2002 CHRYSLER CARAVAN oil

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Page 1952 of 2399

CHRYSLER CARAVAN 2002 Service Manual ASSEMBLY
NOTE: Do not re-use snap rings when servicing the
intermediate shaft assembly. Discard snap rings
and install new ones provided with available snap
ring service kit.
NOTE: When installing 1/2

Page 1954 of 2399

CHRYSLER CARAVAN 2002 Service Manual (6) Install intermediate shaft to synchro assembly
on fixture (Fig. 258).When installing 1/2 synchro-
nizer, make sure to align oil slots on synchro-
nizer hub face with oil hole in the shaft splined

Page 1956 of 2399

CHRYSLER CARAVAN 2002 Service Manual (13) InstallNEW3/4 cluster gear snap ring (Fig.
265).
(14) Install 5th gear to intermediate shaft (Fig.
266).(15) Install 5th gear blocker ring to synchronizer
(Fig. 267).
(16) Install 5th gear synchr

Page 1969 of 2399

CHRYSLER CARAVAN 2002 Service Manual (3) Grasp the wheel cover at the edges in line with
the remaining installed wheel mounting nuts and
pull straight outward from the wheel. This will pop
the wheel cover retaining tabs over the two rema

Page 1978 of 2399

CHRYSLER CARAVAN 2002 Service Manual Over inflation causes rapid center wear and loss of
the tires ability to cushion shocks (Fig. 26).
STANDARD PROCEDURE - TIRE PRESSURE
FOR HIGH SPEED OPERATION
DaimlerChrysler Corporation advocates dr

Over inflation causes rapid center wear and loss of
the tire's ability to cushion shocks (Fig. 26).
STANDARD PROCEDURE - TIRE PRESSURE
FOR HIGH SPEED OPERATION
DaimlerChrysler Corporation advocates driving at
safe speeds within posted speed limits. Where speed
limits allow the vehicle to be driven at high speeds,
correct tire inflation pressure is very important.
Vehicles loaded to maximum capacity should not be
driven at continuous speeds over 120 km/h (75 mph).
Never exceed the maximum speed capacity of the
tire. For information on tire identification and speed
ratings, (Refer to 22 - TIRES/WHEELS/TIRES -
DESCRIPTION).
STANDARD PROCEDURE - TIRE LEAK
REPAIRING
For proper repairing, a radial tire must be removed
from the wheel. Repairs should only be made if the
defect, or puncture, is in the tread area (Fig. 27). The
tire should be replaced if the puncture is located in
the sidewall.
Deflate tire completely before attempting to dis-
mount the tire from the wheel.Use a lubricant
such as a mild soap solution when dismounting
or mounting tire.Use tools free of burrs or sharp
edges which could damage the tire or wheel rim.
Before mounting tire on wheel, make sure all rust
is removed from the rim bead and repaint if neces-
sary.
Install wheel on vehicle, and progressively tighten
the 5 wheel nuts to a torque of 135 N´m (100 ft. lbs.).
CLEANING - TIRES
Before delivery of a vehicle, remove the protective
coating on the tires with white sidewalls or raisedwhite letters. To remove the protective coating, apply
warm water and let it soak for a few minutes. After-
wards, scrub the coating away with a soft bristle
brush. Steam cleaning may also be used to remove
the coating.
CAUTION: DO NOT use gasoline, mineral oil, oil-
based solvent or a wire brush for cleaning.
WHEELS
DESCRIPTION - WHEEL
Original equipment wheels are designed for proper
operation at all loads up to the specified maximum
vehicle capacity.
All models use either steel or aluminum drop-cen-
ter wheels. Every wheel has raised sections between
the rim flanges and rim drop well called safety
humps (Fig. 28). Initial inflation of the tires forces
the bead over these raised sections. In case of air
loss, the safety humps hold the tire in position on the
wheel until the vehicle can be brought to a safe stop.
Cast aluminum wheels require special balance
weights to fit on the flange of the rim (Fig. 29).
When wheel alignment is necessary on a vehicle
with cast aluminum wheels, special wheel clamps are
required to avoid damage to the wheel's finish.
The wheel studs and nuts are designed for specific
wheel applications and must be replaced with equiv-
alent parts.
Fig. 26 Over Inflation Wear
1 - THIN TIRE TREAD AREAFig. 27 Tire Repair Area
1 - REPAIRABLE AREA
RSTIRES/WHEELS22-17
TIRES (Continued)
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Page 1987 of 2399

CHRYSLER CARAVAN 2002 Service Manual RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES
CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION
ASA ACRYLONITRILE STYRENE
ACRYLITELURAN S CONSOLES, GRILLES
ABS ACRYLONITRILE
BUTADIENE STYRE

Page 1988 of 2399

CHRYSLER CARAVAN 2002 Service Manual CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION
UP UNSATURATED
POLYESTER
(THERMOSETTING)SMC, BMC, TMC, ZMC, IMC,
XSMC, UPGRILLE OPENING PANEL,
LIFTGATES, FLARESIDE
FENDERS, FENDER
EXTENSIONS
EE

Page 1990 of 2399

CHRYSLER CARAVAN 2002 Service Manual ²Panel repair for both flexible and rigid panels
are basically the same. The primary difference
between flexible panel repair and rigid panel repair
is in the adhesive materials used (Fig. 5).
²The

²Panel repair for both flexible and rigid panels
are basically the same. The primary difference
between flexible panel repair and rigid panel repair
is in the adhesive materials used (Fig. 5).
²The technician should first decide what needs to
be done when working on any type of body panel.
One should determine if it is possible to return the
damage part to its original strength and appearance
without exceeding the value of the replacement part.
²When plastic repairs are required, it is recom-
mended that the part be left on the vehicle when
every possible. That will save time, and the panel
will remain stationary during the repair. Misalign-
ment can cause stress in the repair areas and can
result in future failure.
VISUAL INSPECTION
Composite materials can mask the severity of an
accident. Adhesive bond lines, interior structure of
the doors, and steel structures need to be inspected
carefully to get a true damage assessment. Close
inspection may require partial removal of interior
trim or inner panels.
Identify the type of repair: Puncture or Crack -
Damage that has penetrated completely through the
panel. Damage is confined to one general area; a
panel section is not required. However, a backer
panel, open fiberglass tape, or matted material must
be bonded from behind (Fig. 7) (Fig. 6).
PANEL SURFACE PREPARATION
If a body panel has been punctured, cracked, or
crushed, the damaged area must be removed from
the panel to achieve a successful repair. All spider
web cracks leading away from a damaged area must
be stopped or removed. To stop a running crack in a
panel, drilla6mm(0.250 in.) hole at the end of the
crack farthest away from the damage. If spider web
cracks can not be stopped, the panel would require
replacement. The surfaces around the damaged area
should be stripped of paint and freed from wax and
oil. Scuff surfaces around repair area with 360 grit
wet/dry sandpaper, or equivalent, to assure adhesion
of repair materials.
PATCHING PANELS
An panel that has extensive puncture type damage
can be repaired by cutting out the damaged material
(Fig. 7). Use a suitable reciprocating saw or cut off
wheel to remove the section of the panel that is dam-
aged. The piece cut out can be used as a template to
shape the new patch. It is not necessary to have
access to the back of the panel to install a patch.
Bevel edges of cutout at 20 degrees to expose a larger
bonding area on the outer side. This will allow for an
increased reinforcement areas.
Fig. 4 BEVELING ANGLE - 20 DEGREE
Fig. 5 FIBERGLASS TAPE
Fig. 6 DAMAGE COMPONENT
1 - PUNCTURE
RSBODY23-7
BODY (Continued)
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