2005 CHRYSLER CARAVAN sensor

(2) Install transaxle oil filter (Fig. 374). Inspect
the o-ring and replace if necessary.
(3) Ensure the transaxle oil pan and transaxle
case sealing surfaces are clean and dry. Install an
1/8º bead of MopartSilicone Rubber Adhesive Seal-
ant to the oil pan and install (Fig. 375). Torque oil
pan-to-transaxle case bolts (Fig. 376) to 19 N´m (165
in. lbs.).
(4) Lower vehicle.
(5) Connect transmission range sensor connector.
(6) Install manual valve lever to manual shaft.
(7) Install gearshift cable to manual valve lever.
(8) Connect battery negative cable.
(9) Fill transaxle with MopartATF +4 Transmis-
sion fluid. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 41TE/FLUID - STANDARD
PROCEDURE)
Fig. 374 Oil Filter
1 - OIL FILTER
2 - O-RING
Fig. 375 Oil Pan
1 - OIL PAN
2 - 1/8 INCH BEAD OF RTV SEALANT
3 - OIL FILTER
Fig. 376 Oil Pan Bolts
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
21 - 296 41TE AUTOMATIC TRANSAXLERS
VALVE BODY (Continued)

TIRES/WHEELS
TABLE OF CONTENTS
page page
TIRES/WHEELS
DIAGNOSIS AND TESTING - TIRE AND
WHEEL VIBRATION.....................1
STANDARD PROCEDURE
STANDARD PROCEDURE - TIRE AND
WHEEL BALANCE......................5
STANDARD PROCEDURE - TIRE AND
WHEEL MATCH MOUNTING..............7
STANDARD PROCEDURE - TIRE AND
WHEEL ROTATION.....................7
REMOVAL
REMOVAL - TIRE AND WHEEL ASSEMBLY
(ALUMINUM WHEEL)....................8
REMOVAL - TIRE AND WHEEL ASSEMBLY
(STEEL WHEEL).......................8
INSTALLATION
INSTALLATION - TIRE AND WHEEL
ASSEMBLY (ALUMINUM WHEEL)..........8
INSTALLATION - TIRE AND WHEEL
ASSEMBLY (STEEL WHEEL)..............8
TIRE PRESSURE MONITORING
DESCRIPTION..........................9
OPERATION...........................10
SENSOR - TPM
DESCRIPTION.........................10
OPERATION...........................10
CAUTION.............................11
DIAGNOSIS AND TESTING - TIRE PRESSURE
SENSOR............................11
REMOVAL.............................11
INSTALLATION.........................11
TIRES
DESCRIPTION
DESCRIPTION - TIRE..................13
DESCRIPTION - RADIAL-PLY TIRES.......13
DESCRIPTION - REPLACEMENT TIRES....14
DESCRIPTION - SPARE TIRE
(TEMPORARY).......................14DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - TIRE NOISE . . . 14
DIAGNOSIS AND TESTING - TIRE/VEHICLE
LEAD...............................14
DIAGNOSIS AND TESTING - TIRE WEAR
PATTERNS..........................16
DIAGNOSIS AND TESTING - TREAD WEAR
INDICATORS.........................16
STANDARD PROCEDURE
STANDARD PROCEDURE - TIRE INFLATION
PRESSURES.........................16
STANDARD PROCEDURE - TIRE
PRESSURE FOR HIGH SPEED
OPERATION.........................17
STANDARD PROCEDURE - TIRE LEAK
REPAIRING..........................17
CLEANING - TIRES.....................18
WHEELS
DESCRIPTION - WHEEL..................18
DIAGNOSIS AND TESTING - WHEEL
INSPECTION.........................19
CLEANING
WHEEL AND WHEEL TRIM CARE.........19
SPECIFICATIONS
WHEEL.............................19
WHEEL COVER
DESCRIPTION.........................19
REMOVAL.............................19
INSTALLATION.........................20
WHEEL MOUNTING STUDS - FRONT
REMOVAL.............................21
INSTALLATION.........................21
WHEEL MOUNTING STUDS - REAR
REMOVAL.............................22
INSTALLATION.........................22
TIRES/WHEELS
DIAGNOSIS AND TESTING - TIRE AND WHEEL
VIBRATION
Tire and wheel imbalance, runout and force varia-
tion can cause vehicles to exhibit steering wheel
vibration.
VISUAL INSPECTION
Visual inspection of the vehicle is recommended
prior to road testing or performing any other proce-
dure. Raise vehicle on a suitable hoist. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
Inspect for the following:
²Verify correct (OEM) wheel and tire, as well as
correct wheel weights. Aluminum wheels require
RSTIRES/WHEELS22-1

(3) Place the wheel cover on the wheel in the fol-
lowing fashion:
(a) Align the valve notch in the wheel cover with
the valve stem on the wheel.
(b) At the same time, align the two holes in the
wheel cover having the retaining tabs with the two
installed wheel nuts (Fig. 15).
(c) Press in on center of wheel cover until wheel
cover retaining tabs push past and engage rear of
previously installed wheel mounting nuts (Fig. 15).
This will hold the wheel cover in place.(4) Install andlightly tightenthe three remain-
ing wheel mounting nuts, securing the wheel cover in
place (Fig. 12).
(5) Progressively tighten all five wheel mounting
nuts in the proper sequence (Fig. 16). Tighten wheel
nuts to a torque of 135 N´m (100 ft. lbs.).
(6) Lower the vehicle.
TIRE PRESSURE MONITORING
DESCRIPTION
Some versions of this vehicle are equipped with
Tire Pressure Monitoring (TPM). TPM monitors air
pressure in the four road tires. The system alerts the
driver when tire pressure in any of the four road
wheels falls below a predetermined threshold (pres-
sure too low).
Depending on optional equipment, a vehicle may
have four or five sensors (fifth sensor located in spare
wheel). Although a pressure sensor may be present in
the spare tire wheel of the five sensor system, pres-
sure in the spare tire is not monitored.
There are two systems available, Base and Pre-
mium. The Base system offers an indicator lamp,
warning the driver of a pressure issue. An audible
chime also sounds once when a pressure issue occurs.
In addition to these features, the Premium system
offers an Electronic Vehicle Information Center
(EVIC) display of information.
For further information, refer to the Owners Man-
ual or the appropriate diagnostic information.
Fig. 14 TWO WHEEL MOUNTING NUTS INSTALLED
1 - WHEEL
2 - VALVE STEM
3 - HUB PILOT
4 - NUTS
Fig. 15 WHEEL COVER INSTALLATION OVER TWO
NUTS
1 - RETAINING TABS
2 - VALVE STEM
3 - BOLT-ON WHEEL COVER
Fig. 16 NUT TIGHTENING SEQUENCE
RSTIRES/WHEELS22-9
TIRES/WHEELS (Continued)

OPERATION
The Tire Pressure Monitoring (TPM) system uses
radio and sensor technology to monitor tire air pres-
sure levels. Sensors, mounted to each road wheel as
part of the valve stem, transmit a low frequency indi-
cating their individual pressure to a receiver located
in the Wireless Control Module (WCM) portion of the
Sentry Key Remote Electronic Entry Module
(SKREEM). These transmissions occur approximately
once every minute at speeds over 20 mph (32 km/h).
The Tire Pressure Monitoring system remains active
even if no tire pressure related message is displayed.
The sensors lay dormant (Park Mode), then wake
and start transmitting (Drive Mode) when the vehicle
first reaches speeds over 20 mph (32 km/h). Once the
wheels stop rotating for a period of approximately 30
minutes, the sensors shut down until again awaken.
Although not transmitting as when in Drive Mode,
while in Park Mode, the sensors still transmit
approximately once every 13 hours to let the receiver
know air pressure status at that time.
The receiver only receives information from the
four rotating tires. A fifth sensor may be located in
the spare tire wheel, depending on vehicle options.
Although this fifth sensor may be present, it does not
broadcast any information because it does not rotate.
When the system detects that a tire is going low,
below the Low Pressure (lamp) ON Threshold (See
following table), the driver is alerted to the situation.
The Base system illuminates an indicator lamp,
warning the driver of a pressure issue and sounds an
audible chime. In equipped with the Premium sys-
tem, the information is also displayed on the Elec-
tronic Vehicle Information Center (EVIC).
Once pressure in the suspect tire raises above the
Low Pressure (lamp) OFF Threshold, the lamp will
go out and the system returns to normal.
TPM THRESHOLD PRESSURES
DESCRIPTION SPECIFICATION
Placard Pressure (Cold) 36 PSI (248 kPa)
Low Pressure OFF Threshold 33 PSI (228 kPa)
Low Pressure ON Threshold 28 PSI (193 kPa)
SENSOR - TPM
DESCRIPTION
On vehicles equipped with Tire Pressure Monitor-
ing, one tire pressure sensor is mounted to each road
wheel (Fig. 18), and depending on factory wheel
options, a sensor may be located in the spare tire
wheel. Both aluminum and steel wheels are used in
this system, although sensors for one type wheel can-
not be used in the other type wheel.Each sensor has an internal battery that lasts up
to 10 years. The battery is not serviceable. At the
time of battery failure, the sensor must be replaced.
The serviceable components of the tire pressure sen-
sor are:
²Sensor-To-Wheel Grommet
²Valve Stem Cap
²Valve Stem Core
Valve stem caps and cores are specifically designed
for the tire pressure monitoring sensors. Although
similar to standard valve stem caps and cores, they
are different.
CAUTION: Do not use a standard valve stem cap or
core in a tire pressure sensor. Always use the orig-
inal equipment style sensor cap and core.
CAUTION: Do not reuse the Sensor-To-Wheel Grom-
met. Always use a new grommet when installing a
pressure sensor and properly torque the sensor
nut.
CAUTION: Do not attempt to install a tire pressure
sensor in an aftermarket wheel. Use only in original
style factory wheels.
OPERATION
The battery operated tire pressure sensors lay dor-
mant (Park Mode), then wake and start transmitting
(Drive Mode) when the vehicle first reaches speeds
over 20 mph (32 km/h). Once the wheels stop rotat-
ing for a period of approximately 30 minutes, the
sensors shut down until again awaken. Although not
transmitting as when in Drive Mode, while in Park
Mode, the sensors still transmit approximately once
every 13 hours to let the receiver know air pressure
status at that time.
Each sensor transmits tire pressure data approxi-
mately once every minute. Each sensor's (transmit-
ter) broadcast is uniquely coded so that the wireless
control module (WCM) can monitor the state of each
of the sensors on the four rotating road wheels. The
WCM (located in the SKREEM) automatically learns
and stores the sensor's ID while driving after a sen-
sor has been replaced. There is no retraining neces-
sary.
The receiver only receives information from the
four rotating tires. A fifth sensor may be located in
the spare tire wheel, depending on vehicle options.
Although this fifth sensor may be present, it does not
broadcast any information because it does not rotate.
For additional information, refer to Appropriate
Diagnostic Information.
22 - 10 TIRES/WHEELSRS
TIRE PRESSURE MONITORING (Continued)

CAUTION
CAUTION: The use of tire sealants is strictly prohib-
ited for vehicles equipped with the Tire Pressure
Monitoring system. Tire sealants can clog tire pres-
sure sensors.
CAUTION: Tire pressure sensor valve stem caps
and cores are specially designed for the sensors.
Due to risk of corrosion, do not use a standard
valve stem cap or core in a tire pressure sensor in
place of the original equipment style sensor cap
and core.
CAUTION: Do not attempt to install a tire pressure
sensor in a steel wheel or aftermarket wheel. Use
tire pressure sensors in original style factory
wheels only.
NOTE: TPM thresholds have been established for
the original tire size equipped on the vehicle. Use
original size tires only to maintain system accuracy.
DIAGNOSIS AND TESTING - TIRE PRESSURE
SENSOR
NOTE: Tire pressure may increase from 2 to 6 psi
(14 to 41 kPa) during normal driving conditions. Do
NOT reduce this normal pressure build up.
If a fault in the system is detected, always check
air pressure in the tires first with a known accurate
air gauge and correct the inflation pressure. If any
tire is low, inspectallthe tires.
If the gauge-read pressure in the tires does not
indicate a tire pressure issue, refer to the appropri-
ate diagnostic information.
REMOVAL
(1) Remove tire and wheel assembly from vehicle.
(Refer to 22 - TIRES/WHEELS - REMOVAL)
CAUTION: The cap used on this valve stem con-
tains an O-ring seal to prevent contamination and
moisture from entering the valve stem. Retain this
valve stem cap for reuse. Do not substitute a regu-
lar valve stem cap in its place.
CAUTION: The valve stem used on this vehicle is
made of aluminum and the core is nickel plated
brass. The original valve stem core must be rein-
stalled and not substituted with a valve stem core
made of a different material. This is required to pre-
vent corrosion in the valve stem caused by the dif-
ferent metals.(2) Dismount tire from wheel following tire
changer manufacturers instructions while paying
special attention to the following to avoid damaging
the pressure sensor:
(a) When breaking the tire bead loose from the
wheel rim, avoid using the Bead Breaker in the
area of the sensor. That includes both front and
rear beads of the tire.
(b) When preparing to dismount the tire from
the wheel, carefully insert the mounting/dimount-
ing tool at the valve stem   10É (Fig. 17), then pro-
ceed to dismount the tire from the wheel. Use this
process on both the upper and lower tire beads.
(3) Using a thin wall socket, remove special nut
retaining sensor to wheel (Fig. 18).
(4) Remove sensor from wheel (Fig. 18).
INSTALLATION
NOTE: Before reinstalling a tire pressure sensor,
replace sealing grommet at base of valve stem.
(1) Wipe area clean where sensor sealing grommet
contacts wheel. Make sure surface of wheel is not
damaged.
(2) Install sensor in wheel as shown (Fig. 18). Do
not attempt to mount sensor otherwise, damage may
occur.
(3) Using a thin wall socket, install special sensor
nut (Fig. 18). Tighten nut to 4 N´m (35 in. lbs.)
torque.
Fig. 17 Start Mount/Dismount Tool Within 10
Degrees Of Valve Stem
RSTIRES/WHEELS22-11
SENSOR - TPM (Continued)

CAUTION: Over-torquing the sensor nut by as little
as 12 N´m (106 in. lbs.) may result in sensor sepa-
ration from the valve stem. Under this condition,
the sensor may still function, however, the condi-
tion should be corrected immediately.
(4) Mount tire on wheel following tire changer
manufacturers instructions, paying special attention
to the following to avoid damaging tire pressure sen-
sor:
(a) Rotating Wheel Tire Changers - Once the
wheel is mounted to the changer, position the sen-
sor valve stem approximately 210É from the head
of the changer in a clockwise direction before rotat-
ing the wheel (also in a clockwise direction) to
mount the tire (Fig. 19). Use this procedure on
both the upper and lower tire beads.
(b) Rotating Tool Tire Changers - Position the
wheel on the changer so that the sensor valve stem
is approximately 210É from the head of the changer
in a clockwise direction from the mounting end of
the tool (Fig. 20) Make sure the sensor is clear of
the lower bead breaker area to avoid damaging the
sensor when the breaker rises (Fig. 20). Rotate the
tool in a counterclockwise direction to mount the
tire. Use this procedure on both the upper and
lower tire beads.
(5) Install wheel and tire assembly on vehicle.
(Refer to 22 - TIRES/WHEELS - INSTALLATION)
Fig. 18 Sensor Mounting To Wheel
1 - TIRE PRESSURE SENSOR
2 - WHEEL
3 - NUT
Fig. 19 Mounting Tire Using Rotating Wheel
Machine
1 - HEAD OF CHANGER LOCATED HERE
2 - VALVE STEM
Fig. 20 Mounting Tire Using Rotating Tool Machine
1 - VALVE STEM
2 - MOUNTING END OF TOOL
3 - BEAD BREAKER (KEEP CLEAR OF SENSOR)
22 - 12 TIRES/WHEELSRS
SENSOR - TPM (Continued)

DIAGNOSIS AND TESTING - WHEEL
INSPECTION
Inspect wheels for:
²Excessive runout
²Dents, cracks or irregular bends
²Damaged wheel stud (lug) holes
²Air Leaks
NOTE: Do not attempt to repair a wheel by hammer-
ing, heating or welding.
If a wheel is damaged, an original equipment
replacement wheel should be used. When obtaining
replacement wheels, they must be equivalent in load
carrying capacity. The diameter, width, offset, pilot
hole and bolt circle of the wheel should be the same
as the original wheel.
WARNING: FAILURE TO USE EQUIVALENT
REPLACEMENT WHEELS MAY ADVERSELY
AFFECT THE SAFETY AND HANDLING OF THE
VEHICLE.
WARNING: REPLACEMENT WITH USED WHEELS IS
NOT RECOMMENDED. THE SERVICE HISTORY OF
THE WHEEL MAY HAVE INCLUDED SEVERE TREAT-
MENT OR VERY HIGH MILEAGE. THE RIM COULD
FAIL WITHOUT WARNING.
CLEANING
WHEEL AND WHEEL TRIM CARE
All wheels and wheel trim, especially aluminum
and chrome plated, should be cleaned regularly using
mild soap and water to maintain their luster and to
prevent corrosion. Wash them with the same soap
solution recommended for the body of the vehicle.
When cleaning extremely dirty wheels, care must
be taken in the selection of tire and wheel cleaning
chemicals and equipment to prevent damage to the
wheels. MopartWheel Treatment or MopartChrome
Cleaner is recommended. Any of the ªDO NOT USEº
items listed below can damage wheels and wheel
trim.DO NOT USE:
²Any abrasive cleaner
²Any abrasive cleaning pad (such as steel wool)
or abrasive brush
²Any cleaner that contains an acid which can
react with and discolor the chrome surface.Many
wheel cleaners contain acids that can harm the
wheel surface.
²Oven cleaner
²A car wash that uses carbide-tipped wheel clean-
ing brushes or acidic solutions.
SPECIFICATIONS
WHEEL
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Wheel Mounting (Lug)
Nut Hex Size19 mm
Wheel Mounting Stud
SizeM12 x 1.5 mm
TORQUE SPECIFICATIONS
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
TPM Sensor Mounting Nut 4 Ð 35
Wheel Mounting (Lug ) Nut 135 100 Ð
WHEEL COVER
DESCRIPTION
This vehicle uses a bolt-on type wheel cover (Fig.
29).
This bolt-on wheel cover cannot be removed from
the wheel until three of the five wheel mounting nuts
shown are removed (Fig. 29). The bolt-on wheel cover
can then be removed with the remaining two wheel
nuts tightened in place.
REMOVAL
(1) Noting the location of the valve stem in rela-
tionship to the wheel mounting nuts, remove the
three wheel mounting nuts securing the wheel cover
to the wheel and hub (Fig. 29).
CAUTION: When removing the wheel cover, do not
pry the wheel cover from the wheel. This can result
in damage to the wheel cover. The wheel cover is
removed by pulling it off the wheel by hand.
RSTIRES/WHEELS22-19
WHEELS (Continued)

INSTRUMENT PANEL
ASSEMBLY
REMOVAL
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, OCCUPANT
CLASSIFICATION SYSTEM, SEAT BELT TEN-
SIONER, IMPACT SENSOR, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
DISCONNECT AND ISOLATE THE BATTERY NEGA-
TIVE (GROUND) CABLE, THEN WAIT TWO MINUTES
FOR THE SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH ON VEHICLES EQUIPPED WITH THE OCCU-
PANT CLASSIFICATION SYSTEM (OCS), ONLY THE
OCCUPANT CLASSIFICATION MODULE (OCM) AND
THE SEAT CUSHION TRIM MAY BE SERVICED SEP-
ARATELY. ALL OTHER COMPONENTS OF THE PAS-
SENGER SIDE FRONT SEAT CUSHION ASSEMBLY
MUST BE SERVICED ONLY AS A COMPLETE FAC-
TORY-CALIBRATED, ASSEMBLED AND TAMPER-EV-
IDENT SERVICE REPLACEMENT PACKAGE. THIS
PACKAGE INCLUDES THE FRAME, SPRINGS, PAD,
BLADDER, SENSOR, FOAM, WIRING AND A CALI-
BRATED OCM. WHEN INSTALLING THIS PACKAGE
ALWAYS REPLACE ALL OF THE EXISTING COMPO-
NENTS WITH THE NEW COMPONENTS AS A UNIT.
DO NOT ATTEMPT TO SEPARATE OR DISCONNECT
ANY OF THE NEW OCS COMPONENTS IN THE SER-
VICE REPLACEMENT PACKAGE FROM EACH
OTHER, AND DO NOT ATTEMPT TO REUSE ANY OF
THE REPLACED COMPONENTS IN THIS OR ANY
OTHER VEHICLE. FAILURE TO TAKE THE PROPER
PRECAUTIONS COULD RESULT IN FAILURE OF
THE PASSENGER AIRBAG TO DEPLOY WHEN
REQUIRED, OR IN PASSENGER AIRBAG DEPLOY-
MENT WHEN NOT REQUIRED.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the lower console:
(a) Remove five retaining screws.
(b) Pull rearward and disconnect the auxiliary
power outlet.(c) Remove lower console from vehicle.
(3) Remove the bolts attaching the lower supports
to the instrument panel frame (Fig. 3).
(4) Remove the bolts attaching the lower supports
to the floor pan.
(5) Remove the both left and right side A-pillar
trim covers using a trim stick (special tool #C-4755)
or equivalent gently pry out on the trim covers and
remove.
(6) Remove the instrument panel top cover. (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL TOP PAD - REMOVAL).
(7) Disconnect the wire connectors from the Pas-
senger Airbag.
(8) Remove the two screws to each right and left
cowl trim covers.
(9) Remove screws attaching instrument panel
frame to the dash panel below windshield opening
(Fig. 4).
(10) Remove the glove box:
(a) Push in on sides of glove box bin and lower
door.
(b) Pivot glove box downward and disengage
hinge hooks from instrument panel.
(c) Remove glove box from vehicle.
(11) Disconnect the antenna lead connector from
behind the glove box.
(12) Disconnect the right side wire connectors from
the HVAC behind the glove box area and the two
antenna connectors behind the glove box hinge.
Fig. 3 FLOOR TO CENTER STACK BRACKETS
1 - DASH PANEL OCCUPANT BRACKET
2 - FLOOR BRACKET NUT
3 - FLOOR TO CENTER STACK BRACKET (RIGHT)
4 - BRACKET ATTACHING SCREW(S)
5 - FLOOR TO CENTER STACK BRACKET (LEFT)
RSINSTRUMENT PANEL23-67