2003 CHRYSLER CARAVAN Service Manual

refrigerant type height run flat maintenance reset trailer spare tire

Page 1417 of 2177

CHRYSLER CARAVAN 2003 Service Manual (3) Unsnap the upper shroud from the lower on
the right side as follows:
(a) Hook a finger on the right hand around the
rear of the shrouds at the seam (Fig. 34), near the
snap points.
(b) Grasp the u

(3) Unsnap the upper shroud from the lower on
the right side as follows:
(a) Hook a finger on the right hand around the
rear of the shrouds at the seam (Fig. 34), near the
snap points.
(b) Grasp the upper shroud at the rear using the
left hand (Fig. 34).
(c) As the right hand's hooked finger is pulled
outward against the seam, pull the upper shroud
upward using the left hand, disconnecting the
shroud snaps.
(4) Lift the upper shroud straight up off the steer-
ing column. If vehicle is equipped with traction con-
trol, disconnect wiring connector at traction control
switch pig tail. Remove upper shroud.(5) Remove the lower shroud-to-column mounting
screw (Fig. 32).
(6) Remove the lower shroud from the steering col-
umn.
(7) If the vehicle is equipped with adjustable ped-
als:
(a) Disconnect wiring connector at adjustable
pedals switch.
(b) Depress retaining tabs on top and bottom of
switch and remove switch from lower shroud.
INSTALLATION
(1) If the vehicle is equipped with adjustable ped-
als:
(a) Install the switch into the lower shroud,
snapping it into place.
(b) Connect wiring harness to connector at
adjustable pedals switch.
(2) Position the lower shroud under the steering
column and install the lower shroud-to-column
mounting screw (Fig. 32). Tighten the screw to 2 N´m
(17 in. lbs.) torque.
(3) Place the upper shroud over the lower, aligning
the snap clips and alignment tabs. If the vehicle is
equipped with traction control, connect the wiring
connector at the traction control switch pig tail
before lining the shrouds up to one another.
(4) Snap the upper shroud to the lower shroud.
Once snapped into place, verify there are no gaps
between the two mating surfaces of the shrouds.
(5) Install the two shroud-to-shroud mounting
screws (Fig. 32). Tighten the screws to 2 N´m (17 in.
lbs.) torque.
(6) Ensure that the shrouds are snug and fit is
acceptable.
Fig. 32 Shroud Mounting Screw Location
1 - LOWER SHROUD
2 - LOWER SHROUD-TO-COLUMN SCREW
3 - SHROUD-TO-SHROUD SCREWS
Fig. 33 Hands Positioned To Release Left Side
1 - UPPER SHROUD
2 - LOWER SHROUD
3 - TILT LEVER
Fig. 34 Hands Positioned To Release Right Side
1 - LOWER SHROUD
2 - UPPER SHROUD
3 - SHIFT LEVER
4 - ADJUSTABLE PEDALS SWITCH (IF EQUIPPED)
19 - 22 COLUMNRS
SHROUD - LOWER (Continued)
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Page 1418 of 2177

CHRYSLER CARAVAN 2003 Service Manual SHROUD - UPPER
REMOVAL
(1) Remove the two shroud-to-shroud mounting
screws from the lower shroud (Fig. 32).
(2) Unsnap the upper shroud from the lower on
the left side as follows:
(a) Hook a finger on

SHROUD - UPPER
REMOVAL
(1) Remove the two shroud-to-shroud mounting
screws from the lower shroud (Fig. 32).
(2) Unsnap the upper shroud from the lower on
the left side as follows:
(a) Hook a finger on the left hand around the
rear of the shrouds at the seam (Fig. 33), near the
snap points.
(b) Grasp the upper shroud at the rear using the
right hand (Fig. 33).
(c) As the left hand's hooked finger is pulled out-
ward against the seam, pull the upper shroud
upward using the right hand, disconnecting the
shroud snaps.
(3) Unsnap the upper shroud from the lower on
the right side as follows:
(a) Hook a finger on the right hand around the
rear of the shrouds at the seam (Fig. 34), near the
snap points.
(b) Grasp the upper shroud at the rear using the
left hand (Fig. 34).
(c) As the right hand's hooked finger is pulled
outward against the seam, pull the upper shroud
upward using the left hand, disconnecting the
shroud snaps.
(4) Lift the upper shroud straight up off the steer-
ing column. If vehicle is equipped with traction con-
trol, disconnect wiring connector at traction control
switch pig tail. If vehicle is equipped with power fold-
away mirrors (Export), disconnect wiring connector
at mirror switch pig tail. Remove upper shroud.
(5) If vehicle is equipped with traction control,
remove traction control switch from shroud.
(6) If vehicle is equipped with power foldaway mir-
rors (Export), remove power fold-away switch from
upper shroud.
INSTALLATION
(1) If the vehicle is equipped with power foldaway
mirrors (Export), install the power fold-away switch
in the upper shroud.
(2) If vehicle is equipped with traction control,
install the traction control switch in the upper
shroud.
(3) Place the upper shroud over the lower shroud,
aligning the snap clips and alignment tabs. If the
vehicle is equipped with traction control, connect the
wiring connector at the traction control switch pig
tail before lining the shrouds up to one another.
(4) Snap the upper shroud to the lower shroud.
Once snapped into place, verify there are no gaps
between the two mating surfaces of the shrouds.(5) Install the two shroud-to-shroud mounting
screws (Fig. 32). Tighten the screws to 2 N´m (17 in.
lbs.) torque.
(6) Ensure that the shrouds are snug and fit is
acceptable.
STEERING WHEEL
REMOVAL
NOTE: Before proceeding, (Refer to 19 - STEERING/
COLUMN - WARNING)(Refer to 8 - ELECTRICAL/RE-
STRAINTS - WARNING).
(1) Adjust the steering wheel so that the tires are
in thestraight-aheadposition.
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the two bolts from the rear of the
steering wheel attaching the driver airbag. Lift the
airbag from the steering wheel.
(4) Disconnect airbag squib wiring connectors from
the airbag and the horn/speed control switch pigtail
connector from the clockspring (Fig. 35). If the steer-
ing wheel is equipped with remote radio controls, dis-
connect the connector from the clockspring (Fig. 36).
Properly store the driver airbag out of the way.
(Refer to 8 - ELECTRICAL/RESTRAINTS - WARN-
ING)
(5) Remove the steering wheel retaining nut from
the steering column shaft (Fig. 36).
(6) Remove the steering wheel damper from the
steering wheel (Fig. 36).
Fig. 35 Airbag Wiring Connections
1 - AIRBAG FEED SQUIB CONNECTORS
2 - DRIVER AIRBAG
3 - HORN/SPEED CONTROL CONNECTOR
4 - CLOCKSPRING
RSCOLUMN19-23
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Page 1419 of 2177

CHRYSLER CARAVAN 2003 Service Manual CAUTION: Do not bump or hammer on steering col-
umn or steering column shaft when removing steer-
ing wheel from steering column shaft.
CAUTION: When installing steering wheel puller
bolts in steering

Page 1420 of 2177

CHRYSLER CARAVAN 2003 Service Manual steering wheel onto the steering column shaft by
hand. Use care not to pinch any wiring.
NOTE: Before installing the damper on the steering
wheel, inspect the damper to ensure the rubber iso-
lator on

Page 1421 of 2177

CHRYSLER CARAVAN 2003 Service Manual GEAR
TABLE OF CONTENTS
page page
GEAR
DESCRIPTION.........................26
OPERATION...........................27
WARNING
WARNINGS AND CAUTIONS.............27
REMOVAL
REMOVAL - LHD GEAR.............

Page 1422 of 2177

CHRYSLER CARAVAN 2003 Service Manual OPERATION
Turning of the steering wheel is converted into lin-
ear (side-to-side) travel through the meshing of the
helical pinion teeth with the rack teeth in the steer-
ing gear. This travel pushes

OPERATION
Turning of the steering wheel is converted into lin-
ear (side-to-side) travel through the meshing of the
helical pinion teeth with the rack teeth in the steer-
ing gear. This travel pushes and pulls the tie rods to
change the direction of the vehicle's front wheels.
Power assist steering provided by the power steer-
ing pump is controlled by an open center, rotary type
control valve which directs oil from the pump to
either side of the integral rack piston upon demand.
Road feel is controlled by the diameter of a torsion
bar which initially steers the vehicle. As required
steering effort increases, as in a turn, the torsion bar
twists, causing relative rotary motion between the
rotary valve body and the valve spool. This move-
ment directs oil behind the integral rack piston
which, in turn, builds hydraulic pressure and assists
in the turning effort.
Manual steering control of the vehicle can be main-
tained if power steering assist is lost. However,
under this condition, steering effort is significantly
increased.
WARNING
WARNINGS AND CAUTIONS
WARNING: POWER STEERING FLUID, ENGINE
PARTS AND EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH THE ENGINE OFF TO PREVENT PERSONAL
INJURY FROM MOVING PARTS.
CAUTION: When the system is open, cap all open
ends of the hoses, power steering pump fittings or
power steering gear ports to prevent entry of for-
eign material into the components.
REMOVAL
REMOVAL - LHD GEAR
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much fluid as
possible from the power steering fluid reservoir.Use
care not to damage the filter mesh below the
fluid surface.
CAUTION: Locking the steering column in the
straight-ahead position will prevent the clockspring
from being accidentally over-extended when the
steering column is disconnected from the interme-
diate steering coupler.
(3) Position the steering wheel in the STRAIGHT-
AHEAD position. Lock the steering wheel in place
using a steering wheel holding tool.
(4) With the vehicle on the ground, disconnect the
steering column shaft coupler from the steering gear
intermediate coupler (Fig. 2).
Fig. 2 Steering Column Shaft To Intermediate Shaft
Attachment
1 - STEERING COLUMN SHAFT COUPLER
2 - NUT
3 - SAFETY PIN
4 - INTERMEDIATE SHAFT
5 - PINCH BOLT
RSGEAR19-27
GEAR (Continued)
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Page 1423 of 2177

CHRYSLER CARAVAN 2003 Service Manual (5) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(6) Remove front wheel and tire assemblies.
(7) Remove front emissions vapor canister. (Refer
to 25 - EMISSIONS

Page 1424 of 2177

CHRYSLER CARAVAN 2003 Service Manual (14) Remove the bolts attaching the cradle cross-
member reinforcement to the front suspension cradle
crossmember (Fig. 6). Remove the 2 bolts fastening
the reinforcement and rear of cradle crossmembe

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