2003 CHRYSLER CARAVAN Service Manual

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Page 1497 of 2177

CHRYSLER CARAVAN 2003 Service Manual (32) If previously removed, install clutch release lever pivot ball(s) using slide hammer C-3752 and remover/installer 6891 (Fig. 74) (Fig. 75). (33) Install clutch release bearing to lever. Apply gre

Page 1498 of 2177

CHRYSLER CARAVAN 2003 Service Manual INSTALLATION INSTALLATION - 2.4L GAS (1) Install modular clutch assembly to transaxle. Assemble transaxle to engine. (2) Install and torque transaxle-to-engine bolts to 95 N´m (70 ft. lbs.). (3) Rais

Page 1499 of 2177

CHRYSLER CARAVAN 2003 Service Manual (13) Install right mount bracket to transaxle (Fig. 80). (14) Connect gearshift cables to shift levers/cover assembly (Fig. 81). Install cables into position at mount bracket and secure with retaining

Page 1500 of 2177

CHRYSLER CARAVAN 2003 Service Manual Fig. 82 Transaxle Removal/Installation 1 - TRANSAXLE 2 - BOLT Fig. 83 Transaxle Upper Mount 1 - MOUNT 2 - BOLT (4) Fig. 84 Starter Motor Removal/Installation 1 - STARTER MOTOR 2 - BOLT (3) RST850 MANU

Page 1501 of 2177

CHRYSLER CARAVAN 2003 Service Manual (8) Install engine front mount bracket. Install and torque bracket-to-transaxle bolts to 102 N´m (75 ft. lbs.). Install and torque bracket-to-engine bolts to 68 N´m (50 ft. lbs.). Torque through-bol

Page 1502 of 2177

CHRYSLER CARAVAN 2003 Service Manual (15) Install coolant recovery bottle bracket (Fig. 88). (16) Install coolant recovery bottle to bracket. (17) Connect battery temperature sensor and install battery tray (Fig. 89).(18) Install battery

Page 1503 of 2177

CHRYSLER CARAVAN 2003 Service Manual SPECIFICATIONS - T850 MANUAL TRANSAXLE GENERAL SPECIFICATIONS DESCRIPTION SPECIFICATION Transaxle TypeConstant-mesh, fully synchronized 5-speed with integral differential Lubrication MethodSplash oil

Page 1504 of 2177

CHRYSLER CARAVAN 2003 Service Manual INTERMEDIATE SHAFT BLOCKER RING WEAR GAP 1st Gear 0.66-1.84 mm (0.026-0.072 in.) 2nd Gear 0.66-1.84 mm (0.026-0.072 in.) 5th Gear 0.86-1.54 mm (0.034-0.061 in.) Reverse 0.77-1.63 mm (0.030-0.064 in.)
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