index CHRYSLER TOWN AND COUNTRY 2002 Owner's Manual

(41) Remove bearing cup retainer (Fig. 58).
(42) Remove transfer gear bearing cone using
setup shown in (Fig. 59).(43) Remove transfer shaft bearing cup from
retainer using Tool 6062 (Fig. 60).
(44) Using Tool 6051, remove transfer shaft bear-
ing snap ring (Fig. 61).
Fig. 58 Remove Bearing Cup Retainer
1 - ALIGN INDEXING TAB TO SLOT
2 - BEARING CUP RETAINER
Fig. 59 Remove Transfer Gear Bearing Cone
1 - WRENCHES
2 - TOOL 5048 WITH JAWS TOOL 5048±4 AND BUTTON TOOL
L-4539±2
3 - TRANSFER SHAFT GEAR
Fig. 60 Remove Transfer Shaft Bearing Cup
1 - WRENCHES
2 - TOOL 6062
3 - TRANSFER SHAFT BEARING CUP RETAINER
Fig. 61 Remove Transfer Shaft Bearing Snap Ring
1 - SNAP RING PLIERS TOOL 6051
2 - TRANSFER SHAFT BEARING SNAP RING
3 - TRANSFER SHAFT
RS41TE AUTOMATIC TRANSAXLE21 - 183
41TE AUTOMATIC TRANSAXLE (Continued)
ProCarManuals.com

(27) Using Tool 6051, install transfer shaft bearing
snap ring (Fig. 116).
(28) Install transfer shaft bearing cup into retainer
using Tool 6061 (Fig. 117).(29) Install bearing cup retainer to transaxle (Fig.
118).
(30) Install transfer gear bearing cone to transfer
gear using Tool 5052 (Fig. 119).
Fig. 116 Install Transfer Shaft Bearing Snap Ring
1 - SNAP RING PLIERS TOOL 6051
2 - TRANSFER SHAFT BEARING SNAP RING
3 - TRANSFER SHAFT
Fig. 117 Install Transfer Shaft Bearing Cup Into
Retainer
1 - ARBOR PRESS RAM
2 - HANDLE C-4171
3 - TOOL 6061
4 - TRANSFER SHAFT BEARING CUP RETAINER
5 - USE REMOVED BEARING CUP TO SUPPORT RETAINER
Fig. 118 Remove Bearing Cup Retainer
1 - ALIGN INDEXING TAB TO SLOT
2 - BEARING CUP RETAINER
Fig. 119 Install Transfer Gear Bearing Cone
1 - ARBOR PRESS RAM
2 - HANDLE C-4171
3 - NEW BEARING CONE
4 - TRANSFER SHAFT GEAR
5 - TOOL 5052
RS41TE AUTOMATIC TRANSAXLE21 - 199
41TE AUTOMATIC TRANSAXLE (Continued)
ProCarManuals.com

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)
ProCarManuals.com

exceed 0.76 mm (0.030 inch) with no tread ªdipsº
or ªsteps.º Tread ªdipsº and ªstepsº can be identi-
fied by spikes of the dial indicator gauge.
(c) If runout exceeds limits, mark the original
location of the tire on the wheel at the valve stem
(Fig. 3). Also, mark the tire and wheel to indicate
the original high spot of the assembly and record
the runout measurement.
(d) If runout exceeds limits, the tire will need to
be dismounted from the wheel to verify wheel vs.
tire contribution. Refer to Wheel Runout below.
(3)Lateral Runout.Lateral runout for the vehi-
cle system as well as the tire and wheel assembly
should be less than 0.76 mm (0.030 inch). The same
procedure and theory described for radial runout can
also be applied to identify and reduce lateral runout.
(4)Wheel Runout.This runout check is per-
formed as follows:
(a) Dismount the tire from the wheel.
(b) Mount the wheel back on the wheel balancer.
(c) Measure radial runout of the wheel at the
tire bead seat (Fig. 4). Runout should not exceed
0.254 mm (0.010 inch) for aluminum wheels and
0.508 mm (.020 inch) for steel wheels. Replace the
wheel if it exceeds the limit.
(d) Measure lateral runout of the wheel at the
tire bead seat (Fig. 5). Runout should not exceed
0.762 mm (0.030 inch) for all wheels. Replace the
wheel if it exceeds the limit.
(5)Match Mounting.If the wheel runout is
within specifications, tire and wheel assembly runout
can be improved by re-indexing (match mounting)
the tire to the wheel as described below.
Fig. 2 Radial Runout Measurement
1 - MASKING TAPE
2 - DIAL INDICATOR
Fig. 3 Marking Tire
1 - REFERENCE MARK
2 - EXAMPLE HIGH SPOT ON TIRE
3 - WHEEL
4 - VALVE STEM
Fig. 4 Checking Radial Runout Of Wheel
1 - MOUNTING CONE
2 - SPINDLE SHAFT
3 - WING NUT
4 - PLASTIC CUP
5 - DIAL INDICATOR
6 - WHEEL
7 - DIAL INDICATOR
RSTIRES/WHEELS22-3
TIRES/WHEELS (Continued)
ProCarManuals.com

(a) Remount the tire on the rim 180 degrees
from its original location (Fig. 6). Ensure the tire
bead is properly seated.
(b) Re-measure the total runout. Mark the tire
at the high spot and record the measurement.If runout is still excessive, perform the following:
²If the new high spot is within 102 mm (4.0 inch)
of the first high spot on the tire, replace the tire.
²If the new high spot is within 102 mm (4.0 inch)
of the first high spot on the wheel, the wheel may be
out of specification. Refer to Wheel Runout above.
²If the new high spot is NOT within 102 mm (4.0
inch) of either high spot, draw an arrow on the tread
from new high spot toward the original (Fig. 7).
Break down the tire and remount it 90 degrees on
rim in that direction, then re-measure runout. This
will normally reduce the runout to an acceptable
amount.
(6) Once back together, road test the vehicle for at
least 5 miles, following the format described in Road
Test. If vibration persists, and all components tested
are within specification, the tires may have an exces-
sive radial force condition. Radial force variation can
only be checked as indicated below. If this equipment
is not available, consult with the tire manufacturer.
RADIAL FORCE VARIATION
Radial Force Variation can be checked using the
Hunter GSP 9700 Vibration Control System (Wheel
Balancer) or equivalent, if available. This type of
equipment helps to correct ride disturbances by
reducing the radial force variation of an assembly
through re-indexing of the tire to wheel.
The equipment manufacturer or DaimlerChrysler
Corporation may supply reference values as guide-
Fig. 5 Checking Lateral Runout Of Wheel
1 - MOUNTING CONE
2 - SPINDLE SHAFT
3 - WING NUT
4 - PLASTIC CUP
5 - DIAL INDICATOR
6 - WHEEL
7 - DIAL INDICATOR
Fig. 6 Remount Tire 180 Degrees
1 - VALVE STEM
2 - REFERENCE MARK
Fig. 7 Remount Tire 90 Degrees In Direction of
Arrow
1 - 2ND HIGH SPOT ON TIRE
2 - 1ST HIGH SPOT ON TIRE
22 - 4 TIRES/WHEELSRS
TIRES/WHEELS (Continued)
ProCarManuals.com

lines. Radial force measurements above the reference
value may not always result in a ride disturbance,
nor do they automatically mean the assembly compo-
nents are out of specification. Do not replace compo-
nents based on radial force values alone. Balancing,
runout diagnosis, re-indexing, and subjective road
testing must be performed as outlined in previous
sections of this diagnosis and testing procedure.
Use the Radial Force equipment to identify suspect
assemblies and minimize the radial forces. After all
suspect assemblies are optimized, reinstall the
assemblies and road test the vehicle. If a disturbance
still exists and all other vibration diagnostic proce-
dures have been completed, replace one tire or one
wheel at a time, starting with the assembly having
the highest force variation. Be sure to minimize each
new assembly. Road test the vehicle following each
replacement. Continue this process until the distur-
bance is resolved.
NOTE: When using Radial Force equipment, it is
critically important to set proper tire inflation pres-
sure and ensure centering of the wheel on the
equipment spindle.
RADIAL FORCE VARIATION REFERENCE
VALUES
DESCRIPTION SPECIFICATION
Total Radial Force
Variation (RFV)Less Than 22 Lbs.   2
Lbs.
Radial First Harmonic
(R1H)Less Than 16 Lbs.   2
Lbs.
Radial Second Harmonic
(R2H)Less Than 12 Lbs.   2
Lbs.
STANDARD PROCEDURE
STANDARD PROCEDURE - TIRE AND WHEEL
BALANCE
NOTE: Balance equipment must be calibrated and
maintained per equipment manufacturer's specifica-
tions.
Wheel balancing can be accomplished with either
on-vehicle or off-vehicle equipment.
NOTE: If using on-vehicle balancing equipment, on
the driving axle, remove the opposite wheel and tire
assembly.
It is recommended that a two-plane dynamic bal-
ancer be used when a wheel and tire assemblyrequires balancing. A static balancer should only be
used when a two-plane balancer is not available.
Balance wheel and tire assemblies dynamically and
statically to less than 0.25 (
1¤4) ounce.
For static balancing, find location of heavy spot
causing imbalance. Counter balance wheel directly
opposite the heavy spot. Determine weight required
to counterbalance the area of imbalance. Place half of
this weight on theinnerrim flange and the other
half on theouterrim flange (Fig. 8).
For dynamic balancing, the balance equipment is
designed to indicate the location and amount of
weight to be applied to both the inner and outer rim
flanges (Fig. 9).
The aluminum wheels on this vehicle use a unique
wheel weight (Fig. 10). This wheel weight is designed
to fit the contoured surface of the wheel (Fig. 10).
When balancing an aluminum wheel, this wheel
weight must be used. Do not use any other type of
wheel weight. It will not properly fit the contour of
the wheel.
Always verify the Balance. When using off-vehicle
equipment, rotate assembly 180 degrees on balance
equipment to verify balance. Variation should not be
more than 0.125 (
1¤8) ounce. If variation is more than
0.125 ounce, balancing equipment could be malfunc-
tioning.
If difficult to balance, break down the wheel and
tire assembly and check for loose debris inside tire.
Prior to disassembly, mark (index) the tire at the
valve stem. Use this mark in order to remount the
tire in its original orientation with respect to the
wheel.
STANDARD PROCEDURE - TIRE AND WHEEL
MATCH MOUNTING
Wheels and tires are match mounted at the factory.
This means that the high spot of the tire is matched
to the low spot on the wheel rim. This technique is
used to reduce runout in the wheel and tire assem-
bly. The high spot on the tire is marked with a paint
mark or a bright colored adhesive label on the out-
board sidewall. The low spot on the wheel is identi-
fied with a label on the outside of the rim and a dot
or line in the drop well area of the rim (inside where
the tire mounts). If the outside label has been
removed, the tire will have to be removed to locate
the dot or line on the inside of the rim. The tire can
then be match mounted to the tire.
Information on match mounting the tire to the
wheel can be found in Tire and Wheel Runout/Match
Mounting, items (2) through (5), within Diagnosis
And Testing - Tire And Wheel Vibration. (Refer to 22
- TIRES/WHEELS - DIAGNOSIS AND TESTING)
RSTIRES/WHEELS22-5
TIRES/WHEELS (Continued)
ProCarManuals.com

(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)
ProCarManuals.com

(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)
ProCarManuals.com

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)
ProCarManuals.com

BODY STRUCTURE
TABLE OF CONTENTS
page page
GAP AND FLUSH
SPECIFICATIONS
GAP AND FLUSH MEASUREMENTS......115
OPENING DIMENSIONS
SPECIFICATIONS
BODY OPENING DIMENSIONS..........118
SEALER LOCATIONS
SPECIFICATIONS
BODY SEALING LOCATIONS...........121STUCTURAL ADHESIVE LOCATIONS
SPECIFICATIONS
STRUCTURAL ADHESIVE LOCATIONS....147
WELD LOCATIONS
SPECIFICATIONS
WELD LOCATIONS...................156
GAP AND FLUSH
SPECIFICATIONS
GAP AND FLUSH MEASUREMENTS
INDEX
DESCRIPTION FIGURE
GAP & FLUSH MEASUREMENTS 1
RSBODY STRUCTURE23 - 115
ProCarManuals.com