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  #21  
Old 07-15-2010, 10:32 PM
Gasmiser Gasmiser is offline
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Vehicle: 2008 PT Cruiser
Location: Phoenix,AZ
Posts: 2
Talking Fuel pump issue on 2001 Caravan 3.8 engine?

I have a caravan with a 3.8 v6 and it cranks but won't start.When I remove the fuel pump relay and jump across from point 87 to 30 with a jumper the van starts and idles but wants to die when in gear.Installed a new fuel pump relay and it still cranks but no start.What is going on please can you help?Also anyone can leave me a email at bobandannie@***.net any time please.
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Last edited by Gasmiser; 07-15-2010 at 10:34 PM..
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  #22  
Old 07-15-2010, 10:33 PM
sapporo sapporo is offline
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what is your fuel pressure?
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  #23  
Old 09-05-2010, 11:25 PM
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SLIDING DOOR ADJUSTMENTS
NOTE: For power sliding door procedures refer to POWER SLIDING DOOR SYSTEM in the ELECTRICAL section.

PRELIMINARY CHECKS
Close the sliding door, visually checking C-post striker alignment entry into latch. Striker at this point must not affect alignment. Striker should go straight into the latching mechanism.
On vehicles with left sliding doors, check the fuel door blocker striker entry into latch. Striker at this point must not affect alignment.
Check C-post and B-post for door to aperture gaps and door to door gaps. All gaps should be 5 mm ą 1 mm.
Check door for height using character lines as a reference. Also check roof contour as a controlling factor.
Using the procedures noted below, adjust the side door in the order the individual steps are called out.

DOOR FLUSHNESS ADJUSTMENT
Check sliding door flushness at the C-pillar striker.
Adjust the C-pillar striker in or out until the door is flush.
Check upper B-pillar flushness to A-pillar cover.
Loosen one nut on upper hinge and adjust door in or out until the door is flush.
Check flushness at upper C-pillar.
If upper C-pillar flushness is out of specification use a heavy rubber mallet on the door assembly until door is in specifications.
DOOR GAP ADJUSTMENT - UP/DOWN
Visually inspect the sliding door for fitting low at the top of the door by checking the alignment of the top contour of the door to the quarter panel.
Fully open the sliding door.
Verify that all center hinge bolts are tight.
Adjust the rear of the sliding door up by turning the center hinge bolt clockwise (SLIDING DOOR CENTER HINGE).
Close the door and check the sliding door alignment.
Adjust the front of the sliding door up by adjusting lower hinge bolts.
Open door half way and remove lower hinge bolt access plug.
Loosen bolts as necessary to move the front of door up or down.
Check the upper hinge for possible bind, adjust as necessary.
Close the door and check the sliding door alignment.
Fully open door and apply thread lock nut onto the center hinge bolt. Tighten nut until till it butts up against the welded nut on the center hinge. Tighten nut to 15 Nˇm (130 in. lbs.). It may be necessary to hold the center hinge bolt to prevent it from turning while tightening nut.
Verify alignment, adjust as necessary.
DOOR GAP ADJUSTMENT - FORE/AFT
Check height of sliding door at the B-post and C-post to determine which area is contributing the greatest to the incorrect gaps.
If the sliding door is high at the C-post;
Open the door to mid-point of travel.
Mark outline of center hinge on sliding door to assist in making adjustments.
Loosen center hinge bolts (SLIDING DOOR CENTER HINGE).
Move hinge fore or aft to position the sliding door into the correct location.
Tighten center hinge bolts.
Verify alignment, adjust as necessary.
If the sliding door is low at the B-post;
Remove access plug in the sliding door trim panel.
Open the door to mid-point of travel.
Mark outline of lower roller arm bracket on sliding door to assist in making adjustments.
Loosen lower roller arm bracket bolts (SLIDING DOOR LOWER ROLLER ARM).
Move hinge downward to raise the door.
Tighten lower roller arm bracket bolts.
Verify alignment, adjust as necessary.
If the sliding door is low at the C-post;
Open the door to mid-point of travel.
Mark outline of center hinge on sliding door to assist in making adjustments.
Adjust the adjustment bolt up or down to move the door position. (SLIDING DOOR CENTER HINGE).
Move hinge downward to raise the door.
Tighten center hinge bolts.
Verify alignment adjust as necessary.
If the sliding door is high at the B-post;
Remove access plug in the sliding door trim panel.
Open the door to mid-point of travel.
Mark outline of lower roller arm bracket on sliding door to assist in making adjustments.
Loosen lower roller arm bracket bolts (SLIDING DOOR LOWER ROLLER ARM).
Move hinge upward to raise the door.
Tighten lower roller arm bracket bolts.
Verify alignment, adjust as necessary.
DOOR SEAL COMPRESSION
First check Gap & Flush. Check seal compression near the middle of the door even with the latch assembly. Using a piece of paper, place it across door seal and close door. Pull paper out of door opening. If paper tears setting is to tight, if paper slides thought to easily the compression is insufficient and needs to be adjusted.
Adjust seal compression at the top of the B-post seal;
Open door to mid-point of travel.
Mark outline of upper roller arm on door to assist in making adjustments.
Loosen bolts attaching upper roller arm to door (SLIDING DOOR UPPER STOP).
Decrease the length of the upper roller arm to increase seal compression.
Increase the length of the upper roller arm to decrease seal compression.
Tighten all upper roller arm bolts.
Verify door alignment, adjust as necessary.
Adjust seal compression at the bottom of B-post seal.
Open door to mid-point of travel.
Mark outline of lower roller arm on lower roller arm bracket to assist in making adjustments (Sliding Door Lower Roller Arm).
Loosen bolts holding lower roller arm to lower roller arm bracket.
Pivot lower roller arm toward center of vehicle to decrease seal compression.
Pivot lower roller arm outward to increase seal compression.
Tighten lower roller arm bolts.
Verify alignment, adjust as necessary.
NOTE: Adjusting seal compression at the B-post can affect door flushness the C-post.

STABILIZER ADJUSTMENT - UPPER/LOWER
Open sliding door.
Loosen the bolts holding the male stabilizers to the sliding door enough that the stabilizers can move with some effort.
Close and then reopen sliding door.
Tighten all stabilizers bolts.
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  #24  
Old 09-19-2010, 03:28 PM
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SUBJECT:
Flash: WIN For No Start Or Starts And Immediately Stalls
OVERVIEW:
This bulletin involves flash reprogramming the Wireless Ignition Node (WIN) with new
software.
MODELS:
2010 (RT) Town & Country / Caravan (International
Markets)
2010 (WH) Grand Cherokee (International Markets)
2010 (XH) Commander (International Markets)
SYMPTOM/CONDITION:
The vehicle will not start or start and immediately stalls. The issue is caused by skim lock
out. Dealers may also see Diagnostic Trouble Codes P0513 -Lost Communication with
Column Lock Module and/or B2224 - Column Lock Internal Module.
NOTE: Vehicles must have sales code XGM Tire Pressure Monitor.
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  #25  
Old 09-19-2010, 11:27 PM
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PARKING BRAKE AUTOMATIC ADJUSTER TENSION RESET
1. Raise the vehicle to a comfortable working position and support.


2. Wipe the front parking brake cable strand clean at the intermediate bracket area.

CAUTION: Do use any type of sharp instrument directly on the cable strand to hold it in place. Damage to the cable strand or coating can occur.


3. Clamp an appropriate pair of pliers on the front parking brake cable button only and pull the cable stand rearward until it stops, then grasp the front cable strand and hold it in this position. Remove the pliers from the button.




4. While holding the front cable in this position, install the equalizer (attached to both rear cables) on the front parking brake cable.
5. Release the grasp on the front parking brake cable.
6. Lower the vehicle.
7. Apply and release the parking brake lever one time. This will seat the parking brake cables and allow the auto adjuster in the parking brake lever mechanism to correctly tension the parking brake cables.
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  #26  
Old 09-19-2010, 11:31 PM
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SUBJECT:
NS Strut Tower Corrosion
OVERVIEW:
This bulletin involves correcting a corrosion staining, surface corrosion, or corrosion
perforation condition at the top of the strut tower/s.
MODELS:
1996 - 2000 NS Town&Country/Voyager/Caravan
SYMPTOM/CONDITION:
Cosmetic corrosion or perforation at upper strut tower/s usually between the strut
and upper load path beam inner panel (inner fender).
DIAGNOSIS:
Inspect left and right strut towers for condition. If corrosion is present, perform
one of the following repair procedures.
NOTE: ANY UNDER HOOD LABELS REQUIRING REPLACEMENT DURING THESE
REPAIRS SHOULD BE OBTAINED PRIOR TO BEGINNING REPAIRS.
PARTS/MATERIALS REQUIRED:
Qty. Part No. Description
1 05080009AA Strut Cap (Left Side)
1 Kit 05086513AA NS Strut Cap Installation Kit
(Left Side).
1 05080008AA Strut Cap (Right Side)
1 Kit 05086512AA NS Strut Cap Installation Kit
(Right Side).
11/2 - 2 Cartridges
Per Side
05083855AA Mopar Structural Adhesive
EQUIPMENT REQUIRED:
W-7804R 90-degree drill motor (PSE)
W-861 High-speed air cutter (die grinder) (PSE)
23-044-02 -2-
05016570AA Adhesive dispenser (MOPAR)
W-AK175 ACH Power set rivet gun (PSE)
REPAIR DESCRIPTION:
Repair A - Cosmetic corrosion removal and the application of corrosion
resistant materials and/or primers and topcoats.
Repair B - Corrosion perforation removal and installation of 1 or 2 new cap/s and kit/s.
NOTE: REPAIR PROCEDURES ARE OUTLINED IN THE INSTRUCTION
SHEET INCLUDED IN THE PARTS KITS.
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  #27  
Old 09-20-2010, 02:46 PM
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Flash: WIN For No Start Or Starts And Immediately Stalls
OVERVIEW:
This bulletin involves flash reprogramming the Wireless Ignition Node (WIN) with new
software.
MODELS:
2010 (RT) Town & Country / Caravan (International
Markets)
2010 (WH) Grand Cherokee (International Markets)
2010 (XH) Commander (International Markets)
SYMPTOM/CONDITION:
The vehicle will not start or start and immediately stalls. The issue is caused by skim lock
out. Dealers may also see Diagnostic Trouble Codes P0513 -Lost Communication with
Column Lock Module and/or B2224 - Column Lock Internal Module.
NOTE: Vehicles must have sales code XGM Tire Pressure Monitor.
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  #28  
Old 09-29-2010, 12:13 AM
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This is a TSB that just came out for the 62TE transmission. Check with your dealer on this TSB.
MODELS:
2010 JC Journey
2010 JS Sebring/Avenger
2010 RT Town & Country/Grand Caravan
NOTE: This bulletin applies to select vehicles equipped with a 62TE automatic
transmission (sales code DG2) built from January 1, 2010 (MDH 0101XX)
through July 28, 2010 (MDH 0728XX) and with incorrect bearing preload.
GROUP: Transmission and
Transfer Case
DATE: September 22, 2010
DISCUSSION:
Some vehicles may have been built with transmission transfer gear bearings that were
built with incorrect bearing preload. Incorrect bearing preload may result in transfer gear
bearing noise.
NOTE: Not every vehicle equipped with the 62TE built from January 1, 2010 through
July 28, 2010 is affected by this issue. Only vehicles identified on the VIN list
may have incorrect transfer gear bearing preload.
1. Turn the steering wheel to the far left.
2. Open hood.
3. Raise the vehicle on the hoist.
4. If the vehicle is equipped with wheel center caps that cover the wheel nuts, remove the
left front wheel's cap with an appropriate removal tool utilizing the notch located
between the wheel and the outer edge of the cap. Use care not to damage the wheel
coating.
5. Remove the left front wheel's five wheel mounting (lug) nuts from their studs.
6. Remove the left front tire and wheel assembly from hub.
7. Remove the two bolts securing the left disc brake caliper and adapter bracket to the
steering knuckle.
8. Remove the disc brake caliper and adapter bracket from the knuckle and rotor as an
assembly (Fig. 1). Hang the assembly out of the way using wire or a bungee cord. Use
care not to overextend the brake hose when doing this.
NOTE: The front splash shield on some vehicles is a two piece assembly.
9. Remove push pins that secure the left front splash shield.
10. Remove fasteners that secure the left front splash shield.
11. Remove the left front splash shield.
NOTE: Journey/Sebring/Avenger models continue to next step. Town & Country
Models, proceed to Step #21.
12. Journey/Sebring/Avenger models, lower the vehicle.
13. Remove the air cleaner housing. Refer to the information provided in
DealerCONNECT>TechCONNECT>Service Information>09 - Engine>Air intake
System>Body, Air Cleaner>Removal.
14. Support the transaxle with a floor jack.
15. Remove the bolts at the left transmission mount and remove the mount.
16. Remove the floor jack from the transmission.
17. Raise the vehicle on the hoist.
18. Support the engine with a screw jack.
19. Remove the fore aft member mount through bolt.
20. Lower transaxle. Allow the transaxle to rest on the fore aft member
21. Remove transfer gear cover-to-case bolts.
22. Remove transfer gear cover.
23. Remove the oil scavenger by releasing the two lower tabs and sliding the
scavenger away from the gears.
CAUTION: The scavenger is secured to the transmission case by small tabs. These
tabs break easily. Use extreme care when removing the scavenger from
the transmission.
24. Grind the staked tabs from the transfer gear (underdrive compounder side).
25. Install the Gear Holder 9739 onto the transfer gear (underdrive compounder side) and
remove the nut. Hold Transfer Gear In Vehicle
26. Remove the transfer gear.
27. Remove the transfer gear bearing select fit shim.
Fig. 9 Transfer Gear Select Fit Shim
1 - Transfer Gear Bearing Retainer
2 - Transfer Gear Bearing Select Fit Shim
28. Using a micrometer, measure the select shim that was removed.
29. Refer to the following table and install the appropriate select shim onto the transfer
gear shaft.
Original Shim
Measurement
Install New Shim Part
Number
New Shim Thickness
SPACER, TRANSFER
SHAFT BEARING, 4.04 -
4.06 mm (0.1591 - 0.1600
in.)
04800567AA SPACER, TRANSFER
SHAFT BEARING, 4.13 -
4.15 mm (0.1626 - 0.1634
in.)
SPACER, TRANSFER
SHAFT BEARING, 4.07 -
4.09 mm (0.1602 - 0.1610
in.)
04800568AA SPACER, TRANSFER
SHAFT BEARING, 4.16 -
4.18 mm (0.1638 - 0.1646
in.)
SPACER, TRANSFER
SHAFT BEARING, 4.10 -
4.12 mm (0.1614 - 0.1622
in.)
04800569AA SPACER, TRANSFER
SHAFT BEARING, 4.19 -
4.21 mm (0.1649 - 0.1657
in.)
SPACER, TRANSFER
SHAFT BEARING, 4.13 -
4.15 mm (0.1626 - 0.1634
in.)
04800570AA SPACER, TRANSFER
SHAFT BEARING, 4.22 -
4.24 mm (0.1661 - 0.1669
in.)
SPACER, TRANSFER 04800571AA SPACER, TRANSFER
21-005-10 -10-
SHAFT BEARING, 4.16 -
4.18 mm (0.1638 - 0.1646
in.)
SHAFT BEARING, 4.25 -
4.27 mm (0.1673 - 0.1681
in.)
SPACER, TRANSFER
SHAFT BEARING, 4.19 -
4.21 mm (0.1649 - 0.1657
in.)
04800572AA SPACER, TRANSFER
SHAFT BEARING, 4.28 -
4.30 mm (0.1685 - 0.1693
in.)
SPACER, TRANSFER
SHAFT BEARING, 4.22 -
4.24 mm (0.1661 - 0.1669
in.)
04800573AA SPACER, TRANSFER
SHAFT BEARING, 4.31 -
4.33 mm (0.1697 - 0.1705
in.)
SPACER, TRANSFER
SHAFT BEARING, 4.25 -
4.27 mm (0.1673 - 0.1681
in.)
04800574AA SPACER, TRANSFER
SHAFT BEARING, 4.34 -
4.36 mm (0.1709 - 0.1717
in.)
SPACER, TRANSFER
SHAFT BEARING, 4.28 -
4.30 mm (0.1685 - 0.1693
in.)
04800575AA SPACER, TRANSFER
SHAFT BEARING, 4.37 -
4.39 mm (0.1720 - 0.1728
in.)
SPACER, TRANSFER
SHAFT BEARING, 4.31 -
4.33 mm (0.1697 - 0.1705
in.)
04800576AA SPACER, TRANSFER
SHAFT BEARING, 4.40 -
4.42 mm (0.1732 - 0.1740
in.)
SPACER, TRANSFER
SHAFT BEARING, 4.34 -
4.36 mm (0.1709 - 0.1717
in.)
04800577AA SPACER, TRANSFER
SHAFT BEARING, 4.43 -
4.45 mm (0.1744 - 0.1752
in.)
SPACER, TRANSFER
SHAFT BEARING, 4.37 -
4.39 mm (0.1720 - 0.1728
in.)
04800578AA SPACER, TRANSFER
SHAFT BEARING, 4.46 -
4.48 mm (0.1756 - 0.1764
in.)
SPACER, TRANSFER
SHAFT BEARING, 4.40 -
4.42 mm (0.1732 - 0.1740
in.)
04800579AA SPACER, TRANSFER
SHAFT BEARING, 4.49 -
4.51 mm (0.1768 - 0.1776
in.)
SPACER, TRANSFER
SHAFT BEARING, 4.43 -
4.45 mm (0.1744 - 0.1752
in.)
04800580AA SPACER, TRANSFER
SHAFT BEARING, 4.52 -
4.54 mm (0.1780 - 0.1787
in.)
SPACER, TRANSFER
SHAFT BEARING, 4.46 -
4.48 mm (0.1756 - 0.1764
in.)
04800581AA SPACER, TRANSFER
SHAFT BEARING, 4.55 -
4.57 mm (0.1791 - 0.1799
in.)
30. Install Holder 9739 onto the transfer gear.
31. Install a new transfer gear (underdrive compounder side) nut (p/n 6508521AA) and
tighten to 271 Nˇm (200 ft. lbs.).
-11- 21-005-10
32. Use Staking Tool 9721 and stake the new nut.
33. Clean the transfer gear cover sealing surface and mating surface.
34. Install the oil scavenger.
35. Spread a bead of MOPARŽ ATF RTV (p/n 05010884AA) (MS-GF41) onto the transfer
gear cover sealing surface.
36. Install transfer gear cover-to-case bolts and tighten to 12 Nˇm (105 in. lbs.).
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  #29  
Old 10-26-2010, 11:51 PM
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HYDRAULIC PRESSURE TESTS
Pressure testing is a very important step in the diagnostic procedure. These tests usually reveal the cause of most transaxle problems.

Before performing pressure tests, be certain that fluid level and condition, and shift cable adjustments have been checked and approved. Fluid must be at operating temperature (150 to 200 degrees F.)

Install an engine tachometer, raise vehicle on hoist which allows front wheels to turn, and position tachometer so it can be read.

Attach 150 psi gauges to ports required for test being conducted. A 300 psi gauge (C-3293) is required for reverse pressure test.

Test port locations are shown in
Pressure Taps

TEST ONE-SELECTOR IN LOW 1st GEAR
Attach pressure gauge to the low/reverse clutch tap.
Move selector lever to the (L) position.
Allow vehicle wheels to turn and increase throttle opening to achieve an indicated vehicle speed to 20 mph.
Low/reverse clutch pressure should read 115 to 145 psi.
This test checks pump output, pressure regulation and condition of the low/reverse clutch hydraulic circuit and shift schedule.
TEST TWO-SELECTOR IN DRIVE 2nd GEAR
Attach gauge to the underdrive clutch tap.
Move selector lever to the (3) position.
Allow vehicle wheels to turn and increase throttle opening to achieve an indicated vehicle speed of 30 mph.
Underdrive clutch pressure should read 110 to 145 psi.
This test checks the underdrive clutch hydraulic circuit as well as the shift schedule.
TEST THREE-OVERDRIVE CLUTCH CHECK
Attach gauge to the overdrive clutch tap.
Move selector lever to the (Circle D) position.
Allow vehicle wheels to turn and increase throttle opening to achieve an indicated vehicle speed of 20 mph.
Overdrive clutch pressure should read 74 to 95 psi.
Move selector lever to the (3) position and increase indicated vehicle speed to 30 mph.
The vehicle should be in second gear and overdrive clutch pressure should be less than 5 psi.
This test checks the overdrive clutch hydraulic circuit as well as the shift schedule.
TEST FOUR-SELECTOR IN CIRCLE DRIVE, OVERDRIVE GEAR
Attach gauge to the 2/4 clutch tap.
Move selector lever to the (Circle D) position.
Allow vehicle front wheels to turn and increase throttle opening to achieve an indicated vehicle speed of 30 mph.
The 2/4 clutch pressure should read 75 to 95 psi.
This test checks the 2/4 clutch hydraulic circuit.
TEST FIVE-SELECTOR IN CIRCLE DRIVE, OVERDRIVE
Attach gauge to the torque converter clutch off pressure tap.
Move selector lever to the (Circle D) position.
Allow vehicle wheels to turn and increase throttle opening to achieve an indicated vehicle speed of 50 mph.
CAUTION: Both wheels must turn at the same speed.

Torque converter clutch off pressure should be less than 5 psi.
This test checks the torque converter clutch hydraulic circuit.
TEST SIX-SELECTOR IN REVERSE
Attach gauge to the reverse clutch tap.
Move selector lever to the reverse position.
Read reverse clutch pressure with output stationary (foot on brake) and throttle opened to achieve 1500 rpm.
Reverse clutch pressure should read 165 to 235 psi.
This test checks the reverse clutch hydraulic circuit.
TEST RESULT INDICATIONS
If proper line pressure is found in any one test, the pump and pressure regulator are working properly.
Low pressure in all positions indicates a defective pump, a clogged filter, or a stuck pressure regulator valve.
Clutch circuit leaks are indicated if pressures do not fall within the specified pressure range.
If the overdrive clutch pressure is greater than 5 psi in step (6) of Test Three, a worn reaction shaft seal ring is indicated.
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  #30  
Old 11-22-2010, 01:18 AM
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POWER STEERING GEAR
NOTE: The power steering gear should not be serviced or adjusted. If a malfunction or oil leak occurs, the complete steering gear assembly must be replaced.

NOTE: Before proceeding with this procedure, review the SERVICE WARNINGS AND CAUTIONS at the beginning of the REMOVAL AND INSTALLATION section.

REMOVAL
CAUTION: Positioning the steering column in the locked position will prevent the clockspring from being accidentally over-extended when the steering column is disconnected from the intermediate steering coupler.

Remove cap from power steering fluid reservoir.
Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir.
With the ignition key in the locked position turn the steering wheel to the left until the steering wheel is in the locked position.
With the vehicle on the ground, disconnect the steering column shaft coupler from the steering gear intermediate coupler Steering Column Shaft To Intermediate Shaft Attachment
Raise vehicle on jack stands or centered on a frame contact type hoist. See Hoisting in the Lubrication and Maintenance section of this service manual, for the required lifting procedure to be used for this vehicle.
Remove the front tires.
Raise the heat sleeve Power Steering Fluid Return Hose Connection on the power steering return hose to expose the return hose to steel tube connection. Remove the return hose from the metal tube of the power steering fluid return line Power Steering Fluid Return Hose Connection Then allow the remaining power steering fluid to drain from the system through the hose and metal tube.
Remove nut attaching outer tie rod end to steering knuckle Removing/Installing Tie Rod End Attaching Nut Nut is to be removed from tie rod end using the following procedure, hold tie rod end stud with a 11/32 socket while loosening and removing nut with wrench.
Remove both tie rod ends from steering knuckles, using Puller Special Tool MB-990635 or MB-991113 Tie Rod End Removal From Steering Knuckle
Remove the 2 bolts and loosen the third HCU Bracket Attaching Bolts attaching the antilock brakes hydraulic control unit (HCU) to the front suspension cradle. Then rotate the HCU rearward to allow access to the cradle plate attaching nut and bolt just forward of the HCU.
Remove the 10 nuts and bolts Front Suspension Cradle Plate And Attaching Bolts attaching the cradle plate to the bottom of the front suspension cradle. Then remove the cradle plate from the cradle.
If the vehicle is equipped with All-Wheel-Drive, remove the power transfer unit. Refer to Group 21 in this service manual.
Remove the bracket Tube Bracket (FWD Shown) attaching the power steering fluid tubes to the front suspension cradle.
Using a 18mm crowfoot, Power Steering Fluid Pressure And Return Hoses At Steering Gear remove the power steering fluid pressure and return lines Power Steering Fluid Pressure And Return Hoses At Steering Gear from the power steering gear.
Remove the 3 bolts and nuts Steering Gear Mounting To Suspension Cradle 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 suspension cradle. The steering gear can not be removed from the vehicle with the intermediate coupler attached to the steering gear.

Lower steering gear from suspension cradle enough to allow access to the intermediate coupler roll pin Removing Roll Pin From Intermediate Coupler Install Remover/Installer Special Tool 6831A through the center of the roll pin, securing with the knurled nut Removing Roll Pin From Intermediate Coupler Hold threaded rod stationary while turning nut, this will pull the roll pin out of the intermediate coupler.
Separate the intermediate coupler from the shaft of the steering gear.
Remove the steering gear assembly from the front suspension cradle.
INSTALLATION
Install the steering gear up in the front suspension cradle, leaving room to install intermediate coupler.
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 coupler on the shaft of the steering gear.
Install Remover/Installer Special Tool 6831A through the center of the roll pin, securing it with the knurled nut Installing Roll Pin In Intermediate Coupler Hold threaded rod stationary while turning nut, this will pull the roll pin into the intermediate coupler.
Install steering gear assembly on the front suspension cradle. Install the 3 steering gear to front suspension cradle mounting bolts and nuts Steering Gear Mounting To Suspension Cradle
CAUTION: Proper torque on the steering gear to suspension cradle mounting bolts is very important.

Tighten the 3 steering gear to suspension cradle mounting bolts to a torque of 183 Nˇm (135 ft. lbs.)
Attach the power steering fluid pressure and return lines Power Steering Fluid Pressure And Return Hoses At Steering Gear to the proper fittings on the steering gear. Tighten the power steering fluid line tube nuts to a torque of 31 Nˇm (275 in. lbs.)
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 11/32 socket, Removing/Installing Tie Rod End Attaching Nut tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32 socket Torquing Tie Rod End Attaching Nut , tighten the tie rod end attaching nut to a torque of 54 Nˇm (40 ft. lbs.)
If the vehicle is equipped with All-Wheel-Drive, install the power transfer unit. Refer to Group 21 in this service manual
CAUTION: Proper torque on the cradle plate to suspension cradle mounting bolts is very important.

Install cradle plate on front suspension cradle and install the 10 cradle plate to cradle attaching bolts and nuts Front Suspension Cradle Plate And Attaching Bolts Tighten all attaching bolts to a torque of 165 Nˇm (123 ft. lbs.)
Install the bracket Tube Bracket (FWD Shown) attaching the power steering fluid tubes to the front suspension cradle.
Install the power steering fluid return hose on the steel tube at the front suspension cradle Power Steering Fluid Return Hose Connection
Install a screw type hose clamp on the power steering hose to steel tube connection. Be sure hose clamp is installed on return tube past the upset bead on the tube. Tighten the screw clamp to a torque of 2 Nˇm (18 in. lbs.)
CAUTION: The protective heat shield sleeves must cover the entire rubber hose and hose to tube connection portion of both the power steering fluid pressure and return hoses Power Steering Fluid Return Hose Connection This is required to prevent the power steering hoses from being overheated.

When used, properly position the protective heat sleeves on the power steering hoses. Then, tie strap the heat sleeves to the power steering hoses to keep them in their proper position.
Install the front tire and wheel assemblies on vehicle. Install the wheel lug nuts and torque to 129 Nˇm (95 ft. lbs.)
Lower the vehicle to a level were the interior of vehicle is accessible.
Using the intermediate coupler, turn the front wheels of the vehicle to the left until the intermediate coupler shaft is properly aligned with the steering column coupler. Assemble the steering column shaft coupler Steering Column Shaft To Intermediate Shaft Attachment onto the steering gear intermediate coupler. Install steering column coupler to intermediate shaft retaining pinch bolt Steering Column Shaft To Intermediate Shaft Attachment Tighten the pinch bolt nut to a torque of 28 Nˇm (250 in. lbs.)
Perform the POWER STEERING PUMP INITIAL OPERATION service procedure listed in the POWER STEERING PUMP section of this group to properly fill and bleed the power steering system.
Inspect for leaks.
Adjust front toe.
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  #31  
Old 12-04-2010, 07:25 PM
jumpdrive2 jumpdrive2 is offline
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Default 01 GC sliding door and hatch

Look on the bottom of the distribution cover and post what fuse relay is missing. Sound like you have multiple problems. Here is some info on fuses relays and how the sliding doors work. You will see lots of different things could go wrong with hatch and sliding doors.
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try moving the sliding door fuse
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How doors work
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  #32  
Old 01-23-2011, 05:44 PM
dozer103 dozer103 is offline
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Default

Have a 2005 Grand Caravan SXT that I'm trying to replace the blower motor on. The housing seems to have a hidden fastener crammed up against the firewall-housing is loose and tilts down but won't come out. Any ideas?
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  #33  
Old 03-21-2011, 11:02 PM
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SUBJECT:
Flash: 6 Speed Automatic Transmission Shift Improvements
OVERVIEW:
This bulletin involves selectively erasing and reprogramming the Powertrain Control
Module (PCM).
MODELS:
2008 (RT) Caravan/Town & Country (Includes International Models)
NOTE: This Bulletin applies to models equipped with a 3.8L/4.0L engine & 62TE
automatic transmission (Sales Code EGL/EGQ with DG2).
SYMPTOM/CONDITION:
Some customers may experience transmission shift or performance concerns as follows:
i. During a rapid coast down while braking a bump may be felt just before a stop
ii. 3 - 2 kickdown bump or harshness
iii. 2 - 3 upshift bump or harshness
iv. 4 - 3 - 4 change mind shift bump
v. Improved shift quality/driveability through all gear transactions
NUMBER: 21-017-08 REV. A
GROUP: Transmission
DATE: December 16, 2008
DIAGNOSIS:
Using a Scan Tool (StarSCANŽ) with the appropriate Diagnostic Procedures available in
TechCONNECT, verify all engine systems are functioning as designed. If DTC's are
present record them on the repair order and repair as necessary before proceeding further
with this bulletin.
If the above symptom/condition is experienced or can be verified, perform the Repair
Procedure.
PARTS REQUIRED:
Qty. Part No. Description
1 04275086AB Label, Authorized Modification
SPECIAL TOOLS / EQUIPMENT REQUIRED:
NPN Battery Charger
CH9401 StarSCANŽ Tool
CH9404D StarSCANŽ Vehicle Cable
CH9409 StarSCANŽ Documentation Kit
CH9410 StarSCANŽ Ethernet Cable, 12 ft.
CH9412 StarSCANŽ Software Update Device Kit
TechCONNECT PC or equivalent
REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE:
NOTE: If this flash process is interrupted/aborted, the flash should be restarted.
1. Reprogram the PCM with the latest software. Follow the detailed service procedures
available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical >
Electronic Control Modules - Service Information > Module - Powertrain Control >
Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming,
the following must be performed:
a. Clear the Variable Line Pressure (VLP) Counters, found in the StarSCANŽ Misc
Function Menu. VLP Clear Counters must be completed on all models with a 62TE
transmission.
b. Clear any DTC's that may have been set in other modules due to reprogramming.
c. Perform the Quick Learn function, found in the StarSCANŽ Misc Function Menu.
2. Type the necessary information on the “Authorized Modification Label” and attach it
near the VECI label.
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  #34  
Old 04-09-2011, 12:38 PM
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OVERHEAD CONSOLE
REMOVAL
Open the transmitter bin door Overhead Console .
Remove screw holding the overhead console to the headliner. With the screw removed the console is retained by one engagement tab located inside the sunglasses storage bin.
Open the sunglasses bin door.
Press the retaining tab which is located directly under the door latch.
Lower rear of console away from headliner.
Pull console rearward to disengage clips holding front of console to roof armature and lower console.
Disconnect wire connectors from back of CMTC and reading lamps. Ensure the connectors lock tabs are fully depressed before disconnecting.
Remove overhead console.
INSTALLATION
Reverse the preceding operation.
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  #35  
Old 05-14-2011, 11:44 PM
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I have a part number for the jumper harness for the 1996 1/2 minivans to the 1998 TRS sensors. This way you don't need to cut and spline the new connector. 5093968AA,This is a mopar number.
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  #36  
Old 06-20-2011, 05:06 PM
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Default 2006 DGC Rear Brake Job (pic)

Thanks to help from Tizzy1 and this forum I have done rear disk brake pads and rotors on my 2006 Dodge Grand Caravan,

here is some pics and my advice, so use according to your own ability and at your own risk

warning, so brake materials might contain asbestos so you may want to use gloves, mask and eye protection for safety

it took me 45mins for the first side(taking pics)
2nd side took 25mins
then 20mins bleeding brakes

things you will Need

7mm Allen wrench socket
brake cleaner (I used 1 1/2 cans)
rotors,
pads
3/8 box wrench for bleeding the brakes
Dot 3 brake fluid

optional but I used,
caliper grease
and anti squeal grease

step 1
park the van on level surface, block the both sides of the front tires to prevent rolling
Loosen the Lug nuts
Make sure the Parking brake is Off

step 2
Jack up the back tire, (I only did one at a time) place it on jack stands
remove the tire

step 3
remove the two 7mm Allen head bolts
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step 4
press the one side of the caliper up (press on the side opposite the metal spring type tab) takes a little force to get it loose, then it comes up freely



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step 5
secure the caliper so that it is not hanging on the brake hose



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step 6
remove the rotors
they should pull right off, my first one came off easily
but the other side had never been removed, it still had a clip to hold the rotor on, simply remove it and discard it, that rotor I had to work to get off due to rust, I used a rubber mallet and whacked it along the center hub and on the back of the rotor being carefully not to hit anything else



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step 7
then I sprayed everything off with brake cleaner, being careful not to hit the rubber brake line
also when cleaning after that rotor came off I notice a slight build up off rust along the center hub, so I gently scrapped it off


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step 8
take the new rotor and spray it off with brake cleaner to get the packing oil off,
then simply slide it on to the wheel studs



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step 9
press down on the outboard side of the brake pad (it takes some pressure to get it to separate, then simply pull the pad off



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step 10
using the brake caliper compression tool on top of the old inboard brake pad, Slowly compress the brake caliper, you will want to keep an eye on the master cylinder to make sure it does not over flow, you may have to remove some fluid so it does not over flow
( I personally opened the brake bleeder valve just a crack to help)



Click the image to open in full size.



step 11
remove the inboard brake pad



Click the image to open in full size.



step 12,
reinstall brake pads
you can put the anti squall grease on the back side of the pads if you like on just the metal parts that make metal to metal contact,
also grease the 7mm caliper bolts with caliper grease
with my brake pads the both in-board pads were the same, but my out-board pads Had R and L marks on them so let you know which side they went



Click the image to open in full size.



step 13
reinstall the caliper, this part takes some force, you start by in stalling the side that has the metal spring tab in, (hint, make sure the caliper bolts are pulled out a bit so they are not getting hung up when trying to push the caliper on)



Click the image to open in full size.



step 14
Tighten the 7mm Allen bolts to 26 ft/lbs
put tire on, snugging the lugs, Lower van and do other side
after finishing other side and lowering van, tighten Lugs to 95 ft/lbs
step 15
bleed brakes, starting at DR, PF, PR, DF using your 3/8 brake bleeder wrench
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2002 Jeep Liberty Renegade V6 3.7L
---Rip----2000 Dodge Avenger, 1993 Eagle Talon
1989 Dodge Dakota
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  #37  
Old 06-20-2011, 05:17 PM
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trophyslayer trophyslayer is offline
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Default how to remove wiper crowl, (pics)

how to remove wiper crowl

this is on my 2006 DGC, takes about 15mins to take off, gives alot more room on the back side if needed

15mm socket
13mm socket
10mm socket
small screw driver
2-arm puller (got mine from Harbor Freight 3pc set, smallest size in the set is what I used)
8" or larger extention
T-20 screw driver


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if you want to remove the hood for even more room



Click the image to open in full size.


Notice how much more room there is

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2006 Dodge Grand Caravan SXT v6 3.8L
2002 Jeep Liberty Renegade V6 3.7L
---Rip----2000 Dodge Avenger, 1993 Eagle Talon
1989 Dodge Dakota

Last edited by trophyslayer; 06-20-2011 at 05:21 PM..
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  #38  
Old 06-20-2011, 05:31 PM
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trophyslayer trophyslayer is offline
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Default How To Upload Pictures

How To Upload Pictures on this site

first you have to upload a free service like http://photobucket.com/ or any other picture upload service

the reason you should do this is that this site has a limited upload space, so you will only be able to add 1-2 pictures at most

once files are uploaded at photobucket

as you are viewing the thumbnails view of your pictures then just move you mouse over the pic you want and it will expand to show 4 links,
you will want to copy the Direct Link

Click the image to open in full size.



then come back to this site and in the thread where you are posting the picture, click this button and input the link you just copied


Click the image to open in full size.



the key thing with photobucket pictures is to copy the Direct Link
no matter which view is showing


(important note: after adding the pics to the upload site, file them how/where you want them before adding them here, since if you move the picture on photobucket/upload site, they it will no longer show up here,)
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1989 Dodge Dakota
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  #39  
Old 07-25-2011, 10:13 PM
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OVERHEAD CONSOLE
Any diagnosis of the overhead console should begin with the use of the DRB IIIŽ diagnostic tool. For information on the use of the DRB IIIŽ, refer to the appropriate Diagnostic Procedures information.

If the problem with the overhead console is an inaccurate or dashed (- -) display, refer to SELF-DIAGNOSTIC TEST. If the problem with the overhead console is incorrect Vacuum Fluorescent Display (VFD) dimming levels, use a DRB IIIŽ scan tool and the proper diagnostic procedures information to test for the correct dimming message inputs being received from the Body Control Module (BCM) or Front Control Module (FCM) over the Programmable Communications Interface (PCI) data bus circuit. If the problem is a no-display condition, use the following procedures.

Inspect the related wiring harness connectors for broken, bent, pushed out, or corroded terminals. Refer to the appropriate wiring information.

Check the fused B(+) fuse in the integrated power module. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse.
Check for battery voltage at the fused B(+) fuse in the integrated power module. If OK, go to Step 3. If not OK, repair the open fused B(+) circuit to the fused B(+) fuse in the integrated power module as required.
Check the fused ignition switch output (run/start) fuse in the integrated power module. If OK, go to Step 4. If not OK, repair the shorted circuit or component as required and replace the faulty fuse.
Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (run/start) fuse in the integrated power module. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (run/start) circuit to the ignition switch as required.
Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the overhead console. Check for continuity between the ground circuit cavity of the roof wire harness connector for the electronics module and a good ground. There should be continuity. If OK, go to Step 6. If not OK, repair the open ground circuit as required.
Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the roof wire harness connector for the electronics module. If OK, go to Step 7. If not OK, repair the open fused B(+) circuit to the fused B(+) fuse in the integrated power module as required.
Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (run/start) circuit cavity of the roof wire harness connector for the electronics module. If OK, refer to SELF-DIAGNOSTIC TEST. If not OK, repair the open fused ignition switch output (run/start) circuit to the fuse in the integrated power module as required.
SELF-DIAGNOSTIC TEST
A self-diagnostic test is used to determine that the electronics module is operating properly, and that all the PCI data bus messages are being received for initial operation. Initiate the self-diagnostic test as follows:

With the ignition switch in the Off position, on Electronic Vehicle Information Center (EVIC) and Compass Mini-Trip Computer (CMTC) equipped vehicles simultaneously depress and hold the STEP and the RESET buttons. On Compass Temperature Module (CT) equipped vehicles depress the C/T and the US/M push buttons.
Turn the ignition switch to the On position.
Following completion of these tests, the electronics module will display one of the following messages:
Pass Self Test (EVIC only), PASS (CT, CMTC) - The electronics module is working properly.
Failed Self Test (EVIC only), FAIL (CT, CMTC) - The electronics module has an internal failure. The electronics module is faulty and must be replaced.
NOTE: If the compass functions, but accuracy is suspect, it may be necessary to perform a variation adjustment. This procedure allows the compass unit to accommodate variations in the earth's magnetic field strength, based on geographic location. NOTE: If the compass reading display is blank and only “CAL” appears in the display, demagnetizing may be necessary to remove excessive residual magnetic fields from the vehicle.
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  #40  
Old 08-02-2011, 11:50 PM
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SUBJECT:
Evaporator Hiss Sound
OVERVIEW:
This bulletin involves installing an evaporator inlet flow straightener and a rubber
evaporator insert between the evaporator tubes if necessary.
MODELS:
2002 - 2003 (RS) Town & Country/Caravan/Voyager
NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH MANUAL
SINGLE ZONE HVAC (SALES CODE HAA) BUILT MARCH 25, 2002 (MDH 0325XX)
THROUGH AND INCLUDING FEBRUARY 26, 2003 (MDH 0226XX) OR MANUAL
DUAL ZONE HVAC (SALES CODE HAD) BUILT JULY 22, 2002 (MDH 0722XX)
THROUGH AND INCLUDING FEBRUARY 26, 2003 (MDH 0226XX).
SYMPTOM/CONDITION:
Some customers may experience a "hiss" sound, that originates from the Heating,
Ventilation, Air Conditioning (HVAC) unit. This may be most noticeable when
operating between 18 C - 27 C (65 F - 80 F).
DIAGNOSIS:
Operate the vehicle in a moderate ambient temperature, 18 C - 27 C (65 F - 80 F).
Run the HVAC system in recirculation, panel mode, A/C off, full heat, high blower for
1 to 2 minutes to heat the evaporator. Switch the HVAC system to outside air, panel
mode, A/C on, full cool, low blower, and maintain a steady engine speed of approximately
2000 rpm. Listen for a "hiss" that will occur when the A/C clutch cycles on.
NOTE: PERFORM THIS PROCEDURE AFTER EACH REPAIR TO THE HVAC
SYSTEM, TO VERIFY THE “HISS” IS NO LONGER PRESENT.
PARTS REQUIRED:
Qty. Part No. Description
AR (1) 04885713AA Flow Straightener, Evaporator Inlet
AR (1) 05061454AA Rubber Evaporator Insert
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Old 08-02-2011, 11:50 PM
 
 
 
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