brake CHRYSLER CARAVAN 2002 Service Manual

(3) Remove gearshift boot from center console by
disengaging at three (3) retaining clips (Fig. 156).
(4) Apply park brake to allow park brake handle to
clear center console upon removal.
(5) Remove two (2) cupholder bottom plugs (Fig.
157).
(6) Remove four (4) center console-to-gearshift
mechanism screws. Remove console assembly (Fig.
158).(7) Loosen crossover cable adjustment screw (Fig.
159).
(8) Rock gearshift lever back and forth between
1±2 and 5±R planes. Release lever, allowing shifter
spring to return lever to the neutral position in the
3±4 plane. Place gearshift lever in the 3rd gear posi-
tion.
Fig. 156 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 157 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
Fig. 158 Center Console Removal/Installation (LHD
Shown Ð RHD Typical)
1 - CENTER CONSOLE
2 - SCREW (4)
3 - GEARSHIFT MECHANISM
Fig. 159 Crossover Cable Adjustment Screw
1 - CROSSOVER CABLE
2 - ADJUSTMENT SCREW
RST850 MANUAL TRANSAXLE21 - 367
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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GEARSHIFT MECHANISM
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove gearshift knob by pushing down and
rotating
1¤4turn clock-wise (Fig. 185).
(3) Remove gearshift boot from center console by
disengaging at three (3) retaining clips (Fig. 186).(4) Apply park brake to allow park brake handle to
clear center console upon removal.
(5) Remove two (2) cupholder bottom plugs (Fig.
187).
(6) Remove four (4) center console-to-gearshift
mechanism screws. Remove console assembly (Fig.
188).
Fig. 185 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 186 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 187 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
Fig. 188 Center Console Removal/Installation (LHD
Shown Ð RHD Typical)
1 - CENTER CONSOLE
2 - SCREW (4)
3 - GEARSHIFT MECHANISM
RST850 MANUAL TRANSAXLE21 - 375
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(11) Remove selector cable from gearshift mecha-
nism (Fig. 193).
(12) Remove four (4) gearshift mechanism-to-park
brake bracket nuts. Remove gearshift mechanism
from bracket (Fig. 194).INSTALLATION
(1) Install gearshift mechanism to park brake
bracket (Fig. 195). Install and torque nuts to 12 N´m
(108 in. lbs.).
(2) Install selector cable to gearshift mechanism
(Fig. 196). Install retainer clip (Fig. 197).
Fig. 193 Selector Cable at Gearshift Mechanism
1 - GEARSHIFT MECHANISM
2 - SELECTOR CABLE
Fig. 194 Gearshift Mechanism Removal/Installation
(RHD Shown Ð LHD Typical)
1 - GEARSHIFT MECHANISM
2 - PARK BRAKE BRACKET
3 - NUT (4)
Fig. 195 Gearshift Mechanism Removal/Installation
(RHD Shown Ð LHD Typical)
1 - GEARSHIFT MECHANISM
2 - PARK BRAKE BRACKET
3 - NUT (4)
Fig. 196 Selector Cable at Gearshift Mechanism
1 - GEARSHIFT MECHANISM
2 - SELECTOR CABLE
RST850 MANUAL TRANSAXLE21 - 377
GEARSHIFT MECHANISM (Continued)
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Inspect for the following:
²Verify correct (OEM) wheel and tire, as well as
correct wheel weights. Aluminum wheels require
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.
²
Shift transmission into neutral while vibration is
occurring; if vibration is eliminated, vibration is likely
due to causes other than tire and wheel assemblies.
For brake vibrations, (Refer to 5 - BRAKES -
BASE/HYDRAULIC/MECHANICAL/ROTORS -
DIAGNOSIS AND TESTING).
For powertrain vibrations, (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE - DIAGNOSIS AND TESTING).
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.
(b) 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. Radial runout should not
Fig. 1 Aluminum Wheel Weight
1 - TIRE
2 - WHEEL
3 - WHEEL WEIGHT
22 - 2 TIRES/WHEELSRS
TIRES/WHEELS (Continued)
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(6) Retrain tire pressure sensors. (Refer to 22 -
TIRES/WHEELS/TIRE PRESSURE MONITORING/
SENSOR - STANDARD PROCEDURE)
TIRES
DESCRIPTION
DESCRIPTION - TIRE
Tires are designed and engineered for each specific
vehicle. They provide the best overall performance
for normal operation. The ride and handling charac-
teristics match the vehicle's requirements. With
proper care they will give excellent reliability, trac-
tion, skid resistance, and tread life.
Driving habits have more effect on tire life than
any other factor. Careful drivers will obtain, in most
cases, much greater mileage than severe use or care-
less drivers. A few of the driving habits which will
shorten the life of any tire are:
²Rapid acceleration
²Severe application of brakes
²High-speed driving
²Taking turns at excessive speeds
²Striking curbs and other obstacles
²Operating vehicle with over or under inflated
tire pressuresRadial ply tires are more prone to irregular tread
wear. It is important to follow the tire rotation inter-
val shown in the section on Tire Rotation. This will
help to achieve a greater tread-life potential.
TIRE IDENTIFICATION
Tire type, size, load index and speed rating are
encoded in the letters and numbers imprinted on the
side wall of the tire. Refer to the chart to decipher
the tire identification code (Fig. 22). An All Season
type tire will have eitherM+S,M&SorM-S
(indicating mud and snow traction) imprinted on the
side wall. An Extra or Light Load marking ªXLº or
ªLLº may also be listed on the sidewall. The absence
of an ªXLº or ªLLº marking infers a standard load
tire.
Consult the tire manufacturer regarding any ques-
tions on tire specifications or capabilities.
TIRE CHAINS
Refer to the owners manual supplied with the vehi-
cle to determine whether the use of tire chains is per-
mitted on this vehicle.
DESCRIPTION - RADIAL-PLY TIRES
Radial-ply tires improve handling, tread life, ride
quality and decrease rolling resistance.
Fig. 21 Mounting Tire Using Rotating Tool Machine
1 - VALVE STEM
2 - MOUNTING END OF TOOL
3 - BEAD BREAKER (KEEP CLEAR OF SENSOR)
Fig. 22 Tire Identification (Typical)
RSTIRES/WHEELS22-13
SENSOR - TPM (Continued)
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(3) Tighten all five wheel mounting nuts in the
proper sequence (Fig. 33). Tighten wheel nuts to a
torque of 135 N´m (100 ft. lbs.).
WHEEL MOUNTING STUDS -
FRONT
REMOVAL
CAUTION: If a wheel mounting stud needs to be
replaced in the hub and bearing assembly, the
studs MUST NOT be hammered out of the hub
flange. If a stud is removed by hammering it out of
the bearing flange, damage to the hub and bearing
assembly will occur leading to premature bearing
failure.(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in Lubrication
and Maintenance.
(2) Remove the front wheel and tire assembly from
the vehicle.
(3) Remove the two adapter mounting bolts secur-
ing both the disc brake caliper adapter to the steer-
ing knuckle (Fig. 34).
(4) Remove the disc brake caliper and adapter as
an assembly from the steering knuckle (Fig. 34).
Hang the assembly out of the way using wire or a
bungee cord. Use care not to overextend the brake
hose when doing this.
(5) Remove brake rotor from hub by pulling it
straight off wheel mounting studs (Fig. 34).
(6) On the wheel mounting stud to be removed,
install a wheel mounting (lug) nut far enough so the
threads on the stud are even with end of nut. Install
Remover, Special Tool C-4150A on hub and bearing
assembly flange and wheel stud (Fig. 35).
(7) Tighten down on special tool, pushing wheel
stud out of the hub flange. When shoulder of wheel
stud is past flange, remove special tool from hub and
bearing. Remove nut from stud and remove stud
from hub flange.
Fig. 32 Wheel Cover Installation Over Two Nuts
1 - RETAINING TABS
2 - VALVE STEM
3 - BOLT-ON WHEEL COVER
Fig. 33 Nut Tightening Sequence
Fig. 34 Front Brake Mounting
1 - BRAKE ROTOR
2 - HUB AND BEARING
3 - STEERING KNUCKLE
4 - ADAPTER MOUNTING BOLTS
5 - BRAKE CALIPER
6 - ADAPTER
7 - CLIP
22 - 20 TIRES/WHEELSRS
WHEEL COVER (Continued)
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INSTALLATION
(1) Install replacement wheel stud into flange of
hub and bearing assembly. Install washers on wheel
stud, then install a wheel mounting (lug) nut on stud
with flat side of lug nut against washers as shown
(Fig. 36).(2) Tighten the nut, pulling the wheel stud into
the flange of the hub and bearing. When the head of
the stud is fully seated against the rear of the hub
flange, remove nut and washers from stud.
(3) Install the brake rotor back on the hub and
bearing (Fig. 34).
(4) Install brake caliper and adapter back over
brake rotor aligning adapter with mounting holes on
steering knuckle (Fig. 34).
(5) Install the two adapter mounting bolts securing
the adapter to the steering knuckle. Tighten the
mounting bolts to 169 N´m (125 ft. lbs.) torque.
(6) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting lug nuts in proper
sequence until all nuts are torqued to half specifica-
tion, then repeat the tightening sequence to the full
specified torque of 135 N´m (100 ft. lbs.).
(7) Lower vehicle to the ground.
WHEEL MOUNTING STUDS -
REAR
REMOVAL
CAUTION: If a wheel attaching stud needs to be
replaced in the hub and bearing assembly the studs
MUST NOT be hammered out of the hub flange. If a
stud is removed by hammering it out of the bearing
flange, damage to the hub and bearing assembly
will occur leading to premature hub and bearing
failure.
(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in Lubrication
and Maintenance.
(2) Remove the rear wheel and tire assembly.
(3) Remove the brake drum or disc brake caliper
and rotor. Refer to Brakes.
(4) Install a lug nut on the wheel stud to be
removed from the hub and bearing assembly (Fig. 37)
so the threads on stud are even with end of lug nut.
Install Remover, Special Tool C-4150A on hub and
bearing assembly flange and wheel stud (Fig. 37).
(5) Tightening down on special tool will push
wheel stud out of the hub and bearing assembly
flange.
(6) Remove lug nut from stud and remove wheel
stud from flange.
Fig. 35 Wheel Stud Removal (Typical)
1 - WHEEL MOUNTING (LUG) NUT
2 - HUB AND BEARING ASSEMBLY
3 - SPECIAL TOOL C-4150A
4 - STEERING KNUCKLE
5 - WHEEL STUD
Fig. 36 Installing Wheel Stud (Typical)
1 - WASHERS
2 - HUB AND BEARING ASSEMBLY
3 - WHEEL MOUNTING (LUG) NUT
4 - STEERING KNUCKLE
RSTIRES/WHEELS22-21
WHEEL MOUNTING STUDS - FRONT (Continued)
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INSTALLATION
(1) Install replacement wheel stud into flange of
hub and bearing assembly. Install washers on wheel
stud, then install a wheel lug nut on stud with flat
side of lug nut against washers (Fig. 38).
(2) Tighten the wheel lug nut, pulling the wheel
stud into the flange of the hub and bearing assembly.
When the head of the stud is fully seated against the
bearing flange, remove lug nut and washers from
wheel stud.(3) Install the brake drum or disc brake rotor and
caliper on the hub and bearing assembly.
(4) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting stud nuts in proper
sequence until all nuts are torqued to half specifica-
tion. Then repeat the tightening sequence to the full
specified torque of 135 N´m (100 ft. lbs.).
(5) Lower vehicle to the ground.
Fig. 37 Wheel Stud Removal From Hub And Bearing
1 - HUB AND BEARING ASSEMBLY
2 - WHEEL MOUNTING (LUG) NUT
3 - WHEEL STUD
4 - SPECIAL TOOL C-4150A
Fig. 38 Wheel Stud Installation
1 - WHEEL MOUNTING (LUG) NUT
2 - HUB AND BEARING ASSEMBLY
3 - WASHERS
4 - WHEEL STUD
22 - 22 TIRES/WHEELSRS
WHEEL MOUNTING STUDS - REAR (Continued)
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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
SPECIAL TOOLS
BODY
INDEX
DESCRIPTION FIGURE
STICK, TRIM C 4755 16
REMOVER, MOLDINGS C-4829 17
PLIERS, HEADLINER CLIP 6967 18
Fig. 16 STICK, TRIM C 4755
Fig. 17 REMOVER, MOLDINGS C-4829
Fig. 18 PLIERS, HEADLINER CLIP 6967
RSBODY23-13
BODY (Continued)
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