2002 CHRYSLER CARAVAN steering

(14) Disconnect PRNDL cable from shift lever and
column bracket (Fig. 66).
(15) Disconnect shift cable at shift lever mecha-
nism pin (Fig. 66).(16) Remove pinch side clip, then remove shift
cable from bracket on column.
(17) Turn the steering wheel from the STRAIGHT-
AHEAD position 180É to the right (upside-down posi-
tion), then remove the key and lock the column in
place.
(18) Remove the pinch bolt securing column cou-
pling to intermediate shaft (Fig. 67).
Fig. 64 Steering Column Shrouds
1 - FIXED SHROUD
2 - UPPER SHROUD
3 - CLOCKSPRING
4 - LOWER SHROUD
5 - STEERING COLUMN
Fig. 65 Pedal Switch Wiring Connector
1 - STEERING COLUMN FIXED SHROUD
2 - BRAKE TRANSMISSION SHIFT INTERLOCK
3 - B.T.S.I. WIRING CONNECTOR
4 - PEDAL SWITCH WIRING CONNECTOR
Fig. 66 Shift Cable At Steering Column
1 - SHIFT LEVER MECHANISM
2 - SHIFT CABLE
3 - BRACKET
4 - PRNDL CABLE
5 - STEERING COLUMN
Fig. 67 Pinch Bolt
1 - PINCH BOLT
2 - STEERING COLUMN
5 - 44 BRAKES - BASERS
PEDAL - ADJUSTABLE (Continued)
ProCarManuals.com

(19) Loosen two lower column mounting nuts.
(20) Remove two upper column mounting nuts.
(21) Remove the steering column.
(22) Remove dash seal silencer shell over steering
column intermediate shaft (Fig. 68).
(23) Remove two nuts securing brake lamp switch
bracket to pedal assembly (Fig. 69). Remove bracket.(24) Disconnect pedal wiring harness connector
(Fig. 69).
(25) Remove pedal wiring harness from clips along
pedal bracket.
(26) Position a small screwdriver between the cen-
ter tang on the power brake booster input rod-to-
brake pedal pin retaining clip (Fig. 70).
(27) Rotate screwdriver enough to allow retaining
clip center tang to pass over end of brake pedal pin.
Then pull retaining clip off brake pedal pin.Discard
retaining clip. It is not to be reused. Replace
only with a new retaining clip when assem-
bling.
(28) Slide booster input rod off pedal pin.
(29) Remove the four nuts attaching power brake
booster to dash panel (Fig. 71).
(30) Remove two brake pedal upper mounting bolts
at instrument panel dash bracket (Fig. 71).
(31) Disconnect accelerator cable retainer at accel-
erator pedal; remove cable from pedal.
(32) Remove adjustable brake pedal assembly.
INSTALLATION
(1) Install adjustable brake pedal assembly under
instrument panel.
(2) Install two brake pedal upper mounting bolts
at instrument panel dash bracket (Fig. 71). Do not
fully tighten at this time.
(3) Install four nuts attaching power brake booster
to dash panel (Fig. 71).
Fig. 68 Intermediate Shaft Dash Seal And Silencer
Shell
1 - INTERMEDIATE SHAFT
2 - DASH SEAL
3 - SILENCER SHELL
Fig. 69 Brake Lamp Switch Bracket
1 - BRAKE LAMP SWITCH BRACKET
2 - PEDAL WIRING HARNESS CONNECTOR
3 - STEERING COLUMN INTERMEDIATE SHAFT
4 - BRACKET MOUNTING NUTS
Fig. 70 Input Rod Brake Pedal Retaining Clip
Removal
1 - BRAKE PEDAL
2 - INPUT ROD
3 - SCREWDRIVER
4 - RETAINING CLIP
5 - BRAKE PEDAL PIN
RSBRAKES - BASE5-45
PEDAL - ADJUSTABLE (Continued)
ProCarManuals.com

(4) Tighten four booster mounting nuts and two
pedal bracket upper mounting bolts to 28 N´m (21 ft.
lbs.) torque.
(5) Install accelerator cable to pedal; install cable
retainer at accelerator pedal.
(6) Install booster input rod on brake pedal pin
and install a NEW retaining clip (Fig. 72).
(7) Install wiring harness in clips along pedal
bracket, then connect harness to pedal wiring har-
ness connector (Fig. 69).
(8) Install brake lamp switch bracket on pedal
assembly (Fig. 69). Tighten mounting nuts to 6 N´m
(50 in. lbs.) torque.(9) Install dash seal silencer shell over steering
column intermediate shaft and fasten in place (Fig.
68).
(10) Install the steering column on the mounting
studs. Install the two upper and two lower mounting
nuts. Tighten the upper, then lower mounting nuts to
12 N´m (105 in. lbs.) torque.
(11) Install the column shaft coupling onto the
intermediate shaft and install the pinch bolt (steer-
ing column should still be locked position it was
placed in during removal). Make sure the rounded
side of the intermediate shaft is matched to the cur-
vature of the coupling. Tighten the pinch bolt to 28
N´m (250 in. lbs.).
(12) Attach shift cable housing to bracket on col-
umn.
(13) Connect shift cable end to shift lever mecha-
nism pin (Fig. 66).
(14) Connect PRNDL cable to end of shift lever
mechanism pin and column bracket (Fig. 66).
(15) Connect column wiring harness connectors to
SKIM (if equipped), BTSI solenoid, ignition switch,
halo lamp, multi-function switch, and clockspring.
(16) Install the upper shroud (Refer to 19 -
STEERING/COLUMN/LOWER SHROUD - INSTAL-
LATION).
(17) If equipped, connect traction control off switch
wiring connector.
(18) Install upper shroud (with traction control off
switch if equipped) (Fig. 64).
(19) Connect adjustable pedal switch wiring con-
nector along left side of column (Fig. 65).
(20) Install the lower shroud with adjustable pedal
switch. Install screws fastening steering column
shrouds to steering column (Fig. 64).
CAUTION: Do not reuse the original brake lamp
switch. The switch can only be adjusted once. That
is during initial installation of the switch. If the
switch is not adjusted properly or has been
removed for some service, a new switch must be
installed and adjusted.
(21) Install and adjust NEW brake lamp switch.
(Refer to 8 - ELECTRICAL/LAMPS/LIGHTING -
EXTERIOR/BRAKE LAMP SWITCH - INSTALLA-
TION)
(22) Install instrument panel lower left reinforce-
ment (Fig. 63).
(23) Attach hood release to lower left reinforce-
ment.
(24) Install knee blocker reinforcement plate (Fig.
62).
(25) Connect parking brake release link to release
handle.
(26) Install data link diagnostic connector to
mounting hole in reinforcement plate.
Fig. 71 Booster Mounting (Typical)
1 - DASH BRACKET
2 - POWER BRAKE BOOSTER
3 - BRAKE PEDAL ASSEMBLY
Fig. 72 Retaining Pin Installed On Brake Pedal Pin
1 - BRAKE PEDAL
2 - RETAINING CLIP
3 - BOOSTER INPUT ROD
5 - 46 BRAKES - BASERS
PEDAL - ADJUSTABLE (Continued)
ProCarManuals.com

(27) Install lower steering column cover/knee
blocker (Fig. 62).
(28) Install silencer panel below lower steering col-
umn cover/knee blocker.
NOTE: When reconnecting the battery on a vehicle
that has had the airbag module removed, the fol-
lowing procedure should be used.
(29) Reconnect ground cable to negative post of
battery in following manor:
(a) Connect scan tool (DRBIIIt) to data link
diagnostic connector located below steering column.
(b) Turn ignition key to ON position. Exit vehi-
cle with scan tool leaving scan tool harness
plugged in.
(c) Ensuring that there are no occupants in vehi-
cle, connect ground (-) cable to the negative post of
the battery.
(d) Using scan tool, read and record any airbag
fault codes. Refer to Appropriate Diagnostic Infor-
mation if any faults are found.
(e) Through drivers open window, Reach around
back of steering wheel (between steering wheel and
instrument cluster) and turn ignition key to OFF,
then back ON while observing instrument cluster
airbag indicator lamp. It should go on for six to
eight seconds, then go out. This action indicates
that airbag system is functioning normally. If air-
bag indicator lamp fails to light, blinks on and off,
or goes on and stays on, there is an airbag system
malfunction. Refer to Appropriate Diagnostic Infor-
mation to diagnose the system malfunction.
(30) Using scan tool (DRBIIIt), check for and clear
any existing adjustable pedal fault codes. The adjust-
able pedal system is now activated.
(31) Turn key to OFF and remove scan tool from
vehicle.
(32) Test operation of adjustable pedals, memory
seats (if equipped), RKE (if equipped), and all func-
tions that are steering column operated. If applica-
ble, reset the radio and the clock.
(33) Road test the vehicle to ensure proper opera-
tion of the steering and brake systems.
PEDAL TORQUE SHAFT - RHD
REMOVAL
(1) Remove the instrument panel. (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - REMOVAL)
(2) Remove the HVAC housing. (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - REMOVAL)
(3) Remove the retaining clip at the torque shaft
end of the brake pedal-to-torque shaft link. Removethe link from the torque shaft. Discard the retaining
clip. It is not to be reused. Replace with a new clip
when reassembled.
(4) Locate the booster input rod-to-brake pedal
torque shaft connection and remove the retaining clip
(Fig. 73). Discard the retaining clip. It is not to be
reused. Replace with a new clip when reassembled.
(5) Remove the four (4) brake booster retaining
nuts from inside the passenger compartment (Fig.
74).
(6) Remove the retaining nut from the brake
booster bracket located above the booster in the
engine compartment (Fig. 74).
(7) Remove the power brake booster bracket.
(8) Rotate the pedal torque shaft and remove it out
the left side of the vehicle.
INSTALLATION
(1) Lubricate both ends of the torque shaft with
MS-4517 Lubricant or equivalent and install the
torque shaft from the left side reversing the removal
procedure.
(2) Install the brake booster bracket on the left
end of the shaft.
(3) Install the four brake booster retaining nuts
inside the passenger compartment. Tighten the
mounting nuts to a torque of 29 N´m (250 in. lbs.).
(4) Install the retaining nut for the brake booster
bracket in the engine compartment. Tighten the
mounting nuts to a torque of 29 N´m (250 in. lbs.).
(5) Using lubriplate, or equivalent, coat the sur-
face of the brake pedal torque shaft pin where it con-
tacts the booster input rod. Also coat the surface of
Fig. 73 POWER BRAKE BOOSTER BRACKET
1 - BOOSTER BRACKET
2 - PEDAL TORQUE SHAFT
3 - RETAINING CLIP
4 - BOOSTER MOUNTING NUTS
RSBRAKES - BASE5-47
PEDAL - ADJUSTABLE (Continued)
ProCarManuals.com

(15) Slide master cylinder straight out of power
brake booster. Remove master cylinder with primary
and secondary tubes from vehicle.
CAUTION: A seal on the rear of the master cylinder
is used to create the seal for holding vacuum in the
power brake vacuum booster. The vacuum seal on
the master cylinder MUST be replaced whenever the
master cylinder is removed from the power brake
vacuum booster.
(16) Disconnect vacuum hose from check valve
located on vacuum booster.DO NOT REMOVE
CHECK VALVE FROM POWER BRAKE
BOOSTER.
(17) Inside vehicle, remove silencer panel under
instrument panel below steering column.
(18) Locate the booster input rod to brake pedal
connection under the instrument panel. Position a
small screwdriver between the center tang on the
power brake booster input rod to brake pedal pin
retaining clip (Fig. 79).
(19) Rotate screwdriver enough to allow retaining
clip center tang to pass over end of brake pedal pin.
Then pull retaining clip off brake pedal pin.Discard
retaining clip. It is not to be reused. Replace
only with a new retaining clip when assem-
bling.
(20) Slide booster input rod off pedal pin.
(21) Remove the four nuts attaching power brake
booster to dash panel (Fig. 80).
(22) Slide power brake booster forward and remove
through engine compartment (Fig. 81).CAUTION: Do not attempt to disassemble the power
brake vacuum booster. It is serviced ONLY as a
complete assembly.
Fig. 78 Master Cylinder Mounting
1 - MASTER CYLINDER MOUNTING NUTS
2 - MASTER CYLINDER
3 - SECONDARY TUBE NUT AT ICU
4 - PRIMARY TUBE NUT AT ICU
Fig. 79 Vacuum Booster Input Rod Retaining Pin
1 - BRAKE PEDAL
2 - INPUT ROD
3 - SCREWDRIVER
4 - RETAINING CLIP
5 - BRAKE PEDAL PIN
Fig. 80 Booster Mounting
1 - DASH BRACKET
2 - POWER BRAKE BOOSTER
3 - BRAKE PEDAL ASSEMBLY
RSBRAKES - BASE5-51
POWER BRAKE BOOSTER (Continued)
ProCarManuals.com

(3) Using lubriplate, or equivalent, coat the sur-
face of the brake pedal pin where it contacts the
booster input rod.
CAUTION: When installing the brake pedal pin on
the power brake booster input rod, do not re-use
the old retaining clip.
(4) Install booster input rod on brake pedal pin
and install a NEW retaining clip (Fig. 87).
CAUTION: Do not reuse the original brake lamp
switch. The switch can only be adjusted once. That
is during initial installation of the switch. If the
switch is not adjusted properly or has beenremoved for some service, a new switch must be
installed and adjusted.
(5) Remove and replace the brake lamp switch
with a NEW switch. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - REMOVAL), (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - INSTALLATION)
(6) Install the silencer panel below the steering
column.
(7) Connect vacuum hose to check valve on power
brake booster.
CAUTION: The master cylinder (and its rear seal) is
used to create the seal for holding vacuum in the
vacuum booster. The vacuum seal on the master
cylinder MUST be replaced with a NEW seal when-
ever the master cylinder is removed from the vac-
uum booster.
CAUTION: When removing the vacuum seal from
the master cylinder do not use a sharp tool.
(8) Using a soft tool such as a trim stick, remove
the vacuum seal from the master cylinder mounting
flange.
(9) Install a NEW vacuum seal on rear mounting
flange of the master cylinder (Fig. 88).
(10) Position master cylinder on studs of booster,
aligning push rod on booster with master cylinder
piston.
(11) Install the two nuts mounting the master cyl-
inder to the booster (Fig. 78). Tighten both mounting
nuts to a torque of 25 N´m (225 in. lbs.).
Fig. 86 RHD Booster Removal/Installation
1 - POWER BRAKE BOOSTER
2 - MASTER CYLINDER
Fig. 87 Retaining Pin Installed On Brake Pedal Pin
1 - BRAKE PEDAL
2 - RETAINING CLIP
3 - BOOSTER INPUT ROD
Fig. 88 Vacuum Seal (Typical)
1 - MASTER CYLINDER ASSEMBLY
2 - VACUUM SEAL
5 - 54 BRAKES - BASERS
POWER BRAKE BOOSTER (Continued)
ProCarManuals.com

ROTOR RUNOUT
On-vehicle rotor runout is the combination of the
individual runout of the hub face and the runout of
the rotor. (The hub and rotor runouts are separable).
To measure rotor runout on the vehicle, first remove
the tire and wheel assembly. Reinstall the wheel
mounting nuts on the studs, tightening the rotor to
the hub. Mount the Dial Indicator, Special Tool
C-3339, with Mounting Adaptor, Special Tool SP-
1910 on steering arm. The dial indicator plunger
should contact braking surface of rotor approximately
ten millimeters from edge of rotor (Fig. 95). Check
lateral runout on both sides of the rotor, marking the
low and high spots on both. Runout limits can be
found in the specification table in this section. (Refer
to 5 - BRAKES/HYDRAULIC/MECHANICAL/RO-
TOR - SPECIFICATIONS)
If runout is in excess of the specification, check the
lateral runout of the hub face. Before removing the
rotor from the hub, place a chalk mark across both
the rotor and the one wheel stud closest to where the
high runout measurement was taken. This way, the
original mounting spot of the rotor on the hub is
indexed (Fig. 96).
Remove the rotor from the hub.
NOTE: Clean the hub face surface before checking
runout. This provides a clean surface to get an
accurate indicator reading.Mount Dial Indicator, Special Tool C-3339, and
Mounting Adaptor, Special Tool SP-1910, to the steer-
ing knuckle. Position the indicator stem so it contacts
the hub face near the outer diameter. Care must be
taken to position stem outside of the stud circle, but
inside of the chamfer on the hub rim (Fig. 97).
Hub runout should not exceed 0.03 mm (0.0012
inch). If runout exceeds this specification, the hub
must be replaced. (Refer to 2 - SUSPENSION/
FRONT/HUB / BEARING - REMOVAL)(Refer to 2 -
SUSPENSION/REAR/HUB / BEARING - REMOVAL)
Fig. 94 Checking Rotor For Thickness
1 - CALIPER
Fig. 95 Checking Rotor Runout
1 - SPECIAL TOOL SP-1910
2 - 10 MILLIMETERS FROM EDGE
3 - DISC SURFACE
4 - SPECIAL TOOL C-3339
Fig. 96 Marking Rotor and Wheel Stud
1 - CHALK MARK
5 - 60 BRAKES - BASERS
ROTOR (Continued)
ProCarManuals.com

Minimum allowable thickness is the minimum
thickness which the brake rotor machined surface
may be cut to.
CAUTION: Do not machine the rotor if it will cause
the rotor to fall below minimum thickness.
Before installation, verify the brake rotor face and
the hub adapters are free of any chips, rust, or con-
tamination.
When mounting and using the brake lathe, strict
attention to the brake lathe manufacturer's operating
instructions is required.
Machine both sides of the brake rotor at the same
time. Cutting both sides at the same time minimizes
the possibility of a tapered or uneven cut.
When refacing a rotor, the required TIR (Total
Indicator Reading) and thickness variation limits
MUST BE MAINTAINED. Extreme care in the oper-
ation of rotor turning equipment is required. Specifi-
cations for brake rotor machining can be found in
this section's specification table. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTOR -
SPECIFICATIONS)
REMOVAL - FRONT BRAKE ROTOR
(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in Lubrication
and Maintenance.
(2) Remove the front wheel and tire assembly.
(3) Remove the two mounting bolts securing the
disc brake caliper adapter with brake caliper to the
steering knuckle (Fig. 102).
(4) Remove the disc brake caliper and adapter as
an assembly from the steering knuckle (Fig. 102).
Hang the assembly out of the way using wire or a
bungee cord. Use care not to overextend the brake
hose when doing this.
(5) Remove any retainer clips from the wheel
mounting studs.
(6) Remove brake rotor from hub by pulling it
straight off wheel mounting studs (Fig. 102).
INSTALLATION - FRONT BRAKE ROTOR
(1) Install the brake rotor back on the hub and
bearing (Fig. 102).
(2) Install brake caliper and adapter back over
brake rotor aligning adapter with mounting holes on
steering knuckle (Fig. 102).
(3) Install the two adapter mounting bolts securing
the adapter to the steering knuckle. Tighten the
mounting bolts to 169 N´m (125 ft. lbs.) torque.
(4) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting lug nuts in proper
sequence until all nuts are torqued to half specifica-
Fig. 100 Front Brake Rotor
1 - ROTOR MINIMUM THICKNESS MARKING
2 - ROTOR
Fig. 101 Rear Brake Rotor Minimum Thickness
Markings
1 - ROTOR MINIMUM THICKNESS AND DRUM MAXIMUM
DIAMETER SPECIFICATIONS ARE SHOWN ON THIS SURFACE
2 - REAR ROTOR
Fig. 102 Front Brake Mounting
1 - BRAKE ROTOR
2 - HUB AND BEARING
3 - STEERING KNUCKLE
4 - ADAPTER MOUNTING BOLTS
5 - BRAKE CALIPER
6 - ADAPTER
7 - CLIP
5 - 62 BRAKES - BASERS
ROTOR (Continued)
ProCarManuals.com