DODGE TOWN AND COUNTRY 2001 Service Manual

(11) Remove the bolts attaching the cradle cross-
member reinforcement to the front suspension cradle
crossmember (Fig. 4). Remove the 2 bolts fastening
the reinforcement and rear of cradle crossmember to
the body of the vehicle. Remove the reinforcement.
(12) If the vehicle is equipped with All-Wheel-
Drive, remove the power transfer unit (Refer to 21 -
TRANSMISSION/TRANSAXLE/POWER TRANSFER
UNIT - REMOVAL).
(13) Remove the power steering fluid pressure and
return hoses from the power steering gear (Fig. 5).
(14) Remove the routing clamp bolt securing the
power steering fluid hoses to the rear of the cradle
crossmember (Fig. 6). Allow the hoses to hang down
out of the way.
(15) Remove the heat shield from the steering gear
(Fig. 5).
Fig. 2 Removing/Installing Tie Rod End Attaching
Nut
1 - TIE ROD END
2 - STEERING KNUCKLE
3 - WRENCH
4 - SOCKET
5 - TIE ROD END STUD
Fig. 3 TIE ROD REMOVAL WITH TOOL C-3894-A
1 - OUTER TIE ROD
2 - SPECIAL TOOL C-3894-A
3 - STEERING KNUCKLE
Fig. 4 CRADLE CROSSMEMBER REINFORCEMENT
ATTACHMENT
1 - STEERING GEAR
2 - RIGHT LOWER CONTROL ARM
3 - LEFT LOWER CONTROL ARM
4 - CRADLE CROSSMEMBER REINFORCEMENT
5 - REAR CRADLE CROSSMEMBER ISOLATOR BUSHING
6 - STABILIZER BAR
7 - CRADLE CROSSMEMBER
19a - 2 GEARRG
GEAR (Continued)
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(16) Remove the 3 bolts and nuts mounting the
steering gear to the front suspension cradle.
NOTE: The next step must be done to allow the
removal of the steering gear from the front suspen-
sion cradle. The steering gear cannot be removed
from the vehicle with the intermediate coupler
attached to the steering gear.
(17) Lower steering gear from suspension cradle
enough to allow access to the intermediate coupler
roll pin (Fig. 7). Install Remover/Installer, Special
Tool 6831A, through the center of the roll pin, secur-
ing with the knurled nut (Fig. 7). Hold threaded rod
stationary while turning nut, this will pull the roll
pin out of the intermediate coupler.
(18) Separate the coupler from the steering gear
shaft.
(19) Remove the power steering gear from the
vehicle.
Fig. 5 RHD GEAR HEAT SHIELD AND HOSE
FITTINGS
1 - HEAT SHIELD
2 - CRADLE CROSSMEMBER
3 - RETURN HOSE FITTING
4 - PRESSURE HOSE FITTING
5 - POWER STEERING GEAR
Fig. 6 RHD POWER STEERING GEAR - 2.5L DIESEL
SHOWN
1 - RETURN HOSE
2 - PRESSURE HOSE
3 - CRADLE CROSSMEMBER
4 - POWER STEERING GEAR
5 - RETURN HOSE FITTING
6 - PRESSURE HOSE FITTING
7 - HOSE ROUTING CLAMP
Fig. 7 Removing Roll Pin From Intermediate Coupler
1 - INTERMEDIATE COUPLER
2 - KNURLED NUT
3 - SUSPENSION CRADLE
4 - REMOVER SPECIAL TOOL 6831A
5 - STEERING GEAR
6 - NUT
7 - ROLL PIN
8 - THREADED ROD
RGGEAR19a-3
GEAR (Continued)
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INSTALLATION - RHD GEAR
(1) Install the steering gear up in the front sus-
pension cradle crossmember, leaving room to install
intermediate coupler.
(2) Start the roll pin into the intermediate coupler
before installing coupler on steering gear shaft. Start
roll pin into coupler, using a hammer and tapping it
into the coupler. Then install the intermediate cou-
pler on the shaft of the steering gear.
(3) Install Remover/Installer Special Tool 6831A
through the center of the roll pin, securing it with
the knurled nut (Fig. 8). Hold threaded rod station-
ary while turning nut. This will pull the roll pin into
the intermediate coupler.
(4) Install power steering gear on the front suspen-
sion cradle. Install the 3 steering gear mounting
bolts and nuts. Tighten the 3 steering gear to sus-
pension cradle mounting bolts to a torque of 183 N´m
(135 ft. lbs.).
CAUTION: Proper torque on the steering gear to
suspension cradle mounting bolts is very impor-
tant.
(5) Install the heat shield on the steering gear
(Fig. 5).
(6) Attach the power steering fluid pressure and
return hoses to the proper fittings on the steering
gear (Fig. 5). Do not fully tighten the fittings at this
time.
(7) Install the routing clamp with the bolt securing
the power steering fluid hoses to the rear of the cra-
dle crossmember (Fig. 6).(8) Using a crowfoot wrench on a torque wrench,
tighten the power steering fluid hose tube nuts at the
gear to a torque of 31 N´m (275 in. lbs.).
(9) Install tie rod end into steering knuckle. Start
tie rod end to steering knuckle attaching nut onto
stud of tie rod end. While holding stud of tie rod end
stationary using a socket (Fig. 2), tighten tie rod end
to steering knuckle attaching nut. Then using a
crowfoot and socket (Fig. 9), tighten the tie rod end
attaching nut to a torque of 75 N´m (55 ft. lbs.).
(10) If the vehicle is equipped with All-Wheel-
Drive, install the power transfer unit (Refer to 21 -
TRANSMISSION/TRANSAXLE/POWER TRANSFER
UNIT - INSTALLATION).
CAUTION: Proper torque on the cradle reinforce-
ment to suspension cradle mounting bolts is very
important.
(11) Install the reinforcement on the front suspen-
sion cradle crossmember and install the bolts attach-
ing the reinforcement to the cradle crossmember
(Fig. 4). Tighten the M-14 size bolts to a torque of
163 N´m (120 ft. lbs.). Tighten the M-12 size bolts to
a torque of 108 N´m (80 ft. lbs.).
(12) Install the lower control arm rear bushing
retainer bolts through reinforcement on each side of
each lower control arm rear bushing. Tighten bolts to
a torque of 61 N´m (45 ft. lbs.).
(13) Install the two bolts and bushings attaching
the reinforcement and rear of cradle crossmember to
body of vehicle (Fig. 4). Tighten bolts to a torque of
163 N´m (120 ft. lbs.).
Fig. 8 Installing Roll Pin In Intermediate Coupler
1 - INTERMEDIATE COUPLER
2 - SUSPENSION CRADLE
3 - KNURLED NUT
4 - ROLL PIN
5 - STEERING GEAR
Fig. 9 Torquing Tie Rod End Attaching Nut
1 - STEERING KNUCKLE
2 - TIE ROD END
3 - CROWFOOT
4 - SOCKET
5 - TORQUE WRENCH
19a - 4 GEARRG
GEAR (Continued)
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(14) If equipped, install the power steering cooler
hoses on the cooler inlet and outlet tubes. Install the
clamps.
(15) Install the front tire and wheel assemblies on
vehicle. Install the wheel mounting lug nuts and
tighten to a torque to 135 N´m (100 ft. lbs.).
(16) Lower the vehicle to a level were the interior
of vehicle is accessible (keeping tires off the ground).
(17) Using the intermediate coupler, turn the front
wheels of the vehicle to the left until the intermedi-
ate coupler shaft is properly aligned with the steer-
ing column coupler. Assemble the steering columnshaft coupler onto the steering gear intermediate
coupler (Fig. 1). Install steering column coupler to
intermediate shaft retaining pinch bolt. Tighten the
pinch bolt nut to a torque of 28 N´m (250 in. lbs.).
(18) Perform the POWER STEERING PUMP INI-
TIAL OPERATION procedure to properly fill and
bleed the power steering system. (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE)
(19) Inspect for leaks.
(20) Adjust front wheel toe (Refer to 2 - SUSPEN-
SION/WHEEL ALIGNMENT - STANDARD PROCE-
DURE).
RGGEAR19a-5
GEAR (Continued)
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PUMP
TABLE OF CONTENTS
page page
PUMP
DESCRIPTION............................6
REMOVAL...............................6
INSTALLATION............................6RESERVOIR
DESCRIPTION............................7
REMOVAL...............................7
INSTALLATION............................7
PUMP
DESCRIPTION - PUMP (2.5L DIESEL)
Hydraulic pressure for the operation of the power
steering gear is provided by a belt driven power
steering pump. The power steering pump is mounted
front lower right corner of the engine (Fig. 2).
The pump has a supply fitting for fluid coming
from the reservoir and a pressure port for exiting
fluid that is headed for the steering gear.
REMOVAL - PUMP (2.5L DIESEL)
(1) Remove the negative (-) battery cable from the
battery and isolate cable.
(2) Remove the fill cap from the power steering
fluid reservoir.
(3) Using a siphon pump, remove as much power
steering fluid as possible from the fluid reservoir.
(4) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(5) Remove the splash shields from below the
engine compartment.
(6) Remove the accessory drive belt from the power
steering pump pulley. (Refer to 7 - COOLING/AC-
CESSORY DRIVE/DRIVE BELTS - REMOVAL)
(7) Disconnect the fluid supply hose from the
pump (Fig. 1).
(8) Disconnect the pressure hose from the pump
(Fig. 1).
(9) Remove the bolt fastening the stamped bracket
on the rear of the pump to the cast bracket (Fig. 2).
(10) Remove the three front mounting bolts
through the pulley.
(11) Remove the pump from the cast bracket and
vehicle.
INSTALLATION - PUMP (2.5L DIESEL)
(1) Install the power steering pump on its cast
mounting bracket.
(2) Install the three front power steering pump
mounting bolts. Tighten the mounting bolts to a
torque of 54 N´m (40 ft. lbs.).(3) Install the rear mounting bolt fastening the
stamped bracket to the cast bracket (Fig. 2). Tighten
the mounting bolt to a torque of 54 N´m (40 ft. lbs.).
NOTE: Before installing power steering pressure
hose on power steering pump, inspect the O-ring
on the power steering pressure hose for damage
and replace if required.
(4) Install the power steering fluid pressure hose
fitting into the pressure port of the power steering
pump (Fig. 1). Tighten the pressure line to pump fit-
ting tube nut to a torque of 31 N´m (275 in. lbs.).
(5) Install the power steering fluid supply hose on
the power steering pump supply fitting (Fig. 1).Be
sure hose clamp is properly reinstalled.
(6) Install the accessary drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
Fig. 1 POWER STEERING PUMP - 2.5L DIESEL
1 - PRESSURE HOSE
2 - HOSE CLAMP
3 - SUPPLY HOSE
4 - POWER STEERING PUMP
19a - 6 PUMPRG
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(7) Install the splash shields below the engine
compartment.
(8) Lower the vehicle.
(9) Connect the negative (-) battery cable on the
negative battery post.
(10) Fill and bleed the power steering system
using the Power Steering Pump Initial Operation
Procedure (Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE).
(11) Inspect for leaks.
RESERVOIR
DESCRIPTION - RESERVOIR (2.5L DIESEL)
All vehicles use a remote mounted power steering
fluid reservoir. The power steering fluid reservoir is
mounted to a bracket on the engine manifold (Fig. 3).
REMOVAL - RESERVOIR (2.5L DIESEL)
(1) Open hood.
(2) Remove engine cover.
(3) Remove the filler cap from remote power steer-
ing fluid reservoir.
(4) Siphon as much fluid as possible from the fluid
reservoir.
(5) Remove the clamp attaching the return hose to
the power steering fluid reservoir. Disconnect hose
from reservoir (Fig. 3).
(6) Remove the clamp attaching the supply hose to
the power steering fluid reservoir. Disconnect hose
from reservoir (Fig. 3).(7)
Press the tang on the reservoir mounting bracket
retaining the reservoir to the bracket, then pull upward
on reservoir and remove it from the bracket.
INSTALLATION - RESERVOIR (2.5L DIESEL)
(1) Align the guide on the rear of the reservoir
with the mounting bracket and push reservoir down-
ward until reservoir clicks into place in the bracket.
(2) Install the supply hose onto the reservoir (Fig.
3). Slide the hose clamp into position on the fluid res-
ervoir and attach it.Be sure hose clamp in
installed past bead on fluid reservoir fitting.
(3) Install the return hose onto the reservoir (Fig.
3). Slide the hose clamp into position on the fluid res-
ervoir and attach it.Be sure hose clamp in
installed past bead on fluid reservoir fitting.
(4)
Fill the fluid reservoir to the proper level with
the correct Mopartpower steering fluid or equivalent.
(5) Start the engine and let run for a few seconds,
then turn the engine off.
(6) Add fluid as necessary.
(7) Install the filler cap.
(8) Install engine cover.
Fig. 2 PUMP AND BRACKETS - 2.5L DIESEL
1 - CAST BRACKET
2 - STAMPED BRACKET
3 - POWER STEERING PUMP
Fig. 3 RESERVOIR AND HOSES - 2.5L DIESEL
1 - POWER STEERING FLUID RESERVOIR
2 - RESERVOIR BRACKET
3 - SUPPLY HOSE BRACKET
4 - RETURN HOSE FROM GEAR
5 - ROUTING CLIP
6 - PRESSURE HOSE TO GEAR
7 - SUPPLY HOSE (PUMP END)
8 - PRESSURE HOSE (PUMP END)
9 - SUPPLY HOSE
10 - RETURN HOSE
RGPUMP19a-7
PUMP (Continued)
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TRANSMISSION/TRANSAXLE
TABLE OF CONTENTS
page page
POWER TRANSFER UNIT...................1
AUTOMATIC - 31TH.......................21AUTOMATIC - 41TE......................158
POWER TRANSFER UNIT
TABLE OF CONTENTS
page page
POWER TRANSFER UNIT
DESCRIPTION............................1
OPERATION.............................3
DIAGNOSIS AND TESTING..................3
SEAL IDENTIFICATION...................3
FLUID LEAK DIAGNOSIS..................3
STANDARD PROCEDURE...................4
FLUID LEVEL INSPECTION................4
PTU FLUID CHANGE.....................4
REMOVAL...............................5
INSTALLATION............................6
ADJUSTMENTS...........................7
SPECIFICATIONS.........................7
SPECIAL TOOLS..........................8
DIFFERENTIAL CARRIER SEAL
REMOVAL...............................9
INSTALLATION............................9
END COVER BALL BEARING
REMOVAL...............................9
INSTALLATION...........................10
END COVER SEAL
REMOVAL..............................11INSTALLATION...........................11
HALF SHAFT INNER SEAL
REMOVAL..............................12
INSTALLATION...........................12
INPUT SHAFT COVER SEAL
REMOVAL..............................13
INSTALLATION...........................14
INPUT SHAFT END SEAL
REMOVAL..............................16
INSTALLATION...........................16
INPUT SHAFT SEAL
REMOVAL..............................17
INSTALLATION...........................18
OUTER HALF SHAFT SEAL
REMOVAL..............................18
INSTALLATION...........................19
REAR COVER O-RING
REMOVAL..............................20
INSTALLATION...........................20
POWER TRANSFER UNIT
DESCRIPTION
The Power Transfer Unit (P.T.U.) is attached to a
modified automatic transaxle case where the right
half shaft extension housing would normally be
located.
The Power Transfer Unit is sealed from the trans-
axle and has its own oil sump. The Unit uses
Moparž SAE 80W-90 Gear and Axle Lubricant (MS-
9020) and holds 1.15 liters (1.22 quarts).Service of the Power Transfer Unit is limited to:
²Fluid Change
²Seals
²Gaskets
²One ball bearing
²Output flange
If the ring gear and pinion, any tapered roller
bearings, case, covers, or pinion carrier fail the entire
unit must be replaced.
RSTRANSMISSION/TRANSAXLE21-1
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Power Transfer Unit Components
21 - 2 POWER TRANSFER UNITRS
POWER TRANSFER UNIT (Continued)
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OPERATION
The Transfer Unit provides the power to the rear
wheels through a hypoid ring gear and pinion set.
DIAGNOSIS AND TESTING - SEAL
IDENTIFICATION
For accurate seal diagnosis, repair seal name and
location is critical. Refer to (Fig. 1), (Fig. 2), (Fig. 3)
and (Fig. 4) for correct seal name and location.
DIAGNOSIS AND TESTING - FLUID LEAK
DIAGNOSIS
When diagnosing fluid leaks on the Power Transfer
Unit two weep holes are provided to diagnose certain
seal leaks. These holes are located on the bottom side
of the assembly (Fig. 5).
If fluid leak is detected from either weep hole, seal
replacement is necessary.Do not attempt to repair
the leak by sealing weep holes,they must be kept
clear of sealants for proper seal operation.
If fluid is leaking from weep hole A (Fig. 5) the
type of fluid leaking will determine which seal needs
to be replaced. If the fluid leaking is red in color
1 - PLUG 18 - CASE-PTU 35 - SHIM
2 - WASHER FLAT 19 - PINION-PTU 36 - TAPERED ROLLER BEARING
3 - SEAL RING 20 - O-RING 37 - SHAFT ASSY. FRONT L.H.
4 - SNAP RING 21 - SHIM 38 - SEAL RING
5 - BALL BEARING 22 - TAPERED ROLLER BEARING 39 - OIL WIPER
6 - SEAL RING 23 - COVER-PTU CASE REAR 40 - RETAINER DIFFERENTIAL BEARING
7 - COVER-PTU
CASE END24 - FLANGE TUBE-PTU-OUTPUT ASSY. 41 - SHAFT DIFFERENTIAL PINION
8 - TAPERED ROLLER BEARING 25 - LOCK NUT-HEX FLANGE 42 - PIN
9 - SEAL RING 26 - O- RING 43 - CASE DIFFERENTIAL
10 - SEAL RING 27 - RETAINER PLATE 44 - TAPERED ROLLER BEARING CONE
11 - HEX HEAD SCREW 28 - O-RING 45 - SEAL RING
12 - SHAFT-PTU INPUT 29 - BRACKET 46 - SEAL RING
13 - GEAR-PTU RING 30 - THRUST WASHER 47 - PLUG
14 - TROUGH-PTU (RT.) 31 - SIDE GEAR-DIFFERENTIAL 48 - O-RING
15 - TROUGH-PTU (LT.) 32 - FINAL DRIVE GEAR 49 - SHIM
16 - TAPERED ROLLER BEARING 33 - PINION DIFFERENTIAL 50 - MAGNET
17 - HEX HEAD SCREW 34 - WASHER DIFFERENTIAL PINION 51 - DOWEL
52 - SHAFT ASSY. FRONT R.H.
53 - HEX HEAD SCREW
Fig. 1 Seal
1 - INPUT SHAFT
2 - P.T.U. CASE
3 - MAGNET
4 - INPUT SHAFT END SEAL
5 - OUTPUT SHAFT
6 - RING GEAR
7 - REAR COVER
Fig. 2 Seal Location
1 - REAR COVER
2 - END COVER
3 - OUTER HALFSHAFT SEAL
4 - P.T.U. CASE
5 - P.T.U. OUTPUT SEAL
RSPOWER TRANSFER UNIT21-3
POWER TRANSFER UNIT (Continued)
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