Chrysler Town, Dodge Caravan. Manual - part 362

(6) Attach return hose tubes to suspension cradle

crossmember using routing clamp and bolt (Fig. 20).
Tighten clamp bolt to 23 N·m (200 in. lbs.) torque.

(7) Install the power steering fluid cooler on the

cradle crossmember reinforcement (Fig. 23). Install
the mounting bolts and tighten to 11 N·m (100 in.
lbs.). When installing mounting bolts, include pres-
sure hose routing clamp.

(8) Tighten hose tube nut at power steering gear

port to 31 N·m (275 in. lbs.) torque.

(9) Install front emissions vapor canister. (Refer to

25 - EMISSIONS CONTROL/EVAPORATIVE EMIS-
SIONS/VAPOR CANISTER - INSTALLATION)

(10) Lower vehicle.
(11) Install return hose tube into retainer on ABS

bracket (Fig. 20). Close the bracket.

(12) Install return hose onto reservoir (Fig. 21).

Slide the hose clamp into position on fluid reservoir
and attach it. Be sure hose clamp in installed
past bead on fluid reservoir fitting.

(13) Fill and bleed power steering system using

the Power Steering Pump Initial Operation Proce-
dure. (Refer to 19 - STEERING/PUMP - STANDARD
PROCEDURE)

(14) Inspect system for leaks.

HOSE - POWER STEERING
SUPPLY

REMOVAL

REMOVAL - 2.4L ENGINE

(1) Remove filler cap from power steering fluid res-

ervoir.

(2) Using a siphon pump, remove as much power

steering fluid as possible from the power steering
fluid reservoir.

(3) Raise vehicle. (Refer to LUBRICATION &

MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)

(4) Remove hose clamp securing supply hose to

power steering pump, then remove supply hose from
pump fitting.

(5) Lower vehicle.
(6) Remove hose clamp attaching power steering

fluid supply hose to power steering fluid reservoir,
then remove supply hose.

(7) Remove the power steering fluid supply hose

from the vehicle.

REMOVAL - 3.3L/3.8L ENGINE

NOTE: Before proceeding, review all WARNINGS
and CAUTIONS. (Refer to 19 - STEERING/PUMP -

WARNING)(Refer to 19 - STEERING/PUMP - CAU-
TION)

(1) Remove cap from power steering fluid reser-

voir.

(2) Using a siphon pump, remove as much power

steering fluid as possible from power steering fluid
reservoir.

(3) Place an oil drain pan under vehicle to catch

any draining power steering fluid.

(4) Remove clamp attaching supply hose to power

steering fluid reservoir. Disconnect hose from reser-
voir (Fig. 21).

(5) Pull upward on hose routing clip releasing it

from bracket on cylinder head cover (Fig. 21).

NOTE: It may be necessary to remove air cleaner
housing to gain greater access to supply hose at
power steering pump. (Refer to 9 - ENGINE/AIR
INTAKE

SYSTEM/AIR

CLEANER

HOUSING

REMOVAL)

(6) Remove clamp attaching supply hose to power

steering pump. Disconnect hose from pump and
remove from vehicle (Fig. 21).

INSTALLATION

INSTALLATION - 2.4L ENGINE

(1) Install and correctly route power steering fluid

supply hose from remote fluid reservoir to power
steering pump.

(2) Install fluid supply hose onto power steering

fluid reservoir. Install hose clamp. Be sure hose
clamp is installed past bead on fluid reservoir
fitting.

(3) Raise vehicle. (Refer to LUBRICATION &

MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)

(4) Install power steering fluid supply hose on

power steering pump supply fitting. Install hose
clamp. Be sure hose clamp is installed past bead
on pump fitting.

(5) Lower vehicle.
(6) Fill and bleed power steering system using

Power Steering Pump Initial Operation Procedure.
(Refer to 19 - STEERING/PUMP - STANDARD PRO-
CEDURE)

(7) Inspect system for leaks.

INSTALLATION - 3.3L/3.8L ENGINE

(1) Install supply hose onto supply fitting on power

steering pump (Fig. 21). Slide the hose clamp into
position on fluid reservoir and attach it. Be sure
hose clamp in installed past bead on fluid res-
ervoir fitting.

19 - 50

PUMP

HOSE - POWER STEERING RETURN (Continued)

(2) Align routing clip located toward center of sup-

ply hose with hole in bracket on cylinder head cover
and push into place (Fig. 21).

(3) Install supply hose onto reservoir (Fig. 21).

Slide the hose clamp into position on fluid reservoir
and attach it. Be sure hose clamp in installed
past bead on fluid reservoir fitting.

(4) Fill and bleed power steering system using

Power Steering Pump Initial Operation Procedure.
(Refer to 19 - STEERING/PUMP - STANDARD PRO-
CEDURE)

(5) Inspect system for leaks.

RESERVOIR - POWER
STEERING FLUID

DESCRIPTION

DESCRIPTION - 2.4L/3.3L/3.8L ENGINE

All vehicles use a remote mounted power steering

fluid reservoir. The power steering fluid reservoir is
mounted to the engine near the battery (Fig. 24).

DESCRIPTION - 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.
25).

OPERATION

The power steering fluid reservoir stores and sup-

plies power steering fluid for the power steering sys-
tem.

REMOVAL

REMOVAL - 2.4L ENGINE

(1) Remove cap from power steering fluid reser-

voir.

(2) Using a siphon pump, remove as much power

steering fluid as possible from power steering fluid
reservoir.

(3) Open retainer on side of reservoir and remove

cables from retainer.

(4) Remove clamp attaching supply hose to power

steering fluid reservoir. Disconnect hose from reser-
voir.

(5) Remove bolts and nut securing reservoir in

place.

(6) Remove reservoir.

REMOVAL - 3.3L/3.8L ENGINE

(1) Remove cap from power steering fluid reser-

voir.

(2) Using a siphon pump, remove as much power

steering fluid as possible from power steering fluid
reservoir.

(3) Open retainer on side of reservoir and remove

cables from retainer.

(4) Remove clamp attaching supply hose to power

steering fluid reservoir. Disconnect hose from reser-
voir (Fig. 21).

(5) Remove clamp attaching return hose to power

steering fluid reservoir. Disconnect hose from reser-
voir (Fig. 21).

(6) Remove bolts and nut securing reservoir in

place (Fig. 21).

(7) Remove reservoir.

REMOVAL - 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. 25).

(6) Remove the clamp attaching the supply hose to

the power steering fluid reservoir. Disconnect hose
from reservoir (Fig. 25).

(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.

Fig. 24 Power Steering Fluid Reservoir (Typical)

PUMP

19 - 51

HOSE - POWER STEERING SUPPLY (Continued)

INSTALLATION

INSTALLATION - 2.4L ENGINE

(1) Place reservoir into position on engine.
(2) Install

reservoir

mounting

bolts

and

nut.

Tighten fasteners to 12 N·m (105 in. lbs.) torque.

(3) Install supply hose onto reservoir. Slide the

hose clamp into position on fluid reservoir and attach
it. Be sure hose clamp in installed past bead on
fluid reservoir fitting.

(4) Fill and bleed power steering system using

Power Steering Pump Initial Operation Procedure.

(Refer to 19 - STEERING/PUMP - STANDARD PRO-
CEDURE)

(5) Inspect system for leaks.

INSTALLATION - 3.3L/3.8L ENGINE

(1) Place reservoir into place on engine (Fig. 21).
(2) Install reservoir mounting bolts and nut (Fig.

21). Tighten fasteners to 12 N·m (105 in. lbs.) torque.

(3) Install supply hose onto reservoir (Fig. 21).

Slide the hose clamp into position on fluid reservoir
and attach it. Be sure hose clamp in installed
past bead on fluid reservoir fitting.

(4) Install return hose onto reservoir (Fig. 21).

Slide the hose clamp into position on fluid reservoir
and attach it. Be sure hose clamp in installed
past bead on fluid reservoir fitting.

(5) Fill and bleed power steering system using

Power Steering Pump Initial Operation Procedure.
(Refer to 19 - STEERING/PUMP - STANDARD PRO-
CEDURE)

(6) Inspect system for leaks.

INSTALLATION - 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.

25). Slide the hose clamp into position on the fluid
reservoir and attach it. Be sure hose clamp in
installed past bead on fluid reservoir fitting.

(3) Install the return hose onto the reservoir (Fig.

25). Slide the hose clamp into position on the fluid
reservoir 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 Mopar

t power steering fluid or equiva-

lent.

(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. 25 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

19 - 52

PUMP

RESERVOIR - POWER STEERING FLUID (Continued)

TRANSMISSION/TRANSAXLE

TABLE OF CONTENTS

page

POWER TRANSFER UNIT

. . . . . . . . . . . . . . . . . . 1

T850 MANUAL TRANSAXLE

. . . . . . . . . . . . . . . 21

41TE AUTOMATIC TRANSAXLE

. . . . . . . . . . . . 116