2002 CHRYSLER CARAVAN wheel bolt torque

CONDITION POSSIBLE CAUSES CORRECTION
4. Loose lower control arm mounting
bolts at front suspension
crossmember.4. Tighten control arm mounting bolts to
the specified torques.
5. Lower control arm pivot bushing
worn.5. Replace lower control arm pivot
bushing.
6. Loose strut assembly mounting
fasteners at tower or knuckle.6. Tighten strut assembly fasteners to
the specified torque.
7. Power steering fluid hose touching
the body of the vehicle.7. Adjust hose to proper position by
loosening, repositioning, and tightening
attachments to specified torque. Do not
bend tubing.
8. Internal power steering gear
noise.8. Replace power steering gear.
9. Damaged front suspension
crossmember.9. Replace front suspension
crossmember.
10. Stabilizer bar link ball joints
worn.10. Replace stabilizer bar link.
11. Lug nuts loose. 11. Tighten lug nuts to specifications.
12. Excessive Wheel bearing
free-play.12. Verify correct driveshaft hub nut
torque. Replace bearing if torque is
okay.
POPPING NOISE 1. Worn outer tie rod. 1. Check ball joint for free-play;
Replace outer tie rod.
2. Loose inner tie rod. 2. Replace power steering gear.
CHIRP OR SQUEAL
(POWER STEERING
PUMP)1. Loose power steering pump drive
belt.1. Check and adjust power steering
pump drive belt to specifications or
replace automatic tensioner where
applicable. Replace belt if worn or
glazed.
2. Malfuctioning belt auto-tensioner 2. Replace belt auto-tensioner.
WHINE, GROWL, MOAN
OR GROAN (POWER
STEERING PUMP)***1. Low fluid level. 1. Fill power steering fluid reservoir to
proper level and check for leaks (make
sure all air is bled from the system
fluid).
2. Power steering hose touching
vehicle body or frame.2. Adjust hose to proper position by
loosening, repositioning, and tightening
fitting to specified torque. Do not bend
tubing. Replace hose if damaged.
3. Extreme wear of power steering
pump internal components.3. Replace power steering pump and
flush system as necessary.
4. Extremely low ambient
temperature.4. Some noise can be expected, but will
go away as vehicle warms. Replace
pump if noise is excessive.
SUCKING AIR SOUND 1. Loose clamp on power steering
fluid return hose.1. Tighten or replace hose clamp.
2. Missing O-Ring on power steering
hose connection.2. Inspect connection and replace
O-Ring as required.
19 - 4 STEERINGRS
STEERING (Continued)
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CONDITION POSSIBLE CAUSES CORRECTION
3. Low power steering fluid level. 3. Fill power steering fluid reservoir to
proper level and check for leaks.
4. Loose clamp on fluid supply hose. 4. Tighten or replace hose clamp.
SQUEAK OR RUBBING
SOUND1. Steering column shroud rubbing. 1. Realign shrouds as necessary.
2. Steering column shaft rubbing. 2. Move or realign item rubbing shaft.
3. Clockspring noisy. 3. Remove clockspring. Reinstall wheel.
If noise is gone, replace clockspring.
4. Seal lubrication inadequate. 4. Lube seal (if external).
5. Steering gear internally noisy. 5. Replace steering gear (if no other
cause can be found).
SCRUBBING OR
KNOCKING NOISE.1. Incorrect tire or wheel size. 1. Replace incorrect size tire or wheel
with size used as original equipment.
2. Interference between steering
gear and other vehicle components.2. Check for bent or misaligned
components and correct as necessary.
3. Steering gear internal stops worn
excessively allowing tires to be
steered excessively far.3. Replace steering gear.
NOTE: * There is some noise in all power steering
systems. One of the most common is a hissing
sound evident when turning the steering wheel
when at a standstill or when parking and the steer-
ing wheel is at the end of its travel. Hiss is a very
high frequency noise similar to that experienced
while slowly closing a water tap. The noise is
present in every valve and results when high veloc-
ity fluid passes valve orifice edges. There is no
relationship between this noise and the perfor-
mance of the steering system.
NOTE: ** A light clunk may be felt or heard during
steering wheel reversal while vehicle is stationary.This results from internal steering gear rack move-
ment at the bushings and in no way affects the per-
formance of the steering system. This movement
may be felt in the steering components during
steering wheel reversal.
NOTE: *** Power steering pump growl/moan/groan
results from the development of high pressure fluid
flow. Normally this noise level should not be high
enough to be objectionable.
STEERING WHEEL FEEL
CONDITION POSSIBLE CAUSES CORRECTION
STEERING WHEEL/
COLUMN CLICKING,
CLUNKING OR RATTLING.1. Loose steering coupling pinch
bolt.1. Replace pinch bolt and torque to
specifications.
2. Steering column bearings. 2. Replace steering column.
3. Excessive intermediate shaft
coupling free-play.3. Replace intermediate shaft.
STEERING WHEEL HAS
FORE AND AFT
LOOSENESS.1. Steering wheel retaining nut not
properly tightened and torqued.1. Tighten the steering wheel retaining nut
to its specified torque.
RSSTEERING19-5
STEERING (Continued)
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CONDITION POSSIBLE CAUSES CORRECTION
11. Worn or binding seat and bearing
in front strut assembly.11. Replace seat and bearing in front strut
assembly.
STEERING WHEEL DOES
NOT RETURN TO
CENTER POSITION.1. Tires not inflated properly. 1. Inflate tires to specified pressure.
2. Improper front wheel alignment. 2. Check and adjust wheel alignment as
necessary.
3. Lack of lubrication causing binding
in front lower control arm ball joints.3. Lubricate ball joints if ball joints are not a
lubricated for life type of ball joint, then
inspect ball joint for wear, replace lower
control arm as necessary. If ball joint is a
lubricated for life ball joint, replace lower
control arm ball joint.
4. Steering column coupling joints
misaligned.4. Realign steering column coupling joints.
5. Steering wheel rubbing.** 5. Adjust steering column shrouds to
eliminate rubbing condition.
6. Damaged, mispositioned or
unlubricated steering column coupler
to dash seal.**6. Replace, reposition, or lubricate dash
seal.
7. Binding mount bearing in front
strut assembly.7. Replace mount bearing in front strut
assembly.
8. Binding shaft bearing in steering
column.8. Replace the steering column.
9. Excessive friction in steering
column coupling.9. Replace steering column coupling.
10. Excessive friction in power
steering gear.10. Replace power steering gear.
EXCESSIVE STEERING
WHEEL KICKBACK OR
TOO MUCH STEERING
WHEEL FREE PLAY.1. Air in the fluid of the power
steering system.1. Bleed air from system following the the
power steering pump initial operation
service procedure.*
2. Power steering gear loose on
cradle/crossmember.2. Inspect power steering gear mounting
bolts. Replace as necessary. Tighten to the
specified torque.
3. Steering column coupling or
intermediate shaft worn, broken or
loose.3. Replace steering column coupling or
intermediate shaft.
4. Free play in steering column. 4. Check all components of the steering
column and repair or replace as required.
5. Worn lower control arm ball joints. 5. Replace lower control arm ball joints as
required.
6. Loose steering knuckle-to-ball joint
stud pinch bolt.6. Inspect pinch bolt, replace as necessary,
and tighten to specified torque.
7. Front wheel bearing loose or
worn.7. Replace hub and bearing as necessary.
8. Loose outer tie rod end. 8. Replace outer tie rod end that has
excessive free play.
RSSTEERING19-7
STEERING (Continued)
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(5) Install the mounting plate with the multi-func-
tion switch.
(6) Install the clockspring (Refer to 8 - ELECTRI-
CAL/RESTRAINTS/CLOCKSPRING - INSTALLA-
TION).
(7) Install the steering column to the vehicle.
(8) Install the two upper mounting nuts
(9) Tighten the two lower mounting nuts and the
two upper mounting nuts. Tighten to 12 N´m (105 in.
lbs.).
(10) Install the coupling onto the intermediate
shaft and install the pinch bolt. Tighten the pinch
bolt to 28 N´m (250 in. lbs.).
(11) Install the cable from the bracket on the col-
umn, then install the pinch side clips.
(12) Reconnect the shift cable at the lever.
(13) Reconnect the wiring harness connectors to
the clockspring, multi-function switch, halo lamp,
SKIM module, ignition switch and BTSI solenoid.
(14) Install the steering wheel (Refer to 19 -
STEERING/COLUMN/STEERING WHEEL -
INSTALLATION).
(15) Install the vibration damper weight.
(16) Install the steering wheel retaining nut.
Tighten the nut to 61 N´m (45 ft. lbs.)
(17) Install the airbag (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - INSTALLATION).
(18) Install the knee blocker reinforcement (Refer
to 23 - BODY/INSTRUMENT PANEL/KNEE
BLOCKER - INSTALLATION).(19) Install the parking brake handle link.
(20) Install the knee blocker (Refer to 23 - BODY/
INSTRUMENT PANEL/STEERING COLUMN
OPENING COVER - INSTALLATION).
(21) Install the cluster trim bezel (Refer to 23 -
BODY/INSTRUMENT PANEL/CLUSTER BEZEL -
INSTALLATION).
(22) Install the upper shroud (Refer to 19 -
STEERING/COLUMN/LOWER SHROUD - INSTAL-
LATION).
(23) Install the traction off switch.
(24) Install the lower shroud.
SPECIFICATIONS
COLUMN TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Steering Wheel Retaining
Nut61 45 Ð
Steering Column Mounting
Bracket Attaching Nuts12 Ð 105
Steering Column Coupling
Pinch Bolt28 Ð 250
Steering Column Airbag
Module Attaching Nuts11 Ð 100
19 - 14 COLUMNRS
COLUMN (Continued)
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INSTALLATION
CAUTION: Do not force steering wheel onto steer-
ing column shaft by driving it on. Pull steering
wheel down onto shaft using only the steering
wheel retaining nut.
(1) Align master splines on steering wheel and
steering shaft, and flats on steering wheel with for-
mations on clockspring. Install the steering wheel on
the steering column shaft. All wiring leads from the
clockspring must be routed as shown (Fig. 41).NOTE: Before installing the damper on the steering
wheel, inspect the damper to ensure the rubber iso-
lator on the damper is not deteriorated or damaged.
If the damper is installed with a damaged isolator a
buzz, squeak or rattle condition may develop.
(2) Install the steering wheel damper on the steer-
ing wheel. When damper is installed, it must be posi-
tioned on the steering wheel as shown in (Fig. 39).
(3) Install the steering wheel retaining nut.
Tighten the steering wheel retaining nut to a torque
of 61 N´m (45 ft. lbs.).
(4) Connect the wiring lead from the clockspring to
the remote radio control connector (Fig. 38).
(5) Install the wiring leads from the clockspring on
the airbag, horn switch wire, and speed control
switches (Fig. 37). Attach the wire routing clip to the
studs on the airbag module.
(6) Install the airbag module in the steering wheel.
(7) Install the 3 bolts (1 in each spoke of the steer-
ing wheel) attaching the airbag module to the steer-
ing wheel. Tighten the 3 airbag module attaching
nuts to a torque of 11 N´m (100 in. lbs.).
Fig. 41 Steering Wheel And Clock Spring Wire
Routing
1 - STEERING WHEEL
2 - CLOCK SPRING
3 - CLOCK SPRING WIRING LEADS
RSCOLUMN19-25
STEERING WHEEL (Continued)
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INSTALLATION
INSTALLATION - LHD GEAR
(1) Install the power steering gear up in the front
suspension cradle, leaving room to install intermedi-
ate 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.
CAUTION: Proper torque on the steering gear to
suspension cradle mounting bolts is very impor-
tant.
(4) Install steering gear on the front suspension
cradle. Install the 3 steering gear mounting bolts and
nuts (Fig. 8). Tighten the 3 mounting bolts to the fol-
lowing torque values:
²14 mm bolt ± 183 N´m (135 ft. lbs.) torque
²12 mm bolt ± 95 N´m (70 ft. lbs.) torque
(5) Attach the power steering fluid pressure and
return hoses to the correct ports on the power steer-
ing gear (Fig. 7). Tighten the hose tube nuts at the
gear to a torque of 31 N´m (275 in. lbs.).
(6) If the vehicle is equipped with All-Wheel-Drive,
install the power transfer unit (Refer to 21 - TRANS-MISSION/TRANSAXLE/POWER TRANSFER UNIT -
INSTALLATION).
CAUTION: Proper torque on the cradle reinforce-
ment to suspension cradle mounting bolts is very
important.
(7) 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
153 N´m (113 ft. lbs.). Tighten the M-12 size bolts to
a torque of 106 N´m (78 ft. lbs.).
(8) Install the lower control arm rear bushing
retainer bolts (M-10 size) through reinforcement on
each side of each lower control arm rear bushing.
Tighten bolts to a torque of 61 N´m (45 ft. lbs.).
(9) 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.).
(10) Install outer tie rod end into steering knuckle.
Start outer tie rod 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.).
(11) Install leak detection pump on cradle cross-
member reinforcement. (Refer to 25 - EMISSIONS
CONTROL/EVAPORATIVE EMISSIONS/LEAK
DETECTION PUMP - INSTALLATION)
Fig. 12 Installing Roll Pin In Intermediate Coupler
1 - INTERMEDIATE SHAFT COUPLER
2 - SUSPENSION CRADLE CROSSMEMBER
3 - KNURLED NUT
4 - ROLL PIN
5 - POWER STEERING GEAR
Fig. 13 Torquing Tie Rod End Attaching Nut
1 - STEERING KNUCKLE
2 - TIE ROD END
3 - CROWFOOT
4 - SOCKET
5 - TORQUE WRENCH
19 - 32 GEARRS
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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(17) Lower the vehicle to a level were the interior
of vehicle is accessible (keeping tires off the ground).
(18) 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.).
(19) Remove the steering wheel holding tool.
(20) Perform the POWER STEERING PUMP INI-
TIAL OPERATION procedure to properly fill and
bleed the power steering system. (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE)
(21) Inspect for leaks.
(22) Adjust front wheel toe (Refer to 2 - SUSPEN-
SION/WHEEL ALIGNMENT - STANDARD PROCE-
DURE).
SPECIAL TOOLS
POWER STEERING GEAR
OUTER TIE ROD
REMOVAL
(1) Loosen inner tie rod to outer tie rod jam nut
(Fig. 14).
(2) Remove nut attaching outer tie rod end to
steering knuckle (Fig. 15). The nut is to be removed
from tie rod end by holding tie rod end stud with a
11/32 socket while loosening and removing nut with a
wrench.
(3) Remove the tie rod end stud from steering
knuckle arm, using Remover, Special Tool C-3894±A
(Fig. 16).
(4) Remove outer tie rod end by un-threading it
from the inner tie rod.
INSTALLATION
NOTE: Before installing the outer tie rod, make sure
the jam nut is on inner tie rod (Fig. 14).
Puller C-3894A
Remover/Installer Steering Shaft Roll Pin 6831A
Fig. 14 Inner To Outer Tie Rod Jam Nut
1 - INNER TIE ROD SERRATION
2 - OUTER TIE ROD JAM NUT
3 - OUTER TIE ROD END
4 - INNER TIE ROD
5 - STEERING KNUCKLE
19 - 34 GEARRS
GEAR (Continued)
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