2003 CHRYSLER CARAVAN torque

CONDITION POSSIBLE CAUSES CORRECTION
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.
9. Loose inner tie rod. 9. Replace power steering gear.
10. Defective steering gear rotary
valve.10. Replace power steering gear.
RSSTEERING19-7
STEERING (Continued)
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NOTE: * Steering shudder can be expected in new
vehicles and vehicles with recent steering system
repairs. Shudder should dissipate after the vehicle
has been driven several weeks.
NOTE: ** To evaluate this condition, it may be nec-
essary to disconnect the coupling at the base of the
steering column. Turn the steering wheel and feel or
listen for internal rubbing in steering column. To
avoid damaging the column clockspring, note the
following. Before disconnecting coupling, place
tires in the straight-ahead position and center steer-
ing wheel. Once disconnected, DO NOT rotate
steering wheel more than one revolution in eitherdirection and place steering wheel in original loca-
tion before reconnecting coupling. If this position is
lost, the steering column clockspring must be
recentered following the procedure found within the
procedure for steering column installation in the
steering column section.
NOTE: *** Increased low speed or stationary steer-
ing effort can be expected if the steering fluid is at
a high temperature. High fluid temperature usually
results from high engine rpm due to trailer towing,
ascending grades, or racing the engine for pro-
longed periods of time.
POWER STEERING FLUID
CONDITION POSSIBLE CAUSES CORRECTION
LOW FLUID LEVEL WITH
VISIBLE LEAK.1. Loose power steering hose
fittings.1. Tighten the fitting to its specified torque.
2. Damaged or missing fitting seal,
gasket, or O-ring.2. Replace as necessary.
3. Power steering component
leaking.3. Repair or replace the leaking component
as required.
AERATED FLUID.* 1. Low fluid level. 1. Fill power steering fluid reservoir to
proper level.
2. Air leak at supply hose, power
steering fluid reservoir or pump.2. Inspect for proper sealing. Repair as
necessary.
3. Cracked power steering pump
housing.3. Replace the power steering pump.
RESERVOIR FLUID
OVERFLOW AND FLUID
THAT IS MILKY IN COLOR1. Water contamination of power
steering fluid.1. Drain the power steering fluid from the
system. Flush the system with fresh clean
power steering fluid, drain, then refill to the
proper level.
NOTE: * Extremely cold temperatures may cause
power steering fluid aeration. Aeration should sub-
side as fluid warms.
19 - 8 STEERINGRS
STEERING (Continued)
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SPECIFICATIONS
POWER STEERING FASTENER TORQUE
DESCRIPTION TORQUE
Power Steering Pump:
Flow Control Valve
Pressure Fitting75 N´m (55 ft. lbs.)
Mounting Bolts 54 N´m (40 ft. lbs.)
Rear Bracket To Engine
Mounting Bolts54 N´m (40 ft. lbs.)
Steering Gear:
Mounting Bolt - Size-M14 183 N´m (135 ft. lbs.)
Mounting Bolts -
Size-M1295 N´m (70 ft. lbs.)
Tie Rod Steering Knuckle
Nut75 N´m (55 ft. lbs.)
Tie Rod Jam Nut 75 N´m (55 ft. lbs.)
Coupling Pinch Bolt 28 N´m (250 in. lbs.)
Power Steering Fluid
Hoses:
Hose Tube Nuts 31 N´m (275 in. lbs.)
Routing Bracket Bolts 23 N´m (200 in. lbs.)
SPECIAL TOOLS
POWER STEERING
Power Steering Analyzer 6815
Adapters, Power Steering Analyzer 6893
HOSE, POWER STEERING ANALYZER 6959
RSSTEERING19-9
STEERING (Continued)
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COLUMN
TABLE OF CONTENTS
page page
COLUMN
DESCRIPTION - STEERING COLUMN.......10
WARNING
WARNINGS AND CAUTIONS.............10
DIAGNOSIS AND TESTING - STEERING
COLUMN............................12
REMOVAL.............................12
INSTALLATION.........................13
SPECIFICATIONS
COLUMN TORQUE....................14
IGNITION SWITCH
REMOVAL.............................14
INSTALLATION.........................16
LOCK CYLINDER HOUSING
DESCRIPTION - IGNITION INTERLOCK......17
REMOVAL.............................17
INSTALLATION.........................19KEY/LOCK CYLINDER
DESCRIPTION.........................20
OPERATION...........................20
REMOVAL.............................20
INSTALLATION.........................20
GEAR SHIFT LEVER
REMOVAL.............................21
INSTALLATION.........................21
SHROUD - LOWER
REMOVAL.............................21
INSTALLATION.........................22
SHROUD - UPPER
REMOVAL.............................23
INSTALLATION.........................23
STEERING WHEEL
REMOVAL.............................23
INSTALLATION.........................24
COLUMN
DESCRIPTION - STEERING COLUMN
The steering column has been designed to be ser-
viced as a complete assembly (Fig. 1), except for the
components listed here. They are the key cylinder,
ignition switch, lock cylinder housing, multi-function
switch, clockspring, halo lamp, speed control
switches, driver airbag, trim shrouds, steering wheel
and steering column intermediate shaft (Fig. 2).
These replaceable components of the steering column
can be serviced without requiring removal of the
steering column from the vehicle.
WARNING
WARNINGS AND CAUTIONS
(Refer to 8 - ELECTRICAL/RESTRAINTS - WARN-
ING)
WARNING: BEFORE BEGINNING ANY SERVICE
PROCEDURES THAT INVOLVES REMOVING THE
AIR BAG. REMOVE AND ISOLATE THE NEGATIVE
(-) BATTERY CABLE (GROUND) FROM THE VEHI-
CLE BATTERY. THIS IS THE ONLY SURE WAY TO
DISABLE THE AIR BAG SYSTEM. FAILURE TO DO
THIS COULD RESULT IN ACCIDENTAL AIR BAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
Fig. 1 Steering Column
1 - STEERING COLUMN
2 - B.T.S.I.
3 - TILT RELEASE LEVER
4 - KEY CYLINDER
5 - SHIFT LEVER
6 - MOUNTING HOLES
7 - COUPLING
19 - 10 COLUMNRS
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(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.
Driver Airbag Attaching Bolts 10 Ð 90
Steering Column Coupling
Pinch Bolt28 Ð 250
Steering Column Mounting
Nuts12 Ð 105
Steering Wheel Retaining
Nut61 45 Ð
IGNITION SWITCH
REMOVAL
The ignition switch attaches to the lock cylinder
housing on the end opposite the lock cylinder (Fig. 7).
For ignition switch terminal and circuit identifica-
tion, refer to the appropriate wiring information. The
wiring information includes wiring diagrams, proper
wire and connector repair procedures, further details
on wire harness routing and retention, as well as
pin-out and location views for the various wire har-
ness connectors, splices and grounds.
(1) Disconnect negative cable from battery.
(2) Remove steering column cover retaining screws
(Fig. 8).
Fig. 7 Ignition SwitchÐViewed From Below Column
1 - IGNITION SWITCH
2 - LOCK CYLINDER HOUSING
3 - RETAINING TABS
Fig. 8 Steering Column Cover
1 - SCREWS
2 - STEERING COLUMN COVER
19 - 14 COLUMNRS
COLUMN (Continued)
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INSTALLATION
(1) Install the lock cylinder housing in the bottom
of the steering column lining up the mounting holes.
(2) Install the self-tapping lock cylinder housing
mounting screws through the top of the column into
the housing (Fig. 26). Tighten the two mounting
screws to a torque of 11 N´m (100 in. lbs.).
(3) Connect both tilt mechanism springs back onto
their mounting posts making sure the spring hooks
engage the grooves in the posts (Fig. 25).
(4) Ensure that the ignition switch and the actua-
tor shaft in the lock cylinder housing are in the ON
position.
(5) Carefully install the ignition switch over the
actuator shaft (Fig. 27). The switch will snap over
the retaining tabs on the housing.(6) Install the ignition switch mounting screw (Fig.
23).
(7) Install the key cylinder halo lamp on the lock
cylinder housing.
(8) Install the vehicle wiring harness connector
onto the key cylinder halo lamp (Fig. 22).
(9) Install the key cylinder (with key in it turned
to the ON position) by sliding it straight into the lock
cylinder housing aligning the retaining tab on the
key cylinder with the hole in the lock cylinder hous-
ing.
(10) Turn the key to the OFF position and remove
the key.
(11) Connect the shifter/ignition interlock link to
the lever on the lock cylinder housing by aligning the
Fig. 24 Ignition Switch Retaining Tabs
1 - IGNITION SWITCH
2 - LOCK CYLINDER HOUSING
3 - RETAINING TABS
Fig. 25 Tilt Mechanism Spring Removal/Installation
1 - SPRINGS
2 - POST
3 - GROOVE
Fig. 26 Lock Cylinder Housing Mounting Screw
Location
1 - SPRINGS
2 - MOUNTING SCREWS
Fig. 27 Ignition Switch Installation
1 - IGNITION SWITCH
2 - ACTUATOR SHAFT
3 - RETAINING TABS
RSCOLUMN19-19
LOCK CYLINDER HOUSING (Continued)
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(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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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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