ECU CHRYSLER CARAVAN 2002 Service Manual

(14) Install cupholder plugs (Fig. 152).
(15) Install gearshift boot to console (Fig. 153).
Secure with three (3) retainer clips.
(16) Install gearshift knob to gearshift lever (Fig.
154). Orient shift pattern
1¤4-turn clockwise, push
down and rotate1¤4-turn counter-clockwise and
release. Secure boot to knob.
(17) Connect battery negative cable.
ADJUSTMENTS
ADJUSTMENT
(1) Disconnect battery negative cable.
(2) Remove gearshift knob by pushing down and
rotating
1¤4-turn clock-wise (Fig. 155).
Fig. 152 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
Fig. 153 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 154 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 155 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
21 - 366 T850 MANUAL TRANSAXLERS
GEARSHIFT CABLE - CROSSOVER (Continued)
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(9) Torque crossover lever adjustment screw to 8
N´m (70 in. lbs.).No load should be applied to
the shifter lever in any direction (hands off)
while tightening screw.
(10) Verify gearshift lever travel through all gear
ranges with engine off (not running).
(11) Install center console assembly (Fig. 158).
Install and torque center console-to-gearshift mecha-
nism screws to 5 N´m (45 in. lbs.).
(12) Install cupholder plugs (Fig. 157).
(13) Install gearshift boot to console (Fig. 156).
Secure boot to console with three (3) retainer clips.
(14) Install gearshift knob to gearshift lever (Fig.
155). Orient shift pattern on knob
1¤4-turn clockwise,
push down and rotate1¤4-turn counter-clockwise and
release. Secure boot to knob.
(15) Connect battery negative cable.
GEARSHIFT CABLE -
SELECTOR
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove gearshift knob by pushing down and
rotating
1¤4-turn clock-wise (Fig. 160).(3) Remove gearshift boot from center console by
disengaging at three (3) retaining clips (Fig. 161).
(4) Apply park brake to allow park brake handle to
clear center console upon removal.
(5) Remove two (2) cupholder bottom plugs (Fig.
162).
Fig. 160 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 161 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 162 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
21 - 368 T850 MANUAL TRANSAXLERS
GEARSHIFT CABLE - CROSSOVER (Continued)
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(15) Disconnect crossover cable from transaxle
crossover lever (Fig. 171).
(16) Remove crossover cable retainer clip and dis-
engage cable from mount bracket (Fig. 171).
(17) Raise vehicle on hoist.
(18) Remove selector cable from engine compart-
ment, then remove cable from passenger compart-
ment through opening in floor pan.
INSTALLATION
(1) From underneath vehicle, install gearshift
selector cable into passenger compartment through
floor pan hole. Install remainder of cable into posi-
tion in engine compartment.
(2) Lower vehicle.
(3) Install selector cable to mount bracket and
secure with retainer clip (Fig. 172).
(4) Install cable to transaxle selector lever (Fig.
172).
(5)2.4L Gas models goto Step 10. 2.5L TD
models:Install coolant recovery bottle bracket (Fig.
173).
Fig. 171 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
Fig. 172 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
Fig. 173 Coolant Recovery Bottle Bracket
1 - COOLANT RECOVERY BOTTLE BRACKET
2 - NUT
3 - MOUNT BRACKET
RST850 MANUAL TRANSAXLE21 - 371
GEARSHIFT CABLE - SELECTOR (Continued)
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(14) Install gearshift boot to console (Fig. 182).
Secure with three (3) retainer clips.
(15) Install gearshift knob to gearshift lever (Fig.
183). Orient shift pattern
1¤4-turn clockwise, push
down and rotate1¤4-turn counter-clockwise and
release. Secure boot to knob.
(16) Connect battery negative cable.
GEARSHIFT KNOB
REMOVAL
(1) Separate gearshift boot from base of knob.
(2) Remove gearshift knob by pushing down and
rotating
1¤4-turn clockwise (Fig. 184).
INSTALLATION
(1) Install gearshift knob pattern1¤4-turn clock-
wise, press down, and rotate1¤4-turn counter clock-
wise (Fig. 184).
(2) Secure gearshift boot to base of knob.
Fig. 182 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 183 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 184 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
21 - 374 T850 MANUAL TRANSAXLERS
GEARSHIFT CABLE - SELECTOR (Continued)
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(6) Install center console assembly (Fig. 201).
Install and torque center console-to-gearshift mecha-
nism screws to 5 N´m (45 in. lbs.).
(7) Install cupholder plugs (Fig. 202).(8) Install gearshift boot to console (Fig. 203).
Secure with three (3) retainer clips.
(9) Install gearshift knob to gearshift lever (Fig.
204). Orient shift pattern
1¤4-turn clockwise, push
down and rotate1¤4-turn counter-clockwise and
release. Secure boot to knob.
(10) Connect battery negative cable.
Fig. 201 Center Console Removal/Installation (LHD
Shown Ð RHD Typical)
1 - CENTER CONSOLE
2 - SCREW (4)
3 - GEARSHIFT MECHANISM
Fig. 202 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
Fig. 203 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 204 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
RST850 MANUAL TRANSAXLE21 - 379
GEARSHIFT MECHANISM (Continued)
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(3) Remove input bearing. Place input shaft
assembly onto arbor press table, with the input bear-
ing supported by bearing splitter (Fig. 207). Using
adapter 8486-4, press bearing off of shaft, while
helper supports shaft to prevent dropping.
(4) Place input shaft assembly back into fixture
8487. Secure fixture to bench with fasteners, or
secure to bench vise.
NOTE: 5th gear nut is staked to the shaft. If neces-
sary, grind stake area to ease removal, but use care
not to contact gear.
(5) Remove 5th gear nut with wrench 8478 (Fig.
208). Discard nut and use a new one upon assembly.
(6) Remove 5th gear with arbor press and bearing
splitter.
(7) Remove 4th gear (Fig. 209).
Fig. 207 Input Bearing Removal
1 - ARBOR PRESS RAM
2 - ADAPTER 8486-4
3 - INPUT BEARING
4 - BEARING SPLITTER
Fig. 208 5th Gear Nut Removal/Installation
1 - WRENCH 8478
2 - 5TH GEAR NUT
Fig. 209 4th Gear Removal/Installation
1 - 4th GEAR
RST850 MANUAL TRANSAXLE21 - 381
INPUT SHAFT (Continued)
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STANDARD PROCEDURE - TIRE AND WHEEL
ROTATION
NON-DIRECTIONAL TREAD PATTERN TIRES
Tires on the front and rear axles operate at differ-
ent loads and perform different functions. For these
reasons, they wear at unequal rates, and tend to
develop irregular wear patterns. These effects can be
reduced by timely rotation of tires. The benefits of
rotation are especially worthwhile. Rotation will
increase tread life, help to maintain mud, snow, and
wet traction levels, and contribute to a smooth, quiet
ride.
The suggested rotation method is the forward-cross
tire rotation method (Fig. 11). This method takes
advantage of current tire industry practice which
allows rotation of radial-ply tires. Other rotation
methods may be used, but may not have all the ben-
efits of the recommended method.
NOTE: Only the 4 tire rotation method may be used
if the vehicle is equipped with a low mileage or tem-
porary spare tire.
DIRECTIONAL TREAD PATTERN TIRES
Some vehicles are fitted with special high-perfor-
mance tires having a directional tread pattern. These
tires are designed to improve traction on wet pave-
ment. To obtain the full benefits of this design, the
tires must be installed so that they rotate in the cor-
rect direction. This is indicated by arrows on the tire
sidewalls.When wheels and tires are being installed, extra
care is needed to ensure that this direction of rota-
tion is maintained.
Refer to Owner's Manual for rotation schedule.
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.
Fig. 10 Aluminum Wheel Weight
1 - TIRE
2 - WHEEL
3 - WHEEL WEIGHT
Fig. 11 Forward-Cross Tire Rotation Method
RSTIRES/WHEELS22-7
TIRES/WHEELS (Continued)
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(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).
(3) Place the wheel cover on the wheel in the fol-
lowing fashion:
Fig. 12 NUTS SECURING WHEEL COVER
1 - VALVE STEM
2 - BOLT-ON WHEEL COVER
3 - NUTS SECURING WHEEL COVER
Fig. 13 Tightening Sequence
Fig. 14 TWO WHEEL MOUNTING NUTS INSTALLED
1 - WHEEL
2 - VALVE STEM
3 - HUB PILOT
4 - NUTS
22 - 8 TIRES/WHEELSRS
TIRES/WHEELS (Continued)
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(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
(TPM)
DESCRIPTION
Some versions of this vehicle are equipped with a
Tire Pressure Monitoring (TPM) system. It monitors
air pressure in the four road tires (excludes spare).
Pressure in the spare tire is not monitored.
There is a sensor (transmitter) in each of the vehi-
cle's four road wheels. The system alerts the driver
when tire pressure falls outside predetermined
thresholds (pressure too low or too high). A message
is then displayed on the Electronic Vehicle Informa-
tion Center (EVIC) located in the overhead console.
For further information, refer to the Owners Man-
ual or the appropriate diagnostic information.
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 tire pressure read-
ings to a receiver located in the overhead console.
These transmissions occur 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 in the EVIC.
If any road tire pressure has exceeded the low or
high pressure threshold (refer to chart below), the
TPM system will display a message in the EVIC and
sound a chime. This message will be displayed for
the rest of the ignition cycle, or until either the Low/
High Tire pressure condition has been corrected. If
the C/T, MENU, STEP or RESET button is pressed,
the message is replaced by the new message
requested; however, if the Low/High Tire condition
has not been corrected, the Low/High Tire pressure
message will again be displayed.
If a road tire is replaced by the spare, the TPM
system will detect the swap and the message9SPARE
TIRE IN USE? Y/N9(along with a chime) will be dis-
played.
For further information, refer to the Owners Man-
ual or the Appropriate Diagnostic Information.
TPM THRESHOLD PRESSURES
High Pressure ON Threshold 48 PSI (331 kPa)
High Pressure OFF Threshold 43 PSI (296 kPa)
Placard Pressure (Cold) 36 PSI (248 kPa)
Low Pressure OFF Threshold 33 PSI (228 kPa)
Low Pressure ON Threshold 28 PSI (193 kPa)
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)
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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.
Wheel Mounting (Lug ) Nut 135 100 Ð
WHEEL COVER
DESCRIPTION
This vehicle uses a bolt-on type wheel cover (Fig.
30).
This bolt-on wheel cover cannot be removed from
the wheel until three of the five wheel mounting nuts
shown are removed (Fig. 30). 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. 30).
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.
(2) Grasp the wheel cover at the edges in line with
the remaining installed wheel nuts and pull straight
outward from the wheel. This will pop the wheel
cover retaining tabs over the two remaining wheel
nuts, removing the wheel cover from the wheel.
INSTALLATION
NOTE: Wheel mounting nuts must be installed on
the studs as shown to allow installation of the
wheel cover (Fig. 31).
(1) 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. 32).
(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. 32).
This will hold the wheel cover in place.
(2) Install andlightly tightenthe three remain-
ing wheel mounting nuts, securing the wheel cover in
place (Fig. 30).
Fig. 30 Nuts Securing Wheel Cover
1 - VALVE STEM
2 - BOLT-ON WHEEL COVER
3 - NUTS SECURING WHEEL COVER
Fig. 31 Two Wheel Mounting Nuts Installed
1 - WHEEL
2 - VALVE STEM
3 - HUB PILOT
4 - NUTS
RSTIRES/WHEELS22-19
WHEELS (Continued)
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