2005 CHRYSLER CARAVAN wheel

Kilometers 120 000 125 000 130 000 134 000 139 000 144 000
(Miles) (75,000) (78,000) (81,000) (84,000) (87,000) (90,000)
Change engine oil and engine
oil filter.XXXXX X
Rotate Tires X X X
Inspect the brake linings. X X
Inspect the engine air cleaner
filter, replace if necessary. *XXXX
Replace theengine air
cleaner filterXX
Replace thespark plugson
3.3 liter engines.X
Replace theignition cables
on 3.3 liter engines.X
Replace thespark plugson
2.4 liter engines.X
Inspect and adjust the power
steering pump belt tension on
2.4 liter engines.XX
Inspect the generator belt on
2.4 liter engines, replace if
necessary.XX
Inspect the tie rod ends and
boot seals.X
Inspect engine accessory
drive belts on 3.3 liter
engines, replace if necessary.
³XX
Change the manual
transmission fluid.X
Check thePCV valveand
replace if necessary. Not
required if previously
changed.*X
Change the All Wheel Drive
power transfer unit fluid. (See
the note at the end of this
chart.)XX
Change the All Wheel Drive
(AWD) overrunning clutch and
rear carrier fluid. (See note at
the end of this chart)X
Replace theengine timing
belton 2.4 liter engines. *X
Replace the air conditioning
filter.XX
RSLUBRICATION & MAINTENANCE0-19
MAINTENANCE SCHEDULES (Continued)

Kilometers 149 000 154 000 158 000 160 000 163 000 168 000
(Miles) (93,000) (96,000) (99,000) (100,000) (102,000) (105,000)
Change engine oil and engine
oil filter.XXX X X
Rotate Tires X X
Inspect the brake linings. X
Inspect the engine air cleaner
filter, replace if necessary. *XXXXX
Replace theengine air
cleaner filter*X
Inspect and adjust the power
steering pump belt tension on
2.4 liter engines.X
Inspect the generator belt on
2.4 liter engines, replace if
necessary.X
Inspect engine accessory
drive belts on 3.3 liter
engines, replace if necessary.
³X
Change the manual
transmission fluid.X
Change the All Wheel Drive
(AWD) power transfer unit,
overrunning clutch and rear
carrier fluid. (See note at the
end of this chart)X
Flush and replace the engine
coolant at 60 months or
100,000 miles.X
Replace the air conditioning
filter.X
Kilometers 173 000 178 000 182 000 187 000 192 000
(Miles) (108,000) (111,000) (114,000) (117,000) (120,000)
Change engine oil and engine oil filter.XXXX X
Rotate Tires X X X
Inspect the brake linings. X X
Inspect the engine air cleaner filter, replace
if necessary. *XXXX
Replace theengine air cleaner filter.X
Replace thespark plugson 2.4 liter
engines.X
Replace theignition cableson 2.4 liter
engines.X
Inspect and adjust the power steering pump
belt tension on 2.4 liter engines.X
0 - 20 LUBRICATION & MAINTENANCERS
MAINTENANCE SCHEDULES (Continued)

Kilometers 173 000 178 000 182 000 187 000 192 000
(Miles) (108,000) (111,000) (114,000) (117,000) (120,000)
Inspect the generator belt on 2.4 liter
engines, replace if necessary.X
Inspect engine accessory drive belts on 3.3
liter engines, replace if necessary. ³X
Inspect the tie rod ends and boot seals. X
Inspect thePCV valveand replace as
necessary.*X
Change the automatic transmission fluid
and filter.LX
Change the All Wheel Drive (AWD) power
transfer unit fluid. (See note at the end of
this chart)X
Replace the air conditioning filter.X
* This maintenance is recommended by the manu-
facture to the owner but is not required to maintain
the emissions warranty.
³ This maintenance is not required if previously
replaced.
LThis maintenance is required only for police,
taxi, limousine type operation, or trailer towing.
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
Retain all receipts.
NOTE: The AWD power transfer unit fluid and the
AWD overrunning clutch/ rear carrier fluid must be
changed at the intervals shown in schedule B if the
vehicle is operated under any of the conditions
noted by a diamond at the beginning of the sched-
ule.
WARNING: You can be badly injured working on or
around a motor vehicle. Do only that service work
for which you have the knowledge and the right
equipment. If you have any doubt about your ability
to perform a service job, take your vehicle to a
competent mechanic.
DESCRIPTION - DIESEL ENGINES - EXPORT
There are two maintenance schedules that show
therequiredservice for your vehicle.
First is ScheduleªAº. It is for vehicles that are not
operated under any of the conditions listed under
Schedule9B9.
Second is ScheduleªBº. It is for vehicles that are
operated under the conditions that are listed below
and at the beginning of the schedule.
²Extensive engine idling.²Driving in dusty conditions.
²More than 50% of your driving is at sustained
high speeds during hot weather, above 32É C (90É F).
²Trailer towing.
²Taxi, police, or delivery service (commercial ser-
vice).
Most vehicles are operated under the conditions
listed for Schedule9B9.
Use the schedule that best describes your driving
conditions. Where time and mileage are listed, follow
the interval that occurs first.
Failure to perform the required maintenance items
may result in damage to the vehicle.
At Each Stop for Fuel
²Check the engine oil level about 5 minutes after
a fully warmed engine is shut off. Checking the oil
level while the vehicle is on level ground will
improve the accuracy of the oil level reading. Add oil
only when the level is at or below the ADD or MIN
mark.
²Check the windshield washer solvent and add if
required.
Once a Month
²Check the tire pressure and look for unusual
wear or damage.
²Inspect the battery and clean and tighten the
terminals as required.
²Check the fluid levels of coolant deaeration bot-
tle, brake master cylinder and transmission, add as
needed.
²Check all lights and all other electrical items for
correct operation.
RSLUBRICATION & MAINTENANCE0-21
MAINTENANCE SCHEDULES (Continued)

CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter may over-
heat and could fail.
(7) If engine does not start within 15 seconds, stop
cranking engine and allow starter to cool (15 min-
utes), before cranking again.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
²Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
²When using a Booster vehicle, disconnect
BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive
terminal.
²Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle.
TOWING
STANDARD PROCEDURE - TOWING
WARNINGS AND CAUTIONS
WARNING: DO NOT ALLOW TOWING ATTACHMENT
DEVICES TO CONTACT THE FUEL TANK OR LINES,
FUEL LEAK CAN RESULT.
DO NOT LIFT OR TOW VEHICLE BY FRONT OR
REAR BUMPER.
DO NOT GO UNDER A LIFTED VEHICLE IF NOT
SUPPORTED PROPERLY ON SAFETY STANDS.
DO NOT ALLOW PASSENGERS TO RIDE IN A
TOWED VEHICLE.USE A SAFETY CHAIN THAT IS INDEPENDENT
FROM THE TOWING ATTACHMENT DEVICE.
CAUTION: Do not damage brake lines, exhaust sys-
tem, shock absorbers, sway bars, or any other
under vehicle components when attaching towing
device to vehicle.
Do not secure vehicle to towing device by the use
of front or rear suspension or steering components.
Remove or secure loose or protruding objects from
a damaged vehicle before towing.
Refer to state and local rules and regulations before
towing a vehicle.
Do not allow weight of towed vehicle to bear on
lower fascia, air dams, or spoilers.
RECOMMENDED TOWING EQUIPMENT
To avoid damage to bumper fascia and air dams
use:
²FWD vehicles, use of a flat bed towing device or
a wheel lift is recommended (Fig. 7).
²AWD vehicles, a flat bed towing device or a
wheel lift and towing dolly is recommended (Fig. 7).
When using a wheel lift towing device, be sure the
disabled vehicle has at least 100 mm (4 in.) ground
clearance. If minimum ground clearance cannot be
reached, use a towing dolly. If a flat bed device is
used, the approach angle should not exceed 15
degrees.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels removed,
install lug nuts to retain brake drums or rotors.
A towed vehicle should be raised until the lifted
wheels are a minimum 100 mm (4 in.) from the
ground. Be sure there is at least 100 mm (4 in.)
clearance between the tail pipe and the ground. If
necessary, remove the wheels from the front end of
the vehicle and lower the front end closer to the
Fig. 6 JUMPER CABLE CLAMP CONNECTIONS
1 - BATTERY NEGATIVE TERMINAL
2 - POSITIVE JUMPER CABLE
3 - TEST INDICATOR (IF EQUIPPED)
4 - BATTERY POSITIVE TERMINAL
5 - BATTERY
6 - NEGATIVE JUMPER CABLE
Fig. 7 RECOMMENDED TOWING
1 - WHEEL LIFT
2 - FLAT BED
0 - 26 LUBRICATION & MAINTENANCERS
JUMP STARTING (Continued)

ground, to increase the ground clearance at the rear
of the vehicle. Install lug nuts on wheel attaching
studs to retain brake drums or rotors.
LOCKED VEHICLE TOWING
When a locked vehicle must be towed with the
front wheels on the ground, use a towing dolly or flat
bed hauler.
FLAT TOWING WITH TOW BAR
²Three speed automatic transaxle vehicles can be
flat towed at speeds not to exceed 40 km/h (25 mph)
for not more than 25 km (15 miles). The steering col-
umn must be unlocked and gear selector in neutral.
²Four speed electronic automatic transaxle vehi-
cles can be flat towed at speeds not to exceed 72
km/h (44 mph) for not more than 160 km (100 miles).
The steering column must be unlocked and gear
selector in neutral.
²AWD models should not be flat towed. For addi-
tional information, refer toRECOMMENDED TOW-
ING EQUIPMENTin this section.
FLAT BED TOWING TIE DOWNS
CAUTION: Do not tie vehicle down by attaching
chains or cables to suspension components or
engine mounts, damage to vehicle can result.
The vehicle can be tied to a flat bed device using
the two pair of front slots on the bottom surface of
the rails, behind the front wheels. The two pair of
rear slots on the bottom of the rail between thebumper extension bolts and on the bottom of the rail
just rearward of the jounce bumper. Vehicles
equipped with a rear sway bar have brackets at this
location.
TOWING ± FRONT WHEEL LIFT
If the vehicle is being towed from the front, when-
ever possible ensure at least 10 inches road clearance
to the tires.
TOWING ± REAR WHEEL LIFT
If a vehicle cannot be towed with the front wheels
lifted, the rear wheels can be lifted provided the fol-
lowing guide lines are observed.
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
²On AWD vehicles, all four wheels must be free to
rotate. Use towing dollies at unlifted end of vehicle.
²Unlock steering column and secure steering
wheel in straight ahead position with a clamp device
designed for towing.
²Three speed automatic transaxle vehicles can be
flat towed at speeds not to exceed 40 km/h (25 mph)
for not more than 25 km (15 miles). The steering col-
umn must be unlocked and gear selector in neutral.
²Four speed electronic automatic transaxle vehi-
cles can be flat towed at speeds not to exceed 72
km/h (44 mph) for not more than 160 km (100 miles).
The steering column must be unlocked and gear
selector in neutral.
RSLUBRICATION & MAINTENANCE0-27
TOWING (Continued)

SUSPENSION
TABLE OF CONTENTS
page page
FRONT SUSPENSION.....................1
REAR SUSPENSION......................26WHEEL ALIGNMENT.....................47
FRONT SUSPENSION
TABLE OF CONTENTS
page page
FRONT SUSPENSION
DESCRIPTION - FRONT SUSPENSION.......2
OPERATION - FRONT SUSPENSION.........2
STANDARD PROCEDURE - LUBRICATION....2
SPECIFICATIONS
FRONT SUSPENSION FASTENER TORQUE . . 3
SPECIAL TOOLS
FRONT SUSPENSION...................3
BUSHINGS
REMOVAL - STABILIZER BAR CUSHION......4
INSTALLATION - STABILIZER BAR CUSHION . . . 4
HUB / BEARING
DESCRIPTION..........................5
OPERATION............................5
DIAGNOSIS AND TESTING - HUB AND
BEARING............................5
REMOVAL.............................5
INSTALLATION..........................5
KNUCKLE
DESCRIPTION..........................6
OPERATION............................7
REMOVAL - STEERING KNUCKLE...........7
INSPECTION - STEERING KNUCKLE.........9
INSTALLATION - STEERING KNUCKLE.......9
LOWER BALL JOINT
DESCRIPTION.........................10
OPERATION...........................10
DIAGNOSIS AND TESTING - LOWER BALL
JOINT..............................10
LOWER BALL JOINT SEAL BOOT
DESCRIPTION - EXPORT.................10
REMOVAL
REMOVAL...........................11
REMOVAL - EXPORT...................11INSTALLATION
INSTALLATION.......................11
INSTALLATION - EXPORT...............11
LOWER CONTROL ARM
DESCRIPTION.........................12
OPERATION...........................12
REMOVAL - LOWER CONTROL ARM........12
DISASSEMBLY
DISASSEMBLY - LOWER CONTROL ARM
(REAR BUSHING - STANDARD)..........13
DISASSEMBLY - LOWER CONTROL ARM
(REAR BUSHING - HYDRO).............13
INSPECTION - LOWER CONTROL ARM......14
ASSEMBLY
ASSEMBLY - LOWER CONTROL ARM
(REAR BUSHING - STANDARD)..........14
ASSEMBLY - LOWER CONTROL ARM
(REAR BUSHING - HYDRO).............15
INSTALLATION - LOWER CONTROL ARM....15
STABILIZER BAR
DESCRIPTION.........................16
OPERATION...........................16
REMOVAL.............................17
INSPECTION..........................17
INSTALLATION.........................17
STRUT
DESCRIPTION - STRUT ASSEMBLY.........19
OPERATION - STRUT ASSEMBLY..........19
DIAGNOSIS AND TESTING - STRUT
ASSEMBLY..........................20
REMOVAL - STRUT ASSEMBLY............20
DISASSEMBLY - STRUT ASSEMBLY........21
ASSEMBLY - STRUT ASSEMBLY...........23
INSTALLATION - STRUT ASSEMBLY........25
RSSUSPENSION2-1

FRONT SUSPENSION
DESCRIPTION - FRONT SUSPENSION
This vehicle has a MacPherson Strut type front
suspension (Fig. 1).
OPERATION - FRONT SUSPENSION
The front suspension allows each wheel on a vehi-
cle to adapt to different road surfaces and conditions
without greatly affecting the opposite wheel and the
ability to control the vehicle. Each side of the front
suspension is allowed to pivot so the vehicle can be
steered in the direction preferred.
A strut assembly is used in place of the front sus-
pension upper control arm and upper ball joint.
When a vehicle strikes a bump, the force is trans-
ferred through the hub, bearing, and knuckle, into
the strut assembly to absorb the force and dampen it.
The top of the strut is mounted directly to the strut
tower of the vehicle. During steering maneuvers, the
strut assembly (through a pivot bearing in the upperstrut mount) and steering knuckle (through the lower
ball joint) turn as an assembly.
STANDARD PROCEDURE - LUBRICATION
There are no serviceable lubrication points on the
front suspension. The ball joints are sealed-for-life
and require no maintenance. The lower ball joints
have special grease fitting caps that prevent normal
grease gun attachment. This has been done to elimi-
nate the possibility of over-filling, damaging the non-
vented seal. Do not attempt to remove the special
grease fitting cap and replace it with a normal grease
zirc fitting.
CAUTION: No attempt should be made to replace
the ball joint grease fitting cap with a normal zirc
fitting or fill the ball joint with grease. Damage to
the grease seal can result.
Fig. 1 Front Suspension
1 - TOWER
2 - CROSSMEMBER TAPPING PLATES
3 - LEFT STRUT ASSEMBLY
4 - LEFT STEERING KNUCKLE (WITH HUB AND BEARING)
5 - STABILIZER BAR LINK
6 - STABILIZER BAR
7 - LEFT LOWER CONTROL ARM
8 - CRADLE/CROSSMEMBER9 - CRADLE/CROSSMEMBER REINFORCEMENT
10 - BALL JOINT
11 - ISOLATOR BUSHING
12 - STEERING GEAR TIE ROD
13 - RIGHT STEERING KNUCKLE
14 - RIGHT HUB AND BEARING
15 - RIGHT STRUT ASSEMBLY
2 - 2 FRONT SUSPENSIONRS

SPECIFICATIONS
FRONT SUSPENSION FASTENER TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Ball Joint Nut 108 80 Ð
Cradle Crossmember
Mounting Bolts163 120 Ð
Cradle Crossmember
Reinforcement Bolts - Size
M-14153 113 Ð
Cradle Crossmember
Reinforcement Bolt - Size
M-12106 78 Ð
Cradle Crossmember
Reinforcement Bolts - Size
M-1061 45 Ð
Disc Brake Adapter
Mounting Bolts169 125 Ð
Hub And Bearing Mounting
Bolts65 45 Ð
Hub And Bearing Axle Hub
Nut244 180 Ð
Lower Control Arm Pivot
Bolt183 135 Ð
Stabilizer Bar Bushing
Retainer Bolts68 50 Ð
Stabilizer Bar Link Nuts 88 65 Ð
Strut Body/Tower Mounting
Nuts28 21 250
Strut Clevis-to-Knuckle Nuts 81 +
90É
turn60 +
90É
turnÐ
Strut Shaft Nut 100 75 Ð
Tie Rod Adjuster Jam Nut 75 55 Ð
Tie Rod Steering Arm Nut 75 55 Ð
Wheel Mounting (Lug) Nuts 135 100 Ð
SPECIAL TOOLS
FRONT SUSPENSION
Puller C-3894A
Press, Ball Joint C-4212F
Installer, Ball Joint 6758
Wrench, Strut Rod Nut 6864
RSFRONT SUSPENSION2-3
FRONT SUSPENSION (Continued)