2005 CHRYSLER CARAVAN steering wheel

CONDITION POSSIBLE CAUSES CORRECTION
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.
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.
RSSTEERING19-5
STEERING (Continued)

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.
2. Steering column lower bearing
spring retainer slipped on steering
column shaft.2. Replace steering column.
3. Loose steering column to
instrument panel fasteners.3. Tighten fasteners to specified torque.
STEERING WHEEL, DASH
OR VEHICLE VIBRATES
DURING LOW SPEED OR
STANDSTILL STEERING
MANEUVERS.1. Air in the fluid of the power
steering system.1. Bleed air from system following the
power steering pump initial operation
service procedure.*
2. Tires not properly inflated. 2. Inflate tires to the specified pressure.
3. Excessive engine vibration. 3. Ensure that the engine is tuned properly.
4. Loose tie rod end jam nut. 4. Tighten the inner to outer tie rod jam nut
to the specified torque.
5.Overcharged air conditioning
system.5.Check air conditioning pump head
pressure and correct as necessary.
6. Grounded engine mount. 6. Repair as necessary.
7. Loose outer tie rod. 7. Replace outer tie rod.
STEERING CATCHES,
SURGES OR STICKS IN
CERTAIN POSITIONS OR
IS DIFFICULT TO TURN. ***1. Low power steering fluid level. 1. Fill power steering fluid reservoir to
specified level and check for leaks.
2. Tires not inflated to specified
pressure.2. Inflate tires to the specified pressure.
3. Lack of lubrication in front lower
control arm ball joints.3. Lubricate ball joints if ball joints are not a
lubricated-for-life type ball joint. If ball joint
is a lubricated-for-life ball joint, replace ball
joint.
4. Worn or binding lower control arm
ball joint.4. Replace lower control arm ball joint.
5. Lack of lubrication in steering gear
outer tie rod ends.5. Lubricate tie rod ends if they are not a
lubricated-for-life type. If tie rod end is a
lubricated-for-life type, replace tie rod end.
19 - 6 STEERINGRS
STEERING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
6. Loose power steering pump drive
belt.6. Tighten the power steering pump drive
belt to specifications or replace automatic
tensioner where applicable. If drive belt is
worn or glazed, replace belt.
7. Faulty power steering pump
(Perform Power Steering Flow and
Pressure Test).7. Replace power steering pump.
8. Faulty power steering gear
(Perform Power Steering Flow and
Pressure Test).8. Replace power steering gear.
9. Excessive friction in steering
column or intermediate shaft/coupler.9. Isolate and correct condition.
10. Excessive friction in power
steering gear.10. Replace power steering gear.
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.
RSSTEERING19-7
STEERING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
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.
* 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 rotatesteering wheel more than one revolution in either
direction 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.
19 - 8 STEERINGRS
STEERING (Continued)

COLUMN
TABLE OF CONTENTS
page page
COLUMN
DESCRIPTION - STEERING COLUMN.......10
WARNING
WARNINGS AND CAUTIONS.............10
DIAGNOSIS AND TESTING - STEERING
COLUMN............................11
REMOVAL.............................11
INSTALLATION.........................16
SPECIFICATIONS
COLUMN FASTENER TORQUE...........17
IGNITION SWITCH
REMOVAL.............................17
INSTALLATION.........................19
KEY/LOCK CYLINDER
DESCRIPTION.........................20OPERATION...........................20
REMOVAL.............................20
INSTALLATION.........................20
SHROUD - LOWER
REMOVAL.............................21
INSTALLATION.........................21
SHROUD - UPPER
REMOVAL.............................22
INSTALLATION.........................22
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
following serviceable components:²Key cylinder
²Ignition switch
²Multi-function switch
²Clockspring
²Halo
²Speed control switches
²Driver airbag
²Trim shrouds
²Steering wheel
²Intermediate shaft
These 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 - UPPER MOUNTING NUTS
3 - LOWER MOUNTING NUTS
4 - MOUNTING STUDS
19 - 10 COLUMNRS

WARNING: THE AIR BAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIR BAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE. FAILURE TO DO SO COULD RESULT IN
ACCIDENTAL DEPLOYMENT OF THE AIR BAG AND
POSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIR BAG COMPONENTS, HAVE SPECIAL
COATINGS AND ARE SPECIFICALLY DESIGNED
FOR THE AIR BAG SYSTEM. THEY MUST NEVER
BE REPLACED WITH ANY SUBSTITUTES. ANYTIME
A NEW FASTENER IS NEEDED, REPLACE WITH
THE CORRECT FASTENERS PROVIDED IN THE
SERVICE PACKAGE OR FASTENERS LISTED IN
THE PARTS BOOKS.
WARNING: SAFETY GOGGLES SHOULD BE WORN
AT ALL TIMES WHEN WORKING ON STEERING
COLUMNS.
CAUTION: Disconnect negative (ground) cable from
the battery before servicing any column compo-
nent.
CAUTION: Do not attempt to remove the pivot pins
to disassemble the tilting mechanism. Damage will
occur.
DIAGNOSIS AND TESTING - STEERING
COLUMN
For diagnosis of conditions relating to the steering
column, (Refer to 19 - STEERING - DIAGNOSIS
AND TESTING).
REMOVAL
NOTE: Before proceeding, (Refer to 19 - STEERING/
COLUMN - WARNING)(Refer to 8 - ELECTRICAL/RE-
STRAINTS/DRIVER AIRBAG - REMOVAL).
(1) Make sure the front wheels of the vehicle are
in the STRAIGHT AHEAD position before beginning
the column removal procedure.
(2) Disconnect and isolate the negative (ground)
cable from the battery. Wait at least two minutes for
the airbag system reserve capacitor to discharge
before beginning any steering column, instrument
panel, or airbag system/component service.WARNING: WHEN AN UNDEPLOYED AIRBAG IS TO
BE REMOVED FROM THE VEHICLE, FIRST DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE. ALLOW THE AIRBAG SYSTEM
RESERVE CAPACITOR TO DISCHARGE FOR TWO
MINUTES BEFORE BEGINNING ANY AIRBAG SYS-
TEM OR COMPONENT SERVICE. PERSONAL
INJURY MAY RESULT IF THIS PROCEDURE IS NOT
FOLLOWED.
(3) Remove the driver airbag mounting screws
(Fig. 2).
(4) Lift the airbag from its mount and disconnect
two airbag squib, speed control and horn connectors
(Fig. 3). Remove driver airbag. Properly store the
driver airbag out of the way. (Refer to 8 - ELECTRI-
CAL/RESTRAINTS - WARNING)
(5) Remove the steering wheel retaining bolt (Fig.
4).
(6) Remove damper (Fig. 4).
(7) If equipped, disconnect the remote audio con-
trol switch wiring from the clockspring (Fig. 4).
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 wheel, do not thread bolt into
steering wheel more than a half inch. If the bolts
are threaded into the steering wheel more than a
half inch they will contact and damage the clock-
spring.
Fig. 2 Driver Airbag Mounting
1 - DRIVER AIRBAG
2 - MOUNTING SCREWS
RSCOLUMN19-11
COLUMN (Continued)

(8) Remove the steering wheel using a standard
wheel puller (Fig. 5).
(9) Remove the knee blocker/steering column open-
ing cover (Refer to 23 - BODY/INSTRUMENT PAN-
EL/STEERING COLUMN OPENING COVER -
REMOVAL).(10) Remove the parking brake release handle
link.
(11) Remove the knee blocker/steering column
cover plate (Refer to 23 - BODY/INSTRUMENT PAN-
EL/KNEE BLOCKER - REMOVAL).
(12) Remove the upper shroud mounting screws
(Fig. 6). Using hands on each side of the column,
gently press inward at seams between the two
shrouds at points of contact to disengage inner lock-
ing tabs, then remove upper shroud. If the vehicle is
equipped with traction control, the lower shroud will
need to be removed once the upper shroud is unfas-
tened in order to disconnect the traction control wir-
Fig. 3 Driver Airbag Wiring Connections
1 - DRIVER AIRBAG
2 - SQUIB CONNECTORS
3 - SPEED CONTROL/HORN WIRING CONNECTOR
4 - CLOCKSPRING
Fig. 4 Steering Wheel Mounting
1 - STEERING WHEEL
2 - REMOTE AUDIO CONTROL WIRING CONNECTOR (IF
EQUIPPED)
3 - RETAINING BOLT
4 - DAMPER
Fig. 5 Steering Wheel Removal
1 - STEERING WHEEL
2 - PULLER
Fig. 6 Upper Shroud Mounting
1 - UPPER SHROUD
2 - LOWER SHROUD
3 - MOUNTING SCREWS
19 - 12 COLUMNRS
COLUMN (Continued)

(31) If the steering column is being replaced, slide
the multi-function switch mounting housing off the
column (Fig. 19).
(32) If the steering column is being replaced,
remove the mounting screw fastening the SKIM to
the ignition key cylinder housing (Fig. 13). Remove
the SKIM.
(33) If the steering column is being replaced,
remove the halo from the ignition key cylinder hous-
ing (Fig. 13).
(34) If the steering column is being replaced,
remove the ignition key lock cylinder (Refer to 19 -
STEERING/COLUMN/KEY/LOCK CYLINDER -
REMOVAL).
INSTALLATION
NOTE: Before proceeding, (Refer to 19 - STEERING/
COLUMN - WARNING)(Refer to 8 - ELECTRICAL/RE-
STRAINTS/DRIVER AIRBAG - REMOVAL).
NOTE: Make sure the front wheels of the vehicle are
still in the STRAIGHT AHEAD position before begin-
ning the column installation procedure.
(1) If removed, install the ignition key lock cylin-
der (Refer to 19 - STEERING/COLUMN/KEY/LOCK
CYLINDER - INSTALLATION).
(2) If removed, install the halo on the ignition key
cylinder housing (Fig. 13).(3) If removed, install SKIM (Fig. 13). Install the
mounting screw fastening the SKIM to the ignition
key cylinder housing. Tighten the screw to 4 N´m (30
in. lbs.) torque.
(4) If removed, slide the multi-function switch
mounting housing onto the column (Fig. 19).
(5) If multi-function switch mounting housing is
being installed, install the set-screw fastening the
housing to the column (Fig. 18). Tighten the set-
screw to 14 N´m (124 in. lbs.) torque.
(6) Install the steering column (Fig. 17). Slide the
column lower mounting slots over the lower mount-
ing studs (with nuts started) first, then lift column
into place over the upper mounting studs.
(7) Install the two upper mounting nuts (Fig. 17).
Tighten the two upper mounting nuts, then the two
lower mounting nuts to 12 N´m (105 in. lbs.) torque.
(8) Match the column shaft coupling to the inter-
mediate shaft and install the pinch bolt (Fig. 16).
Tighten the pinch bolt nut to 28 N´m (250 in. lbs.)
torque. Install the hair pin in the end of the pinch
bolt.
(9) Feed the shift cable through the bracket on the
column (Fig. 15), then install the clip fastening the
cable housing to the bracket.
(10) Connect the shift cable to the lever pin (Fig.
15).
(11) Install the screw fastening the horn ground
wire to the column (Fig. 14). Tighten the screw to 7
N´m (60 in. lbs.) torque.
(12) If equipped with Sentry Key Immobilizer, con-
nect the wiring connector to the SKIM (Fig. 13).
(13) Connect the column harness wiring connectors
for the clockspring and SQUIB (Fig. 12).
(14) Connect the column harness wiring connector
for the multi-function switch (Fig. 12).
(15) Connect the column harness wiring connectors
for the Brake Transmission Shift Interlock (BTSI)
and ignition switch (Fig. 11).
(16) Install the fixed shroud (Fig. 10). Install the
screws fastening the fixed shroud in place and
tighten the screws to 3 N´m (23 in. lbs.) torque.
(17) If equipped with Autostick, connect the wiring
connector (Fig. 9).
(18) If equipped with traction control, position the
upper shroud above the column and route the switch
wiring down around the column. Connect the wiring
connector from the column wiring harness to the
traction control switch wiring (attached to upper
shroud) (Fig. 9).
Fig. 19 Multi-Function Switch Mounting Housing
1 - MULTI-FUNCTION SWITCH MOUNTING HOUSING
2 - STEERING COLUMN
19 - 16 COLUMNRS
COLUMN (Continued)