamp switch and torque to 23 N´m (17 ft. lbs.) (Fig. 66). (24) Roll transaxle assembly on side. (25) Install differential chip collector magnet (Fig. 67). Retain to case with a d

Page 1893 of 2399

CHRYSLER CARAVAN 2002 Service Manual (29) Install both axle output shaft seals using driver handle C-4171 and installer 8473 (Fig. 70) (Fig. 71).(30) Applya1mm(0.04 in.) bead of MopartGas- ket Maker to shift cover assembly. Place shift c

Page 1894 of 2399

CHRYSLER CARAVAN 2002 Service Manual (32) If previously removed, install clutch release lever pivot ball(s) using slide hammer C-3752 and remover/installer 6891 (Fig. 74) (Fig. 75).(33) Install clutch release bearing to lever. Apply grea

Page 1895 of 2399

CHRYSLER CARAVAN 2002 Service Manual INSTALLATION INSTALLATION - 2.4L GAS (1) Install modular clutch assembly to transaxle. Assemble transaxle to engine. (2) Install and torque transaxle-to-engine bolts to 95 N´m (70 ft. lbs.). (3) Rais

Page 1896 of 2399

CHRYSLER CARAVAN 2002 Service Manual (11) Install halfshafts and front wheel/tire assem- blies. (Refer to 3 - DIFFERENTIAL & DRIVELINE/ HALF SHAFT - INSTALLATION) (12) Lower vehicle. (13) Install right mount bracket to transaxle (Fig. 80
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