Chrysler Caravan/Voyager/Town n Country 1984-1995

Steering Column

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REMOVAL & INSTALLATION



1984-90 Models

See Figures 1 and 2



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Fig. Fig. 1: Exploded view of the steering column assembly-1984-90 models



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Fig. Fig. 2: Upper steering column components-1984-90 models

  1. Disconnect the negative battery cable from the battery. If the vehicle is equipped with a column mounted shift, pry the shift cable rod from the lever grommet at the bottom of the steering column. Remove the cable clip and cable from lower bracket.
  2.  
  3. Disengage the wiring harness connector at the bottom of the steering column.
  4.  
  5. Remove the instrument panel lower steering column cover and disconnect the bezel. On models with floor shift, unsnap and remove shroud cover extensions.
  6.  
  7. If automatic, remove the selector indicator set screw and pointer from the shift housing.
  8.  
  9. Remove the nuts that attach the steering column mounting bracket to the instrument panel support and lower the bracket.
  10.  

Do not remove the roll pin from the steering column assembly connector.

  1. Pull the steering column rearward, disengaging the lower stub shaft from the steering gear connector. If the vehicle is equipped with speed control and a manual transmission, take care not to damage the control switch mounted on the clutch pedal.
  2.  

To install:
  1. Install the anti-rattle coupling spring into the lower coupling tube. Be sure that the spring snaps into the slot in the coupling.
  2.  
  3. Align the column lower shaft stub with coupling and insert. Raise the column and place bracket into position on the mounting studs. Loosely install the mounting nuts. Pull the column rearward, then tighten the nuts to 105 inch lbs. (12 Nm). Tighten stub shaft connector.
  4.  
  5. Connect and adjust the linkage. Connect all harnesses. Connect the shift indicator and adjust as required. Connect the gear shift indicator operating cable into the slot on the shift housing. Slowly move the gearshift from 1st gear to park (P). The pointer will now be properly adjusted. Install the instrument steering column cover.
  6.  

1991 Models
WITH ACUSTAR® STEERING COLUMN

See Figures 3, 4, 5 and 6



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Fig. Fig. 3: Exploded view of the Acustar® steering column assembly-1991 models



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Fig. Fig. 4: Steering column coupler removal-1991 with Acustar® steering column



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Fig. Fig. 5: PRNDL cable removal-1991 with Acustar® steering column



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Fig. Fig. 6: Multi-function switch wiring-1991 with Acustar® steering column

  1. Make sure the wheels are in the straight-ahead position.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Pry the shift link rod out of the grommet on the bottom of the column, if equipped with an automatic transaxle.
  6.  
  7. Remove the steering wheel pad and disconnect the electrical leads.
  8.  
  9. Remove the steering wheel. Remove the upper coupling bolt retaining pin.
  10.  
  11. Remove the nut and bolt from the upper coupling and remove the upper coupling from the lower coupling.
  12.  
  13. For vehicles equipped with an automatic transaxle, disconnect the PRNDL cable from the PRNDL driver arm.
  14.  
  15. If equipped with a tilt column, remove the tilt lever. Remove the upper and lower ignition shroud trim.
  16.  
  17. Remove the turn signal/multifunction switch. Disengage the electrical connectors at the bottom of the column.
  18.  
  19. Remove the upper and lower fixed shrouds, loosen the upper support bracket bolts.
  20.  
  21. Remove the lower dash panel and column support standoff bracket bolts.
  22.  
  23. Remove the column through the passenger compartment.
  24.  

To install:
  1. Install a replacement grommet on the shift rod arm and lubricate it.
  2.  
  3. Install the column in the vehicle, position it on the attaching studs and loosely assemble the upper bracket nuts.
  4.  
  5. Make sure the wheels are still in a straight-ahead position and align the upper and lower coupling. Install the coupling nut, then tighten to 21 ft. lbs. (28 Nm). Install the retaining pin.
  6.  
  7. Install the multifunction switch and connect the column wiring.
  8.  
  9. Install the upper fixed shroud.
  10.  
  11. Make sure the 2 plastic retainer are fully seated on the column bracket, then tighten the bracket bolts to 105 inch lbs. (12 Nm).
  12.  
  13. Install the lower shroud. Position the shift lever, if equipped with an automatic transaxle, in the farthest down position and install the PRNDL cable.
  14.  
  15. Install the tilt lever and the lower dash panel cover. Install the steering wheel. Connect the shift link rod.
  16.  
  17. Check the transaxle linkage adjustment through all of the gear positions.
  18.  
  19. Connect the negative battery cable.
  20.  

1992-95 Models

See Figures 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27 and 28

Before performing repair procedures that require the removal or disconnecting of any air bag system component, refer to the Air Bag Systems Check procedures outlined in Section 6



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Fig. Fig. 7: Parking brake pedal release rod-1992-95 models



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Fig. Fig. 8: Lower steering column cover removal-1992-95 models



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Fig. Fig. 9: Lift gate release switch and electrical connector-1992-95 models



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Fig. Fig. 10: Steering column attachment to instrument panel reinforcement-1992-95 models



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Fig. Fig. 11: DRB diagnostic connector mounting-1992-95 models



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Fig. Fig. 12: Lower instrument panel reinforcement mounting-1992-95 models



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Fig. Fig. 13: Air bag module removed from steering wheel-1992-95 models



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Fig. Fig. 14: Steering wheel horn switch wiring-1992-95 models



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Fig. Fig. 15: Speed control switch wiring harness connector-1992-95 models



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Fig. Fig. 16: Upper steering column shroud attaching screws-1992-95 models



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Fig. Fig. 17: Lower steering column shroud attaching screws-1992-95 models



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Fig. Fig. 18: Clock spring and ignition switch wiring-1992-95 models



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Fig. Fig. 19: Multi-function switch wiring connector-1992-95 models



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Fig. Fig. 20: Clock spring assembly-1992-95 models



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Fig. Fig. 21: Clock spring locking tab disengagement-1992-95 models



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Fig. Fig. 22: Upper-to-lower steering shaft coupler removal-1992-95 models



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Fig. Fig. 23: Steering column upper and lower mounting brackets-1992-95 models



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Fig. Fig. 24: Gear shift indicator cable assembly-1992-95 models



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Fig. Fig. 25: Gear shift indicator cable removal from the steering column-1992-95 models



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Fig. Fig. 26: Gear shift cable retaining clip removal-1992-95 models



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Fig. Fig. 27: Gear shift cable removal from steering column-1992-95 models



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Fig. Fig. 28: Exploded view of the Acustar® steering column assembly-1992-95 models


CAUTION
Disconnect and isolate the negative (ground) battery cable. This will disable the air bag system. Failure to disconnect the battery could result in accidental deployment and possible personal injury. Allow system capacitor to discharge for two minutes then begin air bag system component removal. Refer to Chassis Electrical for additional air bag system precautions and information.

  1. Make sure the front wheels are straight and the steering column is locked in place.
  2.  
  3. Disconnect the negative battery cable at the battery and isolate the cable from the battery terminal.
  4.  
  5. Remove the parking brake release rod, from the parking brake pedal assembly.
  6.  
  7. Remove the 5 screws attaching the steering column assembly cover.
  8.  
  9. Lower the steering column enough to disconnect the lift gate release switch connector.
  10.  
  11. Remove the fuse access/silencer panel assembly from the lower instrument panel.
  12.  
  13. Remove the nut from the stud, attaching the lower steering column bracket to the lower instrument panel reinforcement.
  14.  
  15. Remove the DRB diagnostic connector from its mounting bracket, on the lower instrument panel reinforcement.
  16.  
  17. Remove the 4 attaching bolts and lower instrument panel reinforcement from the lower instrument panel.
  18.  
  19. Position the steering wheel in the locked position and remove the key from the lock cylinder. Remove the 4 nuts attaching the air bag module from the steering wheel, then remove the air bag module from the steering wheel and disconnect the electrical lead at the air bag module.
  20.  
  21. Disengage the steering wheel horn switch wiring connector from the steering wheel wiring harness.
  22.  
  23. Remove the steering column wiring harness connector from the speed control switch assembly.
  24.  
  25. Remove the steering wheel retaining nut and remove the steering wheel using a puller as outlined earlier.
  26.  
  27. Remove the 3 screws attaching the upper steering column shrouds to the steering column, then remove the upper and lower halves of the upper steering column shroud, from the steering column.
  28.  
  29. Remove the 3 screws attaching the lower steering column shrouds to the steering column, then remove the upper and lower steering column shroud, from the steering column.
  30.  
  31. Remove the wiring harness connectors from the clock spring and ignition switch, then remove the halo light and key in buzzer wiring harness connector from the ignition switch assembly.
  32.  
  33. Remove the 0.27 in. (7 mm) hex head bolt from the rear of the multi-function switch connector.
  34.  
  35. Disengage the connector from the switch.
  36.  
  37. Remove the clock spring from the steering column assembly.
  38.  
  39. If the clock spring will not lift off the steering column do the following:.
    1. Insert a screwdriver in the area of the clock spring's lower locking tab as shown.
    2.  
    3. Place the screwdriver against the locking tab of the clock spring assembly, then push the locking tab back and disengage the tab from the steering column.
    4.  
    5. Remove the clock spring from the column.
    6.  

  40.  
  41. Remove the steering column assembly wiring harness from the column.
  42.  

The nut shown in the upper-to-lower steering shaft coupler illustration is part of the upper steering shift coupler and will remain on the coupler when removing the bolt. Do not attempt to remove the nut from the coupler.

  1. Remove the 3 nuts, attaching the lower mounting bracket of the steering column assembly to the dash panel reinforcement/steering column lower mounting bracket, then remove the 2 nuts attaching the upper mounting bracket of the steering column assembly to the dash board liner.
  2.  


WARNING
During the following Step, do not allow the weight of the steering column assembly to be supported by the gear shift indicator cable.

  1. Lower the steering column assembly from the dash board of the vehicle enough to access the gear shift indicator cable assembly, on the jacket of the steering column.
  2.  
  3. Position the gear shift lever on the steering column in the park position and remove the gear shift indicator assembly from the steering column jacket. Remove the indicator assembly, by first releasing the lock bar on the column insert and squeezing the legs of the column insert together and then lift the assembly from the column.
  4.  
  5. Lower the steering column to the floor of the vehicle, then remove the clip attaching the gear shift cable to the lower bracket of the steering column assembly.
  6.  
  7. Remove the gear shift cable from the shift lever of the steering column
  8.  
  9. Carefully remove the steering column assembly from the vehicle.
  10.  

To install:
  1. Install a new gear shift cable attaching grommet into the steering column shift lever.
  2.  
  3. Prior to installing the steering column in the vehicle, install a ground clip on the left side capsule slot. The plastic capsules should be pre-assembled in the bracket slots. Remove the shipping lock pin, located on the lower column jacket when installing a new jacket. Place the steering column on the floor of the vehicle.
  4.  
  5. Install the gear shift cable on the lower mounting bracket of the steering column assembly. Install the gear shift cable into the new grommet on the steering column gear shift lever, then install the clip, attaching the shift cable to the steering column bracket.
  6.  
  7. Route the gear shift indicator assembly and its cable under the left upper mounting bracket of the steering column. Hook the eye of the gear shift indicator cable onto the lever of the steering column gear shift tube. Insert the flange of the gear shift indicator assembly into the steering column jacket. Squeeze the legs of the steering column insert together and install the tabs under the steering column jacket. Engage the lock bar to secure the shift indicator assembly into the steering column jacket.
  8.  
  9. Install the lower mounting bracket of the steering column assembly on the studs of the dash panel/reinforcement steering column mounting bracket then loosely install the 3 mounting nuts. Lift the steering column aligning studs in the dash board liner with insert in the upper mounting bracket of the steering steering column and loosely install the 2 mounting nuts.
  10.  
  11. Slide the steering column down until the lower bracket of the steering column assembly is against the studs in the dash panel reinforcement/steering column bracket. Center the steering column assembly assembly in the dash panel opening, then tighten the mounting nuts at the upper bracket of the steering column assembly, then tighten all 5 steering column assembly mounting nuts to 105 inch lbs. (12 Nm).
  12.  
  13. Install the upper steering shaft coupler on the lower steering shaft coupler and install the upper coupler bolt. Tighten the nut on the upper steering coupler bolt to 21 ft. lbs. (28 Nm). Be sure to reinstall the retaining pin in the steering coupler retaining bolt.
  14.  
  15. Install the clock spring on the steering column assembly, making sure the locking tabs on the clock spring are engaged with the steering column assembly.
  16.  
  17. Install the wiring harness connector onto the multi-function switch. Tighten the multi-function switch wiring harness connector retaining bolt to 17 inch lbs. (2 Nm).
  18.  
  19. Install the wiring harness connectors onto the clock spring and ignition switch assembly.
  20.  
  21. Move the shift lever to the neutral position and check the pointer location in the PRNDL window on the instrument cluster. If the pointer does not indicate neutral, adjust the actuator assembly to center the pointer on N (neutral), and then check the pointer in other gear positions.
  22.  
  23. Install the clips attaching the steering column assembly wiring harness to the steering column assembly.
  24.  
  25. Install the upper and lower halves of the lower steering column shroud assembly on the steering column. Then install and securely tighten the 3 lower steering column shroud attaching screws.
  26.  
  27. Install the upper and lower halves of the upper steering column shroud assembly on the steering column. Then install and securely tighten the 3 upper steering column shroud attaching screws.
  28.  
  29. Install the tilt lever on the column.
  30.  
  31. Feed the speed control switch and air bag module wiring leads through the rectangular hole in the steering wheel, then feed the horn switch wiring lead through the round hole in the steering wheel.
  32.  
  33. Install the steering wheel as outlined earlier in this Section.
  34.  
  35. Connect the horn switch wiring lead from the clock spring, onto the steering wheel horn switch wiring.
  36.  
  37. If equipped with speed control, connect the speed control wiring from the clock spring onto the speed control switch.
  38.  
  39. Install the wiring lead from the clock spring onto the air bag module. Make the wiring connection onto the air bag module, by pressing straight in on the connector. Make sure it is fully seated.
  40.  
  41. Install the air bag module into the steering wheel and then install the 4 air bag module attaching nuts. Tighten all 4 air bag module attaching nuts to 100 inch lbs. (11 Nm).
  42.  
  43. Install the lower instrument panel reinforcement onto the instrument panel, then tighten the 4 retaining bolts to 50 inch lbs. (6 Nm).
  44.  
  45. Install the nut on the stud attaching the lower steering column bracket to the lower instrument panel reinforcement, then tighten the nut to 100 inch lbs. (11 Nm).
  46.  
  47. Install the DRB diagnostic connector onto the instrument panel bracket on the lower instrument panel reinforcement.
  48.  
  49. Install the fuse access/silencer panel assembly on the lower instrument panel.
  50.  
  51. Position the lower steering column in the vehicle. Connect the lift gate release switch connector.
  52.  
  53. Install the steering column cover and 5 attaching screws.
  54.  
  55. Install the parking brake release rod, to the parking brake pedal assembly and lock attaching clip.
  56.  
  57. Readjust then test the transmission shift linkage.
  58.  
  59. Perform the Air Bag System Check procedures outlined in Chassis Electrical before connecting the negative battery cable.
  60.  
  61. Test the operation of any steering column functions such as the horn, lights or speed control system.
  62.  

 
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