2002 CHRYSLER CARAVAN Service Manual

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Page 1905 of 2399

CHRYSLER CARAVAN 2002 Service Manual AXLE SEALS REMOVAL (1) Raise vehicle on hoist. (2) Remove one or both front halfshaft assemblies. (Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF SHAFT - REMOVAL) (3) Using a suitable screwdriver, remove

Page 1906 of 2399

CHRYSLER CARAVAN 2002 Service Manual BACK-UP LAMP SWITCH REMOVAL (1) Raise vehicle on hoist. (2) Disconnect back-up lamp switch connector. (3) Remove back-up lamp switch (Fig. 95). INSTALLATION (1) Install back-up lamp switch (Fig. 95) a

Page 1907 of 2399

CHRYSLER CARAVAN 2002 Service Manual DISASSEMBLY (1) Remove differential side bearings: (a) Install button 8491-1 to differential case (Fig. 97). (b) Set up Tool 5048 (5048-1, -4, -6) as shown in (Fig. 98). (c) Remove differential side b

Page 1908 of 2399

CHRYSLER CARAVAN 2002 Service Manual (3) Using three ring gear bolts as forcing screws (Fig. 101), separate differential support from case (Fig. 102).(4) Remove side gear thrust washer (Fig. 103). (5) Remove side gear (Fig. 104). Fig. 10

Page 1909 of 2399

CHRYSLER CARAVAN 2002 Service Manual (6) Remove long pinion shaft (Fig. 105). (7) Remove both short pinion shafts (Fig. 106).(8) Remove pinion shaft retainer (Fig. 107). (9) Remove four pinion gears and thrust washers (Fig. 108). Fig. 10

Page 1910 of 2399

CHRYSLER CARAVAN 2002 Service Manual (10) Remove side gear (Fig. 109). (11) Remove side gear thrust washer (Fig. 110).ASSEMBLY (1) Install side gear thrust washer (Fig. 111). (2) Install differential side gear (Fig. 112). Fig. 109 Differ

Page 1911 of 2399

CHRYSLER CARAVAN 2002 Service Manual (3) Install four (4) pinion gears and thrust washers (Fig. 113). (4) Install pinion shaft retaining ring (Fig. 114).(5) Install two (2) short pinion shafts (Fig. 115). (6) Install one (1) long pinion

Page 1912 of 2399

CHRYSLER CARAVAN 2002 Service Manual (8) Install side gear thrust washer (Fig. 117). (9) Install differential support plate. Align support plate to differential case with alignment pins 8470 (Fig. 118). (10) Install thrust buttons 8491 t
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