2005 CHRYSLER CARAVAN lock

(7) Remove oil filter (Fig. 337).
(8) Remove the valve body-to-transaxle case bolts
(Fig. 338).
NOTE: To ease removal of the valve body, turn the
manual valve lever fully clockwise to low or first
gear.(9) Remove park rod rollers from guide bracket
and remove valve body from transaxle (Fig. 339) (Fig.
340).
CAUTION: The valve body manual shaft pilot may
distort and bind the manual valve if the valve body
is mishandled or dropped.
Fig. 337 Oil Filter
1 - OIL FILTER
2 - O-RING
Fig. 338 Valve Body Attaching Bolts
1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
Fig. 339 Push Park Rod Rollers from Guide Bracket
1 - PARK SPRAG ROLLERS
2 - SCREWDRIVER
3 - PARK SPRAG GUIDE BRACKET
Fig. 340 Valve Body Removal/Installation
1 - VALVE BODY
RS41TE AUTOMATIC TRANSAXLE21 - 285
VALVE BODY (Continued)

unique wheel weights. They are designed to fit the
contour of the wheel (Fig. 1).
²Inspect tires and wheels for damage, mud pack-
ing and unusual wear; correct as necessary.
²Check and adjust tire air pressure to the pres-
sure listed on the label attached to the rear face of
the driver's door.
ROAD TEST
Road test vehicle on a smooth road for a least five
miles to warm tires (remove any flat spots). Lightly
place hands on steering wheel at the 10:00 and 2:00
positions while slowly sweeping up and down from 90
to 110 km/h (55 to 70 mph) where legal speed limits
allow.
Observe the steering wheel for:
²Visual Nibble (oscillation: clockwise/counter-
clockwise, usually due to tire imbalance)
²Visual Buzziness (high frequency, rapid vibra-
tion up and down)
To rule out vibrations due to brakes or powertrain:
²Lightly apply brakes at speed; if vibration occurs
or is enhanced, vibration is likely due to causes other
than tire and wheel assemblies.
²Shift transmission into neutral while vibration
is occurring; if vibration is eliminated, vibration is
likely due to causes other than tire and wheel assem-
blies.
For brake vibrations, (Refer to 5 - BRAKES -
BASE/HYDRAULIC/MECHANICAL/ROTORS -
DIAGNOSIS AND TESTING).
For powertrain vibrations, (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE - DIAGNOSIS AND TEST-
ING).
For tire and wheel assembly vibrations, continue
with this diagnosis and testing procedure.
TIRE AND WHEEL BALANCE
(1) Balance the tire and wheel assemblies as nec-
essary following the wheel balancer manufacturer's
instructions and using the information listed in Stan-
dard Procedure - Tire And Wheel Balance. (Refer to
22 - TIRES/WHEELS - STANDARD PROCEDURE)
(2) Road test the vehicle for at least 5 miles, fol-
lowing the format described in Road Test.
(3) If the vibration persists, continue with this
diagnosis and testing procedure.
TIRE AND WHEEL RUNOUT/MATCH MOUNTING
(1)System Radial Runout.This on-the-vehicle
system check will measure the radial runout includ-
ing the hub, wheel and tire.
(a) Raise vehicle so tires clear floor. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(b) Apply masking tape around the circumfer-
ence of the tire in the locations to be measured
(Fig. 2). Do not overlap the tape.
(c) Check system runout using Dial Indicator
Set, Special Tool C-3339A with 25-W wheel, or
equivalent. Place the end of the indicator against
each taped area (one at a time) (Fig. 2) and rotate
the tire and wheel. System radial runout should
not exceed 0.76 mm (0.030 inch) with no tread
ªdipsº or ªsteps.º Tread ªdipsº and ªstepsº can be
identified by spikes of the dial indicator gauge.
²Tread9dips9; Rapid decrease then increase in
dial indicator reading over 101.6 mm (4.0 inch) of
tread circumference.
²Tread9steps9; Rapid decrease or increase in dial
indicator reading over 101.6 mm (4.0 inch) of tread
circumference.
(d) If system runout is excessive, re-index the
tire and wheel assembly on the hub. Remove
assembly from vehicle and install it back on the
hub two studs over from original mounting posi-
tion. If re-indexing the tire and wheel assembly
corrects or reduces system runout, check hub
runout and repair as necessary (Refer to 5 -
BRAKES - BASE/HYDRAULIC/MECHANICAL/
ROTORS - DIAGNOSIS AND TESTING).
(e) If system runout is still excessive, continue
with this diagnosis and testing procedure.
(2)Tire and Wheel Assembly Radial Runout.
This radial runout check is performed with the tire
and wheel assembly off the vehicle.
(a) Remove tire and wheel assembly from vehicle
and install it on a suitable wheel balancer.
Fig. 1 Aluminum Wheel Weight
1 - TIRE
2 - WHEEL
3 - WHEEL WEIGHT
22 - 2 TIRES/WHEELSRS
TIRES/WHEELS (Continued)

REMOVAL
REMOVAL - TIRE AND WHEEL ASSEMBLY
(ALUMINUM WHEEL)
(1) Raise the vehicle so the tire and wheel assem-
bly clears ground level.
(2) Remove the 5 wheel mounting nuts from the
studs.
(3) Remove the tire and wheel from the hub.
REMOVAL - TIRE AND WHEEL ASSEMBLY
(STEEL WHEEL)
(1) Raise the vehicle so the tire and wheel assem-
bly clears ground level.
(2) 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. 12).
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.
(3) Grasp the wheel cover at the edges in line with
the remaining installed wheel mounting nuts and
pull straight outward from the wheel. This will pop
the wheel cover retaining tabs over the two remain-
ing wheel nuts, removing the wheel cover from the
vehicle.
(4) Remove the two remaining wheel mounting
nuts from the hub's studs.
(5) Remove the wheel and tire from the hub.
INSTALLATION
INSTALLATION - TIRE AND WHEEL ASSEMBLY
(ALUMINUM WHEEL)
NOTE: Never use oil or grease on studs or wheel
mounting nuts.
(1) Position the tire and wheel assembly on the
wheel mounting studs using the hub pilot as a guide.
Place and hold the wheel flush up against the mount-
ing surface.
(2) Loosely install all 5 wheel mounting nuts.
Lightly snug the wheel nuts, then progressively
tighten them in the proper sequence (Fig. 13).
Tighten wheel mounting nuts to 135 N´m (100 ft.
lbs.).
(3) Lower the vehicle.
INSTALLATION - TIRE AND WHEEL ASSEMBLY
(STEEL WHEEL)
NOTE: Never use oil or grease on studs or wheel
mounting nuts.
(1) Position the tire and wheel assembly on the
wheel mounting studs using the hub pilot as a guide.
Place and hold the wheel flush up against the mount-
ing surface.
NOTE: Wheel mounting nuts must be installed on
the studs as shown (Fig. 14) to allow proper instal-
lation of the wheel cover.
(2) Using the valve stem as an index placed at the
12 O'clock position, install andlightly tightentwo
wheel mounting nuts on the studs located at the 4
O'clock and 8 O'clock positions as shown (Fig. 14).
Fig. 12 NUTS SECURING WHEEL COVER
1 - VALVE STEM
2 - BOLT-ON WHEEL COVER
3 - NUTS SECURING WHEEL COVER
Fig. 13 Tightening Sequence
22 - 8 TIRES/WHEELSRS
TIRES/WHEELS (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)

BODY
TABLE OF CONTENTS
page page
BODY
DESCRIPTION - VEHICLE IDENTIFICATION....1
WARNING
SAFETY PRECAUTIONS AND WARNINGS . . . 1
DIAGNOSIS AND TESTING
WATER LEAKS........................1
WIND NOISE..........................2
STANDARD PROCEDURE
STANDARD PROCEDURE - PLASTIC BODY
PANEL REPAIR........................3
STANDARD PROCEDURE - HEAT STAKING . . 9
SPECIFICATIONS
TORQUE............................10
BODY LUBRICATION...................12
SPECIAL TOOLS
BODY..............................13DOOR - FRONT.........................14
DOORS - SLIDING.......................24
DECKLID/HATCH/LIFTGATE/TAILGATE.......40
EXTERIOR.............................45
HOOD.................................62
INSTRUMENT PANEL.....................65
INTERIOR..............................78
PAINT................................100
SEATS...............................102
STATIONARY GLASS....................161
WEATHERSTRIP/SEALS..................166
SUNROOF.............................169
BODY STRUCTURE.....................177
BODY
DESCRIPTION - VEHICLE IDENTIFICATION
Throughout this group, references to the
DaimlerChrysler Corporation vehicle family identifi-
cation code are used when describing a procedure
that is unique to that vehicle. Refer to Introduction
Group of this manual for detailed information on
vehicle identification. If a procedure is common to all
vehicles covered in this manual, no reference will be
made to a vehicle family code.
WARNING
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE A OSHA APPROVED BREATHING
FILTER WHEN SPRAYING PAINT OR SOLVENTS IN
A CONFINED AREA. PERSONAL INJURY CAN
RESULT.
AVOID PROLONGED SKIN CONTACT WITH PETRO-
LEUM OR ALCOHOL ± BASED CLEANING SOL-
VENTS. PERSONAL INJURY CAN RESULT.
DO NOT STAND UNDER A HOISTED VEHICLE THAT
IS NOT PROPERLY SUPPORTED ON SAFETY
STANDS. PERSONAL INJURY CAN RESULT.
CAUTION: When holes must be drilled or punched
in an inner body panel, verify depth of space to the
outer body panel, electrical wiring, or other compo-nents. Damage to vehicle can result.
Do not weld exterior panels unless combustible
material on the interior of vehicle is removed from
the repair area. Fire or hazardous conditions, can
result.
Always have a fire extinguisher ready for use when
welding.
Disconnect the negative (-) cable clamp from the
battery when servicing electrical components that
are live when the ignition is OFF. Damage to electri-
cal system can result.
Do not use abrasive chemicals or compounds on
painted surfaces. Damage to finish can result.
Do not use harsh alkaline based cleaning solvents
on painted or upholstered surfaces. Damage to fin-
ish or color can result.
Do not hammer or pound on plastic trim panel
when servicing interior trim. Plastic panels can
break.
DIAGNOSIS AND TESTING
WATER LEAKS
Water leaks can be caused by poor sealing,
improper body component alignment, body seam
porosity, missing plugs, or blocked drain holes. Cen-
trifugal and gravitational force can cause water to
drip from a location away from the actual leak point,
making leak detection difficult. All body sealing
points should be water tight in normal wet-driving
conditions. Water flowing downward from the front of
RSBODY23-1

CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION
UP UNSATURATED
POLYESTER
(THERMOSETTING)SMC, BMC, TMC, ZMC, IMC,
XSMC, UPGRILLE OPENING PANEL,
LIFTGATES, FLARESIDE
FENDERS, FENDER
EXTENSIONS
EEBC ETHER/ESTER BLOCKED
CO-POLYMEREEBC BUMPERS
EEBC/PBTP EEBC/POLYBUTYLENE
TEREPTHALATEEEBC, PBTP, BEXLOY BUMPER, ROCKER PANELS
EMPP ETHYLENE MODIFIED
POLYPROPYLENEEMPP BUMPER COVERS
EPDM ETHYLENE/
PROPROPYLENE DIENE
MONOMEREPDM, NORDEL, VISTALON BUMPERS
EPM ETHYLENE/
PROPROPYLENE CO-
POLYMEREPM FENDERS
MPU FOAM POLYURETHANE MPU SPOILERS
PE POLYETHYLENE ALATHON, DYLAN,
LUPOLEN, MARLEX-
PP POLYPROPYLENE
(BLENDS)NORYL, AZDEL, MARLOX,
DYLON, PRAVEXINNER FENDER, SPOILERS,
KICK PANELS,A-PILLARS,
DOOR PANELS, B-PILLARS,
QUARTER PANELS, SPORT
BAR TRIM, LIFTGATE TRIM,
DECKLID TRIM SCUFF
PLATES, KICK PANELS,
CONSOLES
PP/EPDM PP/EPDM ALLOY PP/EPDM SPOILERS, GRILLES
PUR POLYURETHANE COLONELS, PUR, PU FASCIAS, BUMPERS
PUR/PC PUR/PC ALLOY TEXIN BUMPERS
PVC POLYVINYL CHLORIDE APEX, GEON, VINYLITE BODY MOLDINGS, WIRE
INSULATION, STEERING
WHEELS
RIM REACTION INJECTED
MOLDED POLYURETHANERIM, BAYFLEX FRONT FASCIAS, MODULAR
WINDOWS
RRIM REINFORCED REACTION
INJECTED MOLDEDPUR, RRIM FASCIAS, BODY PANELS,
BODY TRIMS
TPE THERMO POLYETHYLENE TPE, HYTREL, BEXLOY-V FASCIAS, BUMPERS,
CLADDINGS
TPO THERMOPOLYOLEFIN POLYTROPE, RENFLEX,
SANTOPRENE, VISAFLEX,
ETA, APEX, TPO, SHIELDS,
CLADDINGSBUMPERS, END CAPS,
TELCAR, RUBBER, STRIPS,
SIGHT, INTERIOR B POST
TPP THERMO-POLYPROPYLENE TPP BUMPERS
TPU THERMOPOLYURETHANE,
POLYESTERTPU, HYTREL, TEXIN,
ESTANEBUMPERS, BODY SIDE,
MOLDINGS, FENDERS,
FASCIAS
RSBODY23-5
BODY (Continued)

(15) Install screws to hold the patch to support
squares (Fig. 12). Tighten screws until patch surface
is flush with panel surface.
(16) Allow adhesive to cure, and remove all screws.
(17) Using a 125 mm (5 in.) 24 grit disc grinder,
grind a 50 mm (2 in.) to 75 mm (3 in.) wide and 2
mm (0.080 in.) deep path across the gaps around the
patch (Fig. 13). With compressed air, blow dust from
around patch.
(18) Apply adhesive backed nylon mesh (dry wall
tape) over gaps around patch (Fig. 14).
(19) Mix enough adhesive to cover the entire patch
area.
(20) Apply adhesive over the mesh around patch,
and smooth epoxy with a wide spreader to reduce fin-
ish grinding. Use two to three layers of mesh and
adhesive to create a stronger repair (Fig. 15).
PATCHED PANEL SURFACING
After patch panel is installed, the patch area can
be finished using the same methods as finishing
other types of body panels. If mesh material is
exposed in the patched area, grind surface down, and
apply a coat of high quality rigid plastic body filler.
Prime, block sand, and paint as required.
STANDARD PROCEDURE - HEAT STAKING
(1) Remove trim panel.
(2) Bend or move the trim panel components at
the heat staked joints. Observe the heat staked loca-
tions and/or component seams for looseness.
(3) Heat stake the components.
Fig. 10 POSITION PATCH IN CUTOUT AND ALIGN
1 - CUTOUT
2 - SUPPORT SQUARES
Fig. 11 APPLY ADHESIVE TO SUPPORT SQUARES
1 - APPLICATOR
2 - SUPPORT SQUARES
3 - ADHESIVE
Fig. 12 INSTALL SCREWS
1 - PATCH
2 - GAP
Fig. 13 GRIND SURFACE
1 - PATCH
2 - GAP
3 - DISC GRINDER
RSBODY23-9
BODY (Continued)

DESCRIPTION N´m Ft. Lbs. In. Lbs.
Sliding door glass nuts 3.4 Ð 30
Sliding door latch striker 28 21 Ð
Sliding door to roller arm bracket 12 9 Ð
Storage bin track guide to seat riser 3.5 Ð 31
Sunroof opening panel to lifter arm screws 5 44
Sunroof opening panel motor screws 4 35
Sunroof trough bracket to roof bolts 6 53
Sunroof trough to trough bracket bolts 6 53
Sunroof trough bracket bolts 6 53
Support cylinders to liftgate 28 21 Ð
BODY LUBRICATION
LUBRICATION REQUIREMENTS
Body mechanisms and linkages should be
inspected, cleaned, and lubricated, as required, to
maintain ease of operation and to provide protection
against rust and wear. When performing other under
hood services, the hood latch release mechanism and
safety catch should be inspected, cleaned, and lubri-
cated. During the winter season, external door lock
cylinders should be lubricated to assure proper oper-
ation when exposed to water and ice.
Prior to the application of any lubricant, the parts
concerned should be wiped clean to remove dust and
grit. If necessary, a suitable solvent can be used to
clean the item to be lubricated. After lubricating a
component, any excess oil or grease should be
removed.
LUBRICANT APPLICATION
DOOR LOCK CYLINDERS
(1) Apply a small amount of lubricant directly into
the lock cylinder.
(2) Apply a small amount of lubricant to the key.
(3) Insert key into lock cylinder and cycle the
mechanism from the locked to the unlocked position.
NOTE: Do not add more lubricant.
(4) Cycle the lock cylinder mechanism several
times to allow the lubricant to flow throughout the
cylinder.
(5) Wipe all lubricant from exterior of lock cylinder
and key.ALL OTHER BODY MECHANISMS
(1) Clean component as described above.
(2) Apply specified lubricant to all pivoting and
sliding contact areas of component.
LUBRICANT USAGE
ENGINE OIL
²Door Hinges ± Hinge Pin and Pivot Contact
Areas
²Hood Hinges ± Pivot Points
²Liftgate Hinges
MOPARTSPRAY WHITE LUBE OR EQUIVALENT
²Door Check Straps
²Liftgate Latches
²Liftgate Prop Pivots
²Ash Receiver
²Fuel Filler Door Remote Control Latch Mecha-
nism
²Parking Brake Mechanism
²Sliding Seat Tracks
²Liftgate Latch
MOPARTMultipurpose GREASE OR EQUIVALENT
²All Other Hood Mechanisms
MOPARTLOCK CYLINDER LUBRICANT OR
EQUIVALENT
²Door Lock Cylinders
²Liftgate Lock Cylinder
23 - 12 BODYRS
BODY (Continued)