Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 5
cle is subjected to severe driving conditions the over-
running clutch would require periodic maintenance
every 36 000 km (22,500 miles). Refer to Severe Service
paragraph in General Information of this group for
definition of severe service. For proper diagnostic and
service procedures, refer to Group 3, Rear Suspension
and Driveline.
SELECTING LUBRICANT
Chrysler Corporation recommends Mopar
t ATF Plus
(automatic transmission fluid type 7176) or equivalent,
be used to add to or replace overrunning clutch fluid.
DRIVE LINE MODULE
The drive line module should be inspected for oil
leaks and proper oil level when other under vehicle
service is performed. To inspect the power transfer unit
oil level, position the vehicle on a level surface and
remove fill plug (Fig. 7) from the module. The oil level
should be at the bottom edge of oil fill opening.
The drive line module does not require periodic
maintenance when subjected to normal driving condi-
tions. The oil should be changed when water contami-
nation is suspected. If oil has foamy or milky appear-
ance it probably is contaminated. If the vehicle is
subjected to severe driving conditions, the drive line
module would require periodic maintenance every 36
000 km (22,500 miles). Refer to Severe Service para-
graph in General Information of this group for defini-
tion of severe service. For proper diagnostic and service
procedures, refer to Group 3, Rear Suspension and
Driveline.
SELECTING LUBRICANT
Chrysler Corporation recommends Mopar
t Gear
Lube, SAE 85W-90, or equivalent, be used to fill the
drive line module.
DRIVE SHAFT CV AND TRIPOD JOINT BOOTS
The front drive shaft constant velocity and tripod
joint boots (Fig. 8) should be inspected when other
under vehicle service is performed. Inspect boots for
cracking, tears, leaks or other defects. If service repair
is required, refer to Group 2, Suspension.
FRONT WHEEL BEARINGS (REAR WHEEL BEAR-
INGS ON ALL WHEEL DRIVE MODELS)
The front wheel bearings are permanently sealed,
requiring no lubrication. For proper diagnostic and
service procedures refer to Group 2, Suspension.
Fig. 5 Power Transfer Unit Fill Plug
Fig. 6 Overrunning Clutch Fill Plug
Fig. 7 Drive Line Module Fill Plug
Fig. 8 Drive Shaft Boots
.
LUBRICATION AND MAINTENANCE
0 - 17
TIRES
The tires should be inspected at every engine oil
change for proper inflation and condition. The tires
should be rotated at the distance intervals described in
the Lubrication and Maintenance Schedules of the
General Information section in this group. For tire
inflation specifications refer to the Owner’s Manual. A
Tire Inflation sticker is located in the driver door
opening. For proper diagnostic procedures, see Group
22, Wheels and Tires.
TIRE ROTATION
The Forward Cross rotation method is recommended
for use on Chrysler Corporation vehicles (Fig. 9). Other
rotation methods can be used, but may not have the
benefits of the recommended method. Only the four tire
rotation method can be used if the vehicle is equipped
with a space saver spare tire.
Fig. 9 Tire Rotation
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LUBRICATION AND MAINTENANCE
.
CHASSIS AND BODY
INDEX
page
page
Body Lubrication
. . . . . . . . . . . . . . . . . . . . . . . . . 22
Brakes
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Driver Supplemental Airbag System
. . . . . . . . . . . 22
Headlamps
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Lower Ball Joints
. . . . . . . . . . . . . . . . . . . . . . . . . 19
Power Steering
. . . . . . . . . . . . . . . . . . . . . . . . . . 19
Rear Wheel Bearings (Front Wheel Drive Only) . . . 21
Steering Linkage
. . . . . . . . . . . . . . . . . . . . . . . . . 19
STEERING LINKAGE
INSPECTION
The steering linkage and steering gear should be
inspected for wear, leaks or damage when other under
vehicle service is performed. The rack and pinion
steering gear end boots should not have excess oil or
grease residue on the outside surfaces or surrounding
areas (Fig.1). If boot is leaking, it should be repaired.
For proper service procedures, see Group 19, Steering.
The tie rod end seal should fit securely between the
steering knuckle and tie rod end (Fig.2). The steering
linkage should be lubricated at the time and distance
intervals described in the Lubrication and Mainte-
nance Schedules. Refer to General Information section
of this group.
TIE ROD END LUBRICATION
Lubricate the steering linkage with Mopar
t, Multi-
mileage Lube or equivalent. Using a wiping cloth, clean
grease and dirt from around grease fitting and joint
seal. Using a grease gun, fill tie rod end until lubricant
leaks from around the tie rod end side of the seal
(Fig.2). When lube operation is complete, wipe off
excess grease.
LOWER BALL JOINTS
INSPECTION
The front suspension lower ball joints should be
inspected for wear, leaks or damage when other under
vehicle service is performed. The ball joint seal should
fit securely between the steering knuckle and lower
control arm (Fig. 3). The ball joints should be lubri-
cated at the time and distance intervals described in
the Lubrication and Maintenance Schedules. Refer to
the General Information section of this group.
BALL JOINT LUBRICATION
CAUTION: Do not over fill ball joint with grease,
damage to seal can result.
Lubricate the ball joints with Mopar
t, Multi-mileage
Lube or equivalent. Using a wiping cloth, clean grease
and dirt from around grease fitting and joint seal.
Using a grease gun, fill ball joint until seal starts to
swell (Fig. 3). When lube operation is complete, wipe
off excess grease.
POWER STEERING
The power steering fluid level should be
inspected when other under hood service is
performed. If the fluid level is low and system
is not leaking, use Mopar
t, Power Steering
Fluid or equivalent. The power steering sys-
tem should be inspected for leaks when
Fig. 1 Inspect Steering Linkage
Fig. 2 Tie Rod End Lubrication
.
LUBRICATION AND MAINTENANCE
0 - 19
other under vehicle service is performed. For proper
service procedures, refer to Group 19, Steering.
The power steering pump drive belt should be in-
spected at the time and distance interval described in
the Lubrication and Maintenance Schedules. Refer to
the General Information section of this group.
POWER STEERING FLUID INSPECTION
WARNING: ENGINE MUST NOT BE RUNNING WHEN
INSPECTING POWER STEERING FLUID LEVEL, PER-
SONAL INJURY CAN RESULT.
CAUTION: Do not over fill power steering reservoir
when adding fluid, seal damage and leakage can
result.
TO INSPECT FLUID LEVEL:
(1) Position vehicle on a level surface with engine at
normal running temperature.
(2) Turn OFF engine and remove ignition key.
(3) Using a wiping cloth, clean oil and dirt residue
from around power steering reservoir cap.
(4) Remove reservoir cap or dipstick and wipe off
fluid.
(5) Install cap or dipstick.
(6) Remove cap or dipstick. Holding handle or cap
above tip of dipstick, read fluid level (Fig. 4, 5, or 6).
Add fluid if reading is below cold level mark on
dipstick.
Fig. 3 Ball Joint Lubrication
Fig. 4 Power Steering Reservoir Dipstick—2.5L En-
gine
Fig. 5 Power Steering Reservoir Dipstick—3.0L En-
gine
Fig. 6 Power Steering Reservoir Dipstick—3.3L En-
gine
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LUBRICATION AND MAINTENANCE
.
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