2003 CHRYSLER CARAVAN Service Manual

Page 1513 of 2177

CHRYSLER CARAVAN 2003  Service Manual (11) Remove side gear thrust washer (Fig. 110).
ASSEMBLY
(1) Install side gear thrust washer (Fig. 111).(2) Install differential side gear (Fig. 112).
(3) Install four (4) pinion gears and thrust wash

Page 1514 of 2177

CHRYSLER CARAVAN 2003  Service Manual (4) Install pinion shaft retaining ring (Fig. 114).
(5) Install two (2) short pinion shafts (Fig. 115).(6) Install one (1) long pinion shaft (Fig. 116).
(7) Install differential side gear.
(8) Install

Page 1515 of 2177

CHRYSLER CARAVAN 2003  Service Manual (9) Install differential support plate. Align support
plate to differential case with alignment pins 8470
(Fig. 118).
(10) Install thrust buttons 8491 to both bearing
journals and press halves togethe

Page 1516 of 2177

CHRYSLER CARAVAN 2003  Service Manual (13) Install tapered roller bearings using installer
8473 and an arbor press (Fig. 122). Insert button
8491 on opposite journal to protect journal and/or
bearing during press operation. Repeat the sam

Page 1517 of 2177

CHRYSLER CARAVAN 2003  Service Manual DIFFERENTIAL BEARING SHIM CHART
PART NUMBERSHIM THICKNESS
METRIC (MM) STANDARD (STD)
4659242 0.50 0.0197
4659243 0.54 0.0213
4659247 0.58 0.0228
4659248 0.62 0.0244
4659249 0.66 0.0260
4659250 0.70 0.

Page 1518 of 2177

CHRYSLER CARAVAN 2003  Service Manual If end play measurement indicates a thrust washer
change is necessary, the differential must be disas-
sembled. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/MANUAL/DIFFERENTIAL - DISASSEMBLY)FLUID
STANDARD

Page 1519 of 2177

CHRYSLER CARAVAN 2003  Service Manual FLUID DRAIN
(1) Raise vehicle on hoist.
(2) Remove transaxle drain plug (Fig. 127) and
drain fluid into suitable container.
(3) Install drain plug and torque to 23 N´m (17 ft.
lbs.).
FLUID FILL
(1) R

Page 1520 of 2177

CHRYSLER CARAVAN 2003  Service Manual INSTALLATION
(1) Install gearshift boot to console and secure
with three (3) retaining clips (Fig. 130).
(2) Install gearshift knob (Fig. 129). Orient shift
pattern
1¤4-turn clockwise, press down, an