Caravan, Grand Voyager, Town and Country, Voyager, 2000-2004

Removal & Installation

Print


CAUTION
The Supplemental Inflatable Restraint (SIR) system must be disarmed before removing the steering wheel. Failure to do so may cause accidental deployment of the air bag, resulting in unnecessary SIR system repairs and/or personal injury.

  1. Disconnect and isolate the negative (ground) battery cable. Allow the system capacitor to discharge for at least 2 minutes before continuing with the removal procedure. This will disable the air bag system.
  2.  
  3. Make sure the front wheels are in the straight-ahead position.
  4.  
  5. Turn the ignition key cylinder to the LOCK position and remove the key. Turn the steering wheel a 1 / 2 turn toward the left until the steering column becomes locked in position.
  6.  
  7. Remove the 3 bolts attaching the air bag module to the steering wheel. Remove the air bag module.
    CAUTION
    When carrying a live air bag, make sure the bag and trim cover are pointed away from the body. In the unlikely event of an accidental deployment, the bag will then deploy with minimal chance of injury. When placing a live air bag on a bench or other surface, always face the bag and trim cover up, away from the surface. This will reduce the motion of the module if accidentally deployed.



    Click image to see an enlarged view

    Fig. The airbag is attached to the steering wheel by three fasteners



    Click image to see an enlarged view

    Fig. After the airbag is unbolted from the steering wheel . . .



    Click image to see an enlarged view

    Fig. . . . reach behind and unplug the electrical connections

  8.  
  9. Disconnect the wiring connectors from the air bag module, horn switch and speed control switches.
  10.  
  11. Remove the routing clip for the wiring harness from the air bag module studs.
  12.  
  13. Remove the steering wheel mounting nut from the steering column shaft and remove the steering wheel damper from the steering wheel.

    Click image to see an enlarged view

    Fig. Always hold the airbag away from your body when transporting it to a storage area



    Click image to see an enlarged view

    Fig. With the airbag removed, the steering wheel retaining nut can be removed



    Click image to see an enlarged view

    Fig. After the nut is removed, set aside the damper plate . . .



    Click image to see an enlarged view

    Fig. . . . and use a paint marker to matchmark the steering wheel shaft with the wheel

  14.  
  15. Using a steering wheel puller tool, remove the steering wheel from the steering column shaft. Do not thread the steering wheel puller tool bolts into the steering wheel more than a 1 / 2 in. or damage to the SRS clockspring will result. Do not hammer or bump the steering column or shaft when removing the steering wheel.
  16.  

To install:

  1. Before installing the steering wheel, the clockspring must be centered . Center the clockspring as follows:
    1. Disengage the lock mechanism by depressing the 2 plastic locking pins.
    2.  
    3. Turn the clockspring rotor clockwise until it stops, while the lock mechanism is disengaged. Do not use excessive force.
    4.  
    5. From the end of the clockwise travel, turn the clockspring rotor counter-clockwise. The clockspring wires should be at the top. Engage the clockspring locking pins.
    6.  
    7. Turn the clockspring a 1 / 2 additional rotation counter-clockwise from the center locked position. This should put the clockspring wiring at the bottom.

      Click image to see an enlarged view

      Fig. A steering wheel puller must be used to remove the wheel from the shaft



      Click image to see an enlarged view

      Fig. Once the wheel is free of the shaft, carefully route the wires through the wheel

    8.  
    9. The clockspring is now correctly positioned for installation of the steering wheel.
    10.  

  2.  
  3. Install the steering wheel onto the steering column shaft. Make sure the master splines of the steering wheel and steering shaft are in correct alignment. Be sure the flats on the steering wheel align with the formations on the clockspring. All wiring leads from the clockspring must be routed correctly.
  4.  
  5. Install the steering wheel damper onto the steering wheel in its original position.
  6.  
  7. Install the steering wheel-to-steering shaft retaining nut. Torque the retaining nut to 45 ft. lbs. (61 Nm).
  8.  
  9. Reconnect the horn switch wiring lead from the clockspring, onto the steering wheel horn switch wiring.
  10.  
  11. If equipped with speed control, reconnect the speed control wiring from the clockspring onto the speed control switch.
  12.  
  13. Install the wiring lead from the clockspring onto the air bag module. Make the wiring connection onto the air bag module, by pressing straight in on the connector. Be sure it is fully seated.
  14.  
  15. Install the air bag module to the steering wheel and then install the 3 air bag module attaching nuts. Torque all 3 air bag module attaching nuts to 100 inch lbs. (11 Nm).
  16.  
  17. When reconnecting the battery on a vehicle that has had the air bag removed, the following procedure should be used:
    1. Connect the DRB or equivalent scan tool, to the ASDM diagnostic 6-way connector.
    2.  
    3. Turn the ignition key to the ON position. Exit the vehicle with the DRB, and install the latest version of the proper diagnostic cartridge into the DRB.
    4.  
    5. Make sure there are no occupants in the vehicle and reconnect the negative battery cable.
    6.  
    7. Using the DRB, read and record active or stored fault codes. Take appropriate actions to correct any faults.
    8.  
    9. Erase stored fault codes. If problems remain, fault codes will not erase.
    10.  
    11. From the passenger side of the vehicle, turn the ignition key to OFF and then ON , observing the instrument cluster air bag lamp. It should go ON for 6-8 seconds, then go out. This will indicate that the air bag system is functioning normally.
      WARNING
      If the air bag warning lamp fails to light, blinks ON and OFF or goes ON and stays ON, there is an air bag system malfunction.

    12.  
    13. Test the operation of any steering column functions such as the horn, lights or speed control system.
    14.  

  18.  
  19. Road test vehicle. Be sure the speed control and steering systems are functioning properly.
  20.  

 
label.common.footer.alt.autozoneLogo