2005 CHRYSLER CARAVAN location

(4) Position the upper shroud on the column (Fig.
35).
(5) If equipped with traction control, 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. 37).
(6) If removed, position the lower shroud on the
column (Fig. 36). Install the lower shroud mounting
screw. Tighten the screw to 2 N´m (17 in. lbs.) torque.(7) Align the upper shroud with the lower, then
snap shrouds together at locking tab locations on
both sides of column.
(8) Install the two shroud-to-shroud mounting
screws (Fig. 35). Tighten the screws to 2 N´m (17 in.
lbs.) torque.
(9) Inspect shroud mating surfaces for excessive
gaps and correct as necessary.
(10) Check operation of any previously discon-
nected switches.
STEERING WHEEL
REMOVAL
NOTE: Before proceeding, (Refer to 19 - STEERING/
COLUMN - WARNING)(Refer to 8 - ELECTRICAL/RE-
STRAINTS - WARNING).
(1) 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.
Fig. 38 Traction Control Switch Routing Clip
1 - ROUTING CLIP
2 - SWITCH WIRING
Fig. 39 Traction Control Switch Mounting
1 - TRACTION CONTROL SWITCH
2 - UPPER SHROUD
Fig. 40 Driver Airbag Mounting
1 - DRIVER AIRBAG
2 - MOUNTING SCREWS
RSCOLUMN19-23
SHROUD - UPPER (Continued)

(9) Remove 2 bolts attaching power steering cooler
to cradle crossmember reinforcement (Fig. 3).
(10) On both sides of vehicle, remove nut attaching
outer tie rod end to steering knuckle (Fig. 4).
Remove nut by holding tie rod end stud with a
socket while loosening and removing nut with
wrench.(11) Remove bolts fastening leak detection pump to
cradle crossmember reinforcement. (Refer to 25 -
EMISSIONS CONTROL/EVAPORATIVE EMIS-
SIONS/LEAK DETECTION PUMP - REMOVAL)
(12) Remove both outer tie rods from steering
knuckles, using Puller, Special Tool C-3894±A (Fig.
5).
(13) Remove the lower control arm rear bushing
retainer bolts located on each side of each lower con-
trol arm rear bushing.
NOTE: The bolts fastening the cradle crossmember
reinforcement are of two different thread sizes. Note
the location of the various sizes.
Fig. 3 Power Steering Cooler
1 - CRADLE CROSSMEMBER REINFORCEMENT
2 - POWER STEERING COOLER
Fig. 4 Removing/Installing Tie Rod End Attaching
Nut
1 - TIE ROD END
2 - STEERING KNUCKLE
3 - WRENCH
4 - SOCKET
5 - TIE ROD END STUD
Fig. 5 Tie Rod Removal With Tool C-3894-A
1 - OUTER TIE ROD
2 - SPECIAL TOOL C-3894-A
3 - STEERING KNUCKLE
19 - 28 GEARRS
GEAR (Continued)

(12) Remove the lower control arm rear bushing
retainer bolts located on each side of each lower con-
trol arm rear bushing.
NOTE: The bolts fastening the cradle crossmember
reinforcement are of two different thread sizes. Note
the location of the various sizes.
(13) Remove the bolts attaching the cradle cross-
member reinforcement to the front suspension cradle
crossmember (Fig. 6). Remove the 2 bolts fastening
the reinforcement and rear of cradle crossmember to
the body of the vehicle. Remove the reinforcement.
(14) If the vehicle is equipped with All-Wheel-
Drive, remove the power transfer unit (Refer to 21 -
TRANSMISSION/TRANSAXLE/POWER TRANSFER
UNIT - REMOVAL).
(15) Remove the power steering fluid pressure and
return hoses from the power steering gear (Fig. 10).
(16) Remove the routing clamp bolt securing the
power steering fluid hoses to the rear of the cradle
crossmember (Fig. 11). Allow the hoses to hang down
out of the way.
(17) Remove the heat shield from the steering gear
(Fig. 10).
(18) Remove the 2 bolts and nuts mounting the
steering gear to the front suspension cradle.
NOTE: The next step must be done to allow the
removal of the steering gear from the front suspen-
sion cradle. The steering gear cannot be removed
from the vehicle with the intermediate coupler
attached to the steering gear.(19) Lower steering gear from suspension cradle
enough to allow access to the intermediate coupler
roll pin (Fig. 9). Install Remover/Installer, Special
Tool 6831A, through the center of the roll pin, secur-
ing with the knurled nut (Fig. 9). Hold threaded rod
stationary while turning nut, this will pull the roll
pin out of the intermediate coupler.
(20) Separate the coupler from the steering gear
shaft.
(21) Remove the power steering gear from the
vehicle.
INSTALLATION
INSTALLATION - LHD GEAR
(1) Install the power steering gear up in the front
suspension cradle, leaving room to install intermedi-
ate coupler.
(2) Start the roll pin into the intermediate coupler
before installing coupler on steering gear shaft. Start
roll pin into coupler, using a hammer and tapping it
into the coupler. Then install the intermediate cou-
pler on the shaft of the steering gear.
Fig. 10 RHD Gear Heat Shield And Hose Fittings
1 - HEAT SHIELD
2 - CRADLE CROSSMEMBER
3 - RETURN HOSE FITTING
4 - PRESSURE HOSE FITTING
5 - POWER STEERING GEAR
Fig. 11 RHD Power Steering Gear - 2.5L Diesel
Shown
1 - RETURN HOSE
2 - PRESSURE HOSE
3 - CRADLE CROSSMEMBER
4 - POWER STEERING GEAR
5 - RETURN HOSE FITTING
6 - PRESSURE HOSE FITTING
7 - HOSE ROUTING CLAMP
RSGEAR19-31
GEAR (Continued)

(1) Remove the power steering pump from the
vehicle. Refer to Removal And Installation in this
section of the service manual.
(2) Remove the pulley from the shaft of the power
steering pump using Puller C-4333 (Fig. 14).
CAUTION: Do not hammer on power steering pump
pulley. This will damage the pulley and the power
steering pump.
(3) Replace pulley if it is found to be bent, cracked,
or loose.
ASSEMBLY - PUMP (PULLEY)
The only serviceable part of the power steering
pump is the pulley. The procedure following is for
removal and installation of the pulley from the pump
once the pump is removed from the vehicle.
(1) Install the pulley with Installer C-4063 (Fig.
15). Do not use the tool adapters.
(2) Ensure that the tool and the pulley remain
aligned with the pump shaft. Prevent the pulley from
being cocked on the shaft.
(3) Install the pulley until it is flush with the end
of the power steering pump shaft (Fig. 16).
(4) Install the power steering pump on the vehicle.
Fig. 13 Pump And Brackets - Diesel
1 - CAST BRACKET
2 - STAMPED BRACKET
3 - POWER STEERING PUMP
Fig. 14 Pulley Removal
1 - POWER STEERING PUMP DRIVE PULLEY
2 - SPECIAL TOOL C-4333
Fig. 15 Pulley Installation
1 - POWER STEERING PUMP DRIVE PULLEY
2 - SPECIAL TOOL
C-4063±A
Fig. 16 Pulley To Pump Shaft Location
1 - PULLEY
2 - PUMP BODY
3 - PUMP SHAFT
4 - HUB
19 - 42 PUMPRS
PUMP (Continued)

The process of elimination can be used to detect
any unit which slips and to confirm proper operation
of good units. Road test analysis can diagnose slip-
ping units, but the cause of the malfunction cannot
be determined. Practically any condition can be
caused by leaking hydraulic circuits or sticking
valves.
DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TESTS
Pressure testing is a very important step in the
diagnostic procedure. These tests usually reveal the
cause of most hydraulic transaxle problems.
Before performing pressure tests, be certain that
fluid level and condition, and shift cable adjustments
have been checked and approved. Fluid must be at
operating temperature (150 to 200 degrees F.).
Install an engine tachometer, raise vehicle on hoist
which allows front wheels to turn, and position
tachometer so it can be read.
Attach 300 psi gauge (C-3293SP) to port(s)
required for test(s) being conducted. Use adapter set
L-4559 to adapt gauge(s) to transaxle.
Test port locations are shown in (Fig. 4).
TEST ONE-SELECTOR IN LOW (1st GEAR)
(1) Attach pressure gauge to the low/reverse clutch
tap.
(2) Move selector lever to the (L) position.
(3) Allow vehicle wheels to turn and increase
throttle opening to achieve an indicated vehicle speed
to 20 mph.
(4) Low/reverse clutch pressure should read 115 to
145 psi.(5) This test checks pump output, pressure regula-
tion and condition of the low/reverse clutch hydraulic
circuit and shift schedule.
TEST TWO-SELECTOR IN DRIVE (2nd GEAR)
NOTE: This test checks the underdrive clutch
hydraulic circuit as well as the shift schedule.
(1) Attach gauge to the underdrive clutch tap.
(2) Move selector lever to the 3 position.
(3) Allow vehicle wheels to turn and increase
throttle opening to achieve an indicated vehicle speed
of 30 mph.
(4) In second gear the underdrive clutch pressure
should read 110 to 145 psi.
TEST TWO A±SELECTOR IN OD (4th Gear)
NOTE: This test checks the underdrive clutch
hydraulic circuit as well as the shift schedule.
(1) Attach gauge to the underdrive clutch tap.
(2) Move selector lever to the (OD) position.
(3) Allow wheels to rotate freely and increase
throttle opening to achieve an indicated speed of 40
mph.
(4) Underdrive clutch pressure should read below
5 psi. If not, then either the solenoid assembly or
PCM/TCM is at fault.
TEST THREE-OVERDRIVE CLUTCH CHECK (3rd and
2nd Gear)
(1) Attach gauge to the overdrive clutch tap.
(2) Move selector lever to the (OD) position.
(3) Allow vehicle wheels to turn and increase
throttle opening to achieve an indicated vehicle speed
of 20 mph. Vehicle should be in 3rd gear.
(4) Overdrive clutch pressure should read 74 to 95
psi.
(5) Move selector lever to the (3) position and
increase indicated vehicle speed to 30 mph.
(6) The vehicle should be in second gear and over-
drive clutch pressure should be less than 5 psi.
(7) This test checks the overdrive clutch hydraulic
circuit as well as the shift schedule.
TEST FOUR-SELECTOR IN OVERDRIVE (4th Gear)
(1) Attach gauge to the 2/4 clutch tap.
(2) Move selector lever to the (OD) position.
(3) Allow vehicle front wheels to turn and increase
throttle opening to achieve an indicated vehicle speed
of 30 mph. Vehicle should be in 4th gear.
(4) The 2/4 clutch pressure should read 75 to 95
psi.
(5) This test checks the 2/4 clutch hydraulic cir-
cuit.
Fig. 4 Pressure Taps
1 - OVERDRIVE CLUTCH
2 - TORQUE CONVERTER OFF
3 - LOW/REVERSE CLUTCH
4 - 2/4 CLUTCH
5 - REVERSE CLUTCH
6 - UNDERDRIVE CLUTCH
21 - 6 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

(3) Remove coolant recovery bottle (Fig. 10).
(4) Remove fluid level indicator/tube assembly.
Plug opening to prevent debris from entering trans-
axle.
(5) Disconnect transaxle oil cooler lines using Tool
8875A. (Refer to 7 - COOLING/TRANSMISSION -
STANDARD PROCEDURE). Install plugs to prevent
debris intrusion.
(6) Disconnect input and output shaft speed sensor
connectors (Fig. 11).
(7) Disconnect transmission range sensor (TRS)
connector (Fig. 11).
(8) Disconnect solenoid/pressure switch assembly
connector (Fig. 11).
(9) Disconnect gear shift cable from manual valve
lever and upper mount bracket (Fig. 12).
(10) Disconnect crankshaft position sensor (if
equipped). Remove sensor from bellhousing.
(11) Reposition leak detection pump harness and
hoses.
Fig. 10 Coolant Recovery Bottle
1 - COOLANT RECOVERY CONTAINER
2 - HOSE
3 - BOLT
4 - SUB FRAME RAIL
Fig. 11 Component Connector LocationÐTypical
1 - SOLENOID/PRESSURE SWITCH ASSY. CONNECTOR
2 - INPUT SPEED SENSOR CONNECTOR
3 - OUTPUT SPEED SENSOR CONNECTOR
4 - TRANSMISSION RANGE SENSOR CONNECTOR
Fig. 12 Gearshift Cable at Transaxle - Typical
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
21 - 10 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

NOTE: Depending on engine application, some
accumulators will have two springs and others will
have one spring. The springs are color-coded
according to application and year. When disassem-
bling, mark accumulator spring location to ease
assembly.
(10) Remove underdrive and overdrive accumula-
tors (Fig. 22).
(11) Remove low/reverse accumulator snap ring
(Fig. 23).(12) Remove low/reverse accumulator plug (Fig.
24).
(13) Remove low/reverse accumulator piston using
suitable pliers (Fig. 25). Remove piston and springs
(Fig. 26).
Fig. 22 Underdrive and Overdrive Accumulators
1 - OVERDRIVE PISTON AND SPRING
2 - UNDERDRIVE PISTON AND SPRING
Fig. 23 Remove Low/Reverse Accumulator Snap
Ring
1 - SNAP RING
2 - PLUG
Fig. 24 Remove Low/Reverse Accumulator Plug
1 - ADJUSTABLE PLIERS
2 - PLUG
Fig. 25 Low/Reverse Accumulator Piston
1 - ACCUMULATOR PISTON
21 - 14 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

Fig. 160 Rear Mount Bracket - Typical
1 - BOLT - VERTICAL 102 N´m (75 ft. lbs.)
2 - BRACKET - REAR MOUNT3 - BOLT - HORIZONTAL 102 N´m (75 ft. lbs.)
Fig. 161 Gearshift Cable at Transaxle - Typical
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
Fig. 162 Component Connector Location - Typical
1 - SOLENOID/PRESSURE SWITCH ASSY. CONNECTOR
2 - INPUT SPEED SENSOR CONNECTOR
3 - OUTPUT SPEED SENSOR CONNECTOR
4 - TRANSMISSION RANGE SENSOR CONNECTOR
21 - 52 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)