2005 CHRYSLER CARAVAN Service Manual

clock setting adding oil fuse diagram navigation update oil type air filter

Page 105 of 2339

CHRYSLER CARAVAN 2005 Service Manual (3) Install the spider assembly to interconnecting
shaft retaining snap-ring into groove on end of inter-
connecting shaft (Fig. 18). Be sure the snap-ring is
fully seated into groove on interconnecti

Page 106 of 2339

CHRYSLER CARAVAN 2005 Service Manual (9) Position sealing boot into the tripod housing
retaining groove. Install seal boot retaining clamp
evenly on sealing boot.
(10) Position trilobal boot to interface with the tri-
pod housing. The lo

(9) Position sealing boot into the tripod housing
retaining groove. Install seal boot retaining clamp
evenly on sealing boot.
(10) Position trilobal boot to interface with the tri-
pod housing. The lobes of the boot must be properly
aligned with the recess's of the tripod housing.
CAUTION: The following positioning procedure deter-
mines the correct air pressure inside the inner CV
joint assembly prior to clamping the sealing boot to
inner CV joint housing. If this procedure is not done
prior to clamping sealing boot to CV joint housing
sealing boot durability can be adversely affected.
CAUTION: When venting the inner CV joint assembly,
use care so that the inner CV sealing boot does not
get punctured, or in any other way damaged. If sealing
boot is punctured, or damaged in any way while being
vented, the sealing boot can not be used.
(11) Insert a trim stick between the CV joint hous-
ing and the sealing boot insert to vent inner CV joint
assembly (Fig. 22).When inserting trim stick
between tripod housing and sealing boot
ensure trim stick is held flat and firmly against
the tripod housing. If this is not done damage
to the sealing boot can occur.
(12)
With trim stick inserted between sealing boot
insert and the CV joint housing, position the intercon-
necting shaft so it is at the center of its travel in the
tripod joint housing. Remove the trim stick from
between the sealing boot insert and the CV joint hous-
ing.This procedure will equalize the air pressurein the CV joint, preventing premature sealing
boot failure.
(13) Clamp CV joint sealing boot to CV joint, using
required procedure for type of boot clamp application.
CRIMP TYPE BOOT CLAMP
If seal boot uses crimp type boot clamp, use the fol-
lowing procedure to install the retaining clamp.
(1) Place crimping tool C-4975-A over bridge of
clamp (Fig. 23).
(2) Tighten nut on crimping tool C-4975-A until
jaws on tool are closed completely together, face to
face (Fig. 24).
Fig. 22 Trim Stick Inserted for Venting CV Joint
1 - INNER CV JOINT SEALING BOOT
2 - SEALING BOOT CLAMP
3 - INNER CV JOINT HOUSING
4 - TRIM STICK
Fig. 23 Crimping Tool Installed on Sealing Boot Clamp
1 - CLAMP
2 - TRIPOD JOINT HOUSING
3 - SPECIAL TOOL C-4975-A
4 - SEALING BOOT
Fig. 24 Sealing Boot Retaining Clamp Installed
1 - CLAMP
2 - TRIPOD HOUSING
3 - SPECIAL TOOL C-4975-A
4 - JAWS OF SPECIAL TOOL C-4975-A MUST BE CLOSED
COMPLETELY TOGETHER HERE
5 - SEALING BOOT
RSHALF SHAFT - FRONT3-9
CV BOOT - INNER (Continued)

Page 107 of 2339

LATCHING TYPE BOOT CLAMP
If seal boot uses low profile latching type boot
clamp, use the following procedure to install the
retaining clamp.
(1) Place prongs of clamp locking tool in the holes
of the clamp (Fig. 25).
(2) Squeeze tool together until top band of clamp is
latched behind the two tabs on lower band of clamp
(Fig. 26).
(14) Install the half shaft back into the vehicle.
(Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - INSTALLATION)
CV BOOT - OUTER
REMOVAL
(1) Remove halfshaft assembly requiring boot
replacement from vehicle. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT - REMOVAL)
(2) Remove large boot clamp retaining C/V joint
sealing boot to C/V joint housing (Fig. 27) and dis-
card. Remove small clamp that retains outer C/V
joint sealing boot to interconnecting shaft and dis-
card. Remove sealing boot from outer C/V joint hous-
ing and slide it down interconnecting shaft.
(3) Wipe away grease to expose outer C/V joint and
interconnecting shaft.
(4) Remove outer C/V joint from interconnecting
shaft using the following procedure: Support inter-
connecting shaft in a vise equipped with protective
caps on jaws of vise to prevent damage to intercon-
necting shaft. Then, using a soft±faced hammer,
sharply hit the end of the C/V joint housing to dis-
lodge housing from internal circlip on interconnecting
shaft (Fig. 28). Then slide outer C/V joint off end of
interconnecting shaft, joint may have to be tapped off
shaft using asoft±facedhammer.
(5) Remove large circlip (Fig. 29) from the inter-
connecting shaft before attempting to remove outer
C/V joint sealing boot.
(6) Slide sealing boot off interconnecting shaft.
(7) Thoroughly clean and inspect outer C/V joint
assembly and interconnecting joint for any signs of
excessive wear.If any parts show signs of exces-
sive wear, the halfshaft assembly will require
replacement. Component parts of these half-
shaft assemblies are not serviceable.
Fig. 25 Clamping Tool Installed on Sealing Boot
Clamp
1 - CLAMP
2 - TOOL YA3050, OR EQUIVALENT
3 - SEALING BOOT
Fig. 26 Sealing Boot Clamp Correctly Installed
1 - INNER TRIPOD JOINT HOUSING
2 - TOP BAND OF CLAMP MUST BE RETAINED BY TABS AS
SHOWN HERE TO CORRECTLY LATCH BOOT CLAMP
3 - SEALING BOOT
Fig. 27 Outer C/V Joint Seal Boot Clamps
1 - SMALL CLAMP
2 - SEALING BOOT
3 - OUTER C/V JOINT HOUSING
4 - LARGE CLAMP
5 - INTERCONNECTING SHAFT
3 - 10 HALF SHAFT - FRONTRS
CV BOOT - INNER (Continued)

Page 108 of 2339

CHRYSLER CARAVAN 2005 Service Manual INSTALLATION
(1) Slide new sealing boot to interconnecting shaft
retaining clamp onto interconnecting shaft. Slide the
outer C/V joint assembly sealing boot onto the inter-
connecting shaft (Fig. 30).

Page 109 of 2339

CHRYSLER CARAVAN 2005 Service Manual (4) Outer C/V joint assembly must be installed on
interconnecting shaft until cross of outer C/V joint
assembly is seated against circlip on interconnecting
shaft (Fig. 32).
(5) Distribute 1/2 the amo

Page 110 of 2339

CHRYSLER CARAVAN 2005 Service Manual (9) Clamp sealing boot onto outer C/V joint hous-
ing using Crimper, Special Tool C-4975-A and the fol-
lowing procedure. Place crimping tool C-4975-A over
bridge of clamp (Fig. 35). Tighten nut on cr

Page 111 of 2339

Page 112 of 2339

CHRYSLER CARAVAN 2005 Service Manual BRAKES
TABLE OF CONTENTS
page page
BRAKES - BASE........................... 1BRAKES - ABS........................... 87
BRAKES - BASE
TABLE OF CONTENTS
page page
BRAKES - BASE
DESCRIPTION
DESCRIPTION

BRAKES
TABLE OF CONTENTS
page page
BRAKES - BASE........................... 1BRAKES - ABS........................... 87
BRAKES - BASE
TABLE OF CONTENTS
page page
BRAKES - BASE
DESCRIPTION
DESCRIPTION - BASE BRAKES...........3
DESCRIPTION - BASE BRAKES (EXPORT) . . . 3
OPERATION - BASE BRAKES..............3
WARNING.............................4
CAUTION..............................4
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM.............................4
STANDARD PROCEDURE - BASE BRAKE
BLEEDING............................8
SPECIFICATIONS
BRAKE FASTENER TORQUE.............9
SPECIAL TOOLS
BASE BRAKE SYSTEM.................10
BRAKE FLUID LEVEL SWITCH
DESCRIPTION.........................10
OPERATION...........................10
REMOVAL.............................11
INSTALLATION.........................11
ADJUSTABLE PEDALS SWITCH
REMOVAL.............................11
INSTALLATION.........................11
HYDRAULIC/MECHANICAL
DESCRIPTION
DESCRIPTION - DISC BRAKES (FRONT) . . . 11
DESCRIPTION - DISC BRAKES (REAR)....13
DESCRIPTION - DISC BRAKES (EXPORT) . . 13
DESCRIPTION - DRUM BRAKES (REAR) . . . 13
OPERATION
OPERATION - DISC BRAKES (FRONT).....13
OPERATION - DISC BRAKES (REAR)......14
DIAGNOSIS AND TESTING - DRUM BRAKE
AUTOMATIC ADJUSTER................14
BRAKE LINES
DESCRIPTION - BRAKE TUBES AND HOSES..14
OPERATION - BRAKE TUBES AND HOSES . . . 14INSPECTION - BRAKE TUBES AND HOSES . . . 14
BRAKE PADS/SHOES - FRONT
REMOVAL
REMOVAL - FRONT DISC BRAKE SHOES
(CONTINENTAL TEVES BRAKES).........15
REMOVAL - FRONT DISC BRAKE SHOES
(TRW BRAKES).......................15
CLEANING - DISC BRAKE SHOES..........16
INSPECTION - DISC BRAKE SHOES........16
INSTALLATION
INSTALLATION - FRONT DISC BRAKE
SHOES (CONTINENTAL TEVES BRAKES) . . . 16
INSTALLATION - FRONT DISC BRAKE
SHOES (TRW BRAKES)................17
BRAKE PADS/SHOES - REAR DISC
REMOVAL - REAR DISC BRAKE SHOES.....17
CLEANING - DISC BRAKE SHOES..........18
INSPECTION - DISC BRAKE SHOES........18
INSTALLATION - REAR DISC BRAKE SHOES . . 19
BRAKE PADS/SHOES - REAR DRUM
REMOVAL - REAR DRUM BRAKE SHOES....19
INSPECTION - REAR DRUM BRAKE SHOE
LINING..............................22
INSTALLATION - REAR DRUM BRAKE SHOES..22
ADJUSTMENTS
ADJUSTMENT - REAR DRUM BRAKE
SHOES.............................23
DISC BRAKE CALIPER - FRONT
REMOVAL
REMOVAL - FRONT DISC BRAKE CALIPER
(CONTINENTAL TEVES BRAKES).........24
REMOVAL - FRONT DISC BRAKE CALIPER
(TRW BRAKES).......................24
DISASSEMBLY
DISASSEMBLY - CALIPER GUIDE PIN
BUSHINGS (CONTINENTAL TEVES
BRAKES)............................24
RSBRAKES5-1

Load next 8 pages

Page: < prev 1-10 ... 73-80 81-88 89-96 97-104 105-112 113-120 121-128 129-136 137-144 ... 2344 next >

clock reset oil type instrument cluster spark plugs wiper fluid jack points