brake CHRYSLER CARAVAN 2005 Service Manual

(8) Road test vehicle to ensure proper operation of
the brakes.
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. 36)
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. 36).
(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.
INSTALLATION
(1) Install replacement wheel stud into flange of
hub and bearing assembly. Install washers on wheelstud, then install a wheel lug nut on stud with flat
side of lug nut against washers (Fig. 37).
(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. 35 Installing Wheel Stud (Typical)
1 - WASHERS
2 - HUB AND BEARING ASSEMBLY
3 - WHEEL MOUNTING (LUG) NUT
4 - STEERING KNUCKLE
Fig. 36 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. 37 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 - FRONT (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)

(8) Route cable back from latch through engine
compartment toward dash panel near power brake
booster (Fig. 5).
(9) Remove attaching clips from cable case.
(10) From inside vehicle, pull cable through dash
panel until mechanic's wire is exposed.
(11) Disconnect cable from mechanic's wire.
(12) Remove hood release cable from vehicle.
INSTALLATION
(1) Place hood release cable in position under
instrument panel.
(2) Attach latch end of hood release cable to
mechanic's wire protruding through dash panel.
(3) Route cable forward through engine compart-
ment toward latch by pulling on mechanic's wire
(Fig. 5).(4) Disconnect mechanic's wire from cable.
(5) Engage rubber grommet cable insulator into
hole in dash panel.
(6) Install hood release handle into instrument
panel.
(7) Place cable in position on latch.
(8) Slide cable case end sideways into keyhole slot
of hood latch.
(9) Engage cable end into hood latch locking mech-
anism.
(10) Install hood latch.
(11) Install attaching clips to cable case and install
clips into original holes in strut tower, fender, head-
lamp area, and radiator closure panel crossmember.
LATCH STRIKER
REMOVAL
(1) Release hood latch and open hood.
(2) Remove bolts attaching striker to inside of
hood.
(3) Remove hood latch striker from vehicle.
INSTALLATION
(1) Position hood latch striker on vehicle, aligning
with paint breaks.
(2) Install bolts attaching hood latch striker to
hood.
(3) Align hood latch striker to engage smoothly
into hood latch.
(4) Verify hood operation and alignment. Adjust as
necessary.
(5) Tighten attaching bolts to 13.5 N´m (10 ft. lbs.)
torque.Fig. 5 HOOD RELEASE CABLE ROUTING
1 - GROMMET
2 - HOOD RELEASE CABLE
3 - RADIATOR CLOSURE PANEL CROSSMEMBER
23 - 64 HOODRS
LATCH RELEASE CABLE (Continued)

(13) Remove the right end cover by pulling out-
board.
(14) Remove the right side A-pillar retaining bolts
(Fig. 5). There are two 13 mm bolts and one 10 mm
bolt.
(15) Loosen the right side cowl side roll down bolt.
(16) Remove over steering column cover. (Refer to
23 - BODY/INSTRUMENT PANEL/STEERING COL-
UMN OPENING COVER - REMOVAL).
(17) Remove the cluster bezel. (Refer to 23 -
BODY/INSTRUMENT PANEL/CLUSTER BEZEL -
REMOVAL).
(18) Remove the lower steering column cover and
end cap. (Refer to 23 - BODY/INSTRUMENT PAN-
EL/LOWER STEERING COLUMN COVER -
REMOVAL)
(19) Remove the inflatable knee blocker. (Refer to
23 - BODY/INSTRUMENT PANEL/INFLATABLE
KNEE BLOCKER - REMOVAL)(20) Remove the two screws to the hood release
handle.
(21) Remove the two steering column fixed shroud
retaining screws (Fig. 6).
(22) Remove the four steering column shroud
retaining screws. Separate the steering column bear-
ing shroud and steering column shroud and remove
from vehicle (Fig. 6).
(23) Disconnect the left side wiring:
(a) Brake switch.
(b) Main bulkhead connector.
(c) Five harness connectors.
(d) Driver airbag connector.
(24) Disconnect the steering column wiring. There
are seven connectors and then unclip the harness
from the column.
(25) Disconnect the Occupant Restraint Controller
(ORC) harness connector.
Fig. 4 INSTRUMENT PANEL REMOVAL
1 - INSTRUMENT PANEL
2 - SIX ATTACHING SCREWS
3 - 13 mm BOLT - TWO ON EACH SIDE4 - ROLL DOWN BRACKET
5 - 10 mm BOLT - STARTING BOLT ONE EACH SIDE
23 - 68 INSTRUMENT PANELRS
INSTRUMENT PANEL ASSEMBLY (Continued)

(26) Remove the three nuts retaining the steering
column to the dash panel steering column mounting
bracket and lower column to the floor (Fig. 7).(27) Remove the three nuts attaching the instru-
ment panel to the brake pedal support bracket.
(28) Remove six instrument panel steering column
cover plate attaching screws and remove cover plate
(Fig. 8).Remove the screws attaching the instrument
panel reinforcement and remove (Fig. 9).
Fig. 5 RIGHT SIDE INSTRUMENT PANEL
ATTACHING SCREWS
1 - INSTRUMENT PANEL ATTACHING SCREWS
2 - INSTRUMENT PANEL TO COWL SIDE LOCATOR SCREW
3 - COWL SIDE COWL REINFORCEMENT
4 - COWL PANEL
5 - INSTRUMENT PANEL COWL SIDE ROLL DOWN BOLT
Fig. 6 STEERING COLUMN SHROUDS
1 - FIXED SHROUD
2 - ATTACHING SCREW(S)
3 - STEERING COLUMN BEARING SHROUD
4 - TRACTION CONTROL DISABLE SWITCH
5 - MULTI-FUNCTION SWITCH AND CLOCKSPRING HOUSING
6 - STEERING COLUMN SHROUD
7 - STEERING COLUMN
Fig. 7 STEERING COLUMN MOUNTING BRACKET
1 - DASH PANEL STEERING COLUMN MOUNTING BRACKET
2 - INSTRUMENT PANEL STEERING COLUMN BRACKET
3 - ATTACHING NUT(S)
Fig. 8 LEFT SIDE I/P ATTACHING SCREWS
1 - INSTRUMENT PANEL ATTACHING SCREWS
2 - INSTRUMENT PANEL
3 - COLUMN COVER PLATE ATTACHING SCREWS
4 - INSTRUMENT PANEL COLUMN COVER PLATE
5 - INSTRUMENT PANEL COWL SIDE ROLL DOWN SCREW
6 - COWL PANEL
RSINSTRUMENT PANEL23-69
INSTRUMENT PANEL ASSEMBLY (Continued)

(7) Place steering column cover plate into position
(Fig. 8).
(8) Install six instrument panel steering column
cover plate attaching screws.
(9) Install the screws attaching the instrument
panel reinforcement (Fig. 9).
(10) Place brake pedal support bracket into posi-
tion and install three nuts attaching to instrument
panel.
(11) Place steering column into position and install
four nuts retaining the steering column to the dash
panel steering column mounting bracket and lower
column to the floor (Fig. 7).
(12) Connect the Occupant Restraint Controller
(ORC) harness connector.
(13) Connect the steering column wiring. There
are seven connectors and clip the harness to the col-
umn.
(14) Connect the left side wiring:
(a) Brake switch.
(b) Main bulkhead connector.
(c) Five harness connectors.
(d) Driver airbag connector.
(15) Place steering column bearing shroud and
steering column shroud into position and install four
steering column shroud retaining screws (Fig. 6).
(16) Place fixed shroud into position and install
two steering column fixed shroud retaining screws
(Fig. 6).
(17) Install two screws to the hood release handle.
(18) Install the inflatable knee blocker. (Refer to
23 - BODY/INSTRUMENT PANEL/KNEE BLOCKER
- INSTALLATION).
(19) Install the lower steering column cover and
end cap. (Refer to 23 - BODY/INSTRUMENT PAN-
EL/LOWER STEERING COLUMN COVER AND
END CAP - INSTALLATION).
(20) Install the cluster bezel. (Refer to 23 - BODY/
INSTRUMENT PANEL/CLUSTER BEZEL -
INSTALLATION).
(21) Install over steering column cover. (Refer to
23 - BODY/INSTRUMENT PANEL/STEERING COL-
UMN OPENING COVER - INSTALLATION).
(22) Install the right end cover. Position over
retaining slots and firmly snap into place.
(23) Connect the right side wire connectors to the
HVAC behind the glove box area and the two
antenna connectors behind the glove box hinge.
(24) Install the glove box:
(a) Install glove box into the vehicle. Line up the
hinges and firmly snap together.(b) Push in on sides of glove box bin and raise
door.
(25) Install two screws to each right and left cowl
trim covers.
(26) Connect the wire connectors to the Passenger
Airbag.
(27) Install the screws attaching the instrument
panel frame to the dash panel below windshield
opening.
(28) Install screws attaching instrument panel
frame to the dash panel below windshield opening
(Fig. 4).
(29) Install the instrument panel top cover and
silencer. (Refer to 23 - BODY/INSTRUMENT PAN-
EL/INSTRUMENT PANEL TOP PAD - INSTALLA-
TION).
(30) Install both left and right side A-pillar trim
covers.
(31) Install bolts attaching the lower supports to
the floor pan (Fig. 3).
(32) Install bolts attaching the lower supports to
the instrument panel frame.
(33) Install the lower console:
(a) Install lower console to vehicle.
(b) Connect the auxiliary power outlet.
(c) Install the six retaining screws.
(34) Connect the battery negative cable.
INSTRUMENT PANEL CENTER
BEZEL
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Insert the trim stick (special tool #C-4755) or
equivalent between access cover and center bezel
gently pry outward.
(3) Carefully pry the access cover from the instru-
ment panel (Fig. 10).
(4) Remove the two center bezel attaching screws.
(5) Using a trim stick or equivalent, gently pry out
on the edge of the instrument panel center bezel and
pull outward.
(6) Disconnect the wire connectors to the accessory
switches and HVAC control.
(7) Remove the instrument panel center bezel from
the vehicle.
RSINSTRUMENT PANEL23-71
INSTRUMENT PANEL ASSEMBLY (Continued)

(3) Place the lower steering column cover into posi-
tion and push spring clips into position.
(4) Install the two screws attaching the lower
steering column cover to instrument panel.
BLOCKER- INFLATABLE KNEE
REMOVAL
(1) Remove lower steering column cover (Refer to
23 - BODY/INSTRUMENT PANEL/STEERING COL-
UMN OPENING COVER - REMOVAL).
(2) Remove the park brake release handle link
from the park brake release handle.
(3) Disengage inflatable knee blocker wire connec-
tor from lower instrument and disconnect the wire
connector (Fig. 17).(4) Remove screws attaching to instrument panel.
(5) Remove inflatable knee blocker from vehicle.
INSTALLATION
(1) Place inflatable knee blocker into position (Fig.
17).
(2) Connect inflatable knee blocker wire connector
and install inflatable knee blocker attaching screws.
(3) Install the steering column cover backing plate
into vehicle.
(4) Install park brake release handle link to park
brake release handle.
(5) Install the lower steering column cover (Refer
to 23 - BODY/INSTRUMENT PANEL/STEERING
COLUMN OPENING COVER - INSTALLATION).
Fig. 16 STEERING COLUMN COVER AND END CAP
1 - INSTRUMENT PANEL UPPER AND LOWER PANEL
2 - ATTACHING SCREW(S)
3 - END CAP
4 - INSTRUMENT PANEL STEERING COLUMN COVER5 - INSTRUMENT PANEL STEERING COLUMN COVER PLATE
6 - COWL PANEL
7 - COWL SIDE TAPPING PLATE
RSINSTRUMENT PANEL23-75
LOWER STEERING COLUMN COVER (Continued)

DESCRIPTION FIGURE
UPPER COWL PLENUM AND REINFORCEMENT - RIGHT HAND DRIVE 201
COWL SIDE PANEL AND DASH PANEL - RIGHT HAND DRIVE 202
LOWER COWL PLENUM, SUPPORT AND DASH PANEL - RIGHT HAND DRIVE 203
STEERING COLUMN REINFORCEMENT, BELT REINFORCEMENT AND DASH PANEL -
RIGHT HAND DRIVE204
INSTRUMENT PANEL TAPPING PLATE AND COWL SIDE PANEL - RIGHT HAND DRIVE 205
DASH PANEL AND BELT REINFORCEMENT - RIGHT HAND DRIVE 206
UPPER SUPPORT, UPPER REINFORCEMENT AND UPPER COWL PLENUM - RIGHT
HAND DRIVE207
UPPER SUPPORT, BRAKE PEDAL BRACKET REINFORCEMENT AND DASH PANEL -
RIGHT HAND DRIVE208
REINFORCEMENT, MOUNTING BRACKETS AND DASH PANEL - RIGHT HAND DRIVE 209
STRUT TOWER, COWL SIDE PANEL - RIGHT HAND DRIVE 210
REINFORCEMENTS, SIDE RAILS, COWL SIDE PANELS AND DASH PANEL - RIGHT
HAND DRIVE211
UPPER COWL PLENUM, GUSSETS, SIDE SHIELDS AND BODY SIDE APERTURE -
RIGHT HAND DRIVE212
SIDE GLASS ANTENNA TAPPING PLATE AND INNER BODY SIDE APERTURE - RIGHT
HAND DRIVE213
Fig. 85 FRONT FENDER SHIELD - RIGHT
RSBODY STRUCTURE23 - 237
WELD LOCATIONS (Continued)

Fig. 208 UPPER SUPPORT, BRAKE PEDAL BRACKET REINFORCEMENT AND DASH PANEL - RIGHT HAND
DRIVE
RSBODY STRUCTURE23 - 345
WELD LOCATIONS (Continued)

FRONT HEATER CORE
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Remove the silencer boot fasteners located
around the base of the lower steering shaft from the
dash panel so that it may be pushed aside.
(2) Remove the brake lamp switch from its mount-
ing bracket (Refer to 8 - ELECTRICAL/LAMPS/
LIGHTING - EXTERIOR/BRAKE LAMP SWITCH -
REMOVAL).
(3) Disconnect the power brake booster input rod
(push rod) from the pin on the brake pedal arm
(Refer to 5 - BRAKES - ABS/HYDRAULIC/ME-
CHANICAL/POWER BRAKE BOOSTER -
REMOVAL).
(4) Remove the heater core tubes (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/
HEATER CORE - REMOVAL).
(5) Remove the two screws that secure the heater
core mounting plate to the distribution housing.
(6) While pulling the accelerator pedal upward
(Fig. 18) and pushing the brake pedal downward
(Fig. 19) far enough for clearance, pull the heater
core out of the distribution housing.
(7) Use absorbent toweling to mop up any engine
coolant spills from the preceding operation. Also, if
the heater core was leaking, use absorbent toweling
and reach into the heater core opening to mop up
any residual engine coolant within the distribution
housing.
INSTALLATION
FRONT HEATER CORE TUBES
(1) Remove the plugs or tape from both heater core
tube fittings and both heater core ports.
(2) Position the heater core tubes and sealing plate
as a unit beneath the instrument panel.
Fig. 18 Accelerator Pedal - LHD Shown, RHD Typical
1 - HEATER CORE
Fig. 19 Brake Pedal - LHD Shown, RHD Typical
1 - HEATER CORE
2 - BRAKE PEDAL
RSPLUMBING - FRONT24-85
HEATER CORE (Continued)