Frame & Bumpers: Removal & Installation Dodge Caravan IV

REMOVAL

1. Release hood latch and open hood.
2. Remove the headlamp assemblies «(Refer to ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/HEADLAMP - REMOVAL)»(ref-248898-S23936812432007022700000).
3. Hoist vehicle and support with safety stands.
4. Remove the five push pin fasteners attaching bottom of fascia/air dam to radiator closure panel.
5. Remove front wheels.
6. Remove front wheelhouse splash shields fasteners as necessary to gain access to bolts attaching front fascia to fender. «(Refer to BODY/EXTERIOR/ WHEELHOUSE SPLASH SHIELD - REMOVAL)»(ref-248887-S30909622102007022700000).
7. Remove the two bolts and two nuts attaching fascia to the front fenders. (Scheme 3)and (Scheme 4).
8. Disconnect fog lamp wire connectors, if necessary.
9. Lower vehicle.
10. Remove two bolts attaching the upper grille support to the headlamp mounting panel at each side of the grille.
11. Remove bumper fascia from vehicle.

Scheme 3

Scheme 4

INSTALLATION

1. Position front bumper fascia on vehicle. (Scheme 3)and (Scheme 4).
2. Install the two bolts attaching fascia to headlamp mounting panel at each side of grille.
3. Hoist vehicle and support with safety stands.
4. Install the two bolts and two nuts attaching fascia to the front fenders. The fascia should be flush to fender.
5. Install front wheelhouse splash shields fasteners. «(Refer to BODY/EXTERIOR/ WHEELHOUSE SPLASH SHIELD - INSTALLATION)»(ref-248887-S24691075272007022700000).
6. Install front wheels.
7. Connect fog lamp wire connectors, if necessary.
8. Install the five push pin fasteners attaching bottom of fascia to radiator closure panel.
9. Lower the vehicle.
10. Install the headlamp assemblies. «(Refer to ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/HEADLAMP - INSTALLATION)»(ref-248898-S37048220432007022700000).

1. Remove front bumper fascia. «(Refer to FRAMES & BUMPERS/BUMPERS/FRONT FASCIA - REMOVAL)»(ref-248897-S42718852262007022700000)
2. Disconnect the solid state relay (SSR) for the cooling module wiring connector. If bumper reinforcement is being replaced, remove the solid state relay.
3. Support front bumper reinforcement on a suitable lifting device.
4. Remove the four nuts attaching front bumper reinforcement to frame rail. (Scheme 5)
5. Remove front bumper reinforcement from vehicle.

Scheme 5

Note. Check position of the arrows molded into the foam for correct orientation.

1. Support front bumper reinforcement using a suitable lifting device and lift into position.
2. Install the four nuts attaching reinforcement to frame rails. Tighten nuts to 54 N.m (40 ft. lbs.) torque.
3. Connect the solid state relay (SSR) wiring connector. If bumper reinforcement was replaced, install the solid state relay onto the bumper reinforcement.
4. Install front fascia. «(Refer to FRAMES & BUMPERS/BUMPERS/FRONT FASCIA - INSTALLATION)»(ref-248897-S22452715182007022700000) .

Scheme 6

Scheme 7

Scheme 8

1. Open liftgate.
2. Remove attaching screw from upper fascia to the liftgate tower, right side and left side.
3. Hoist and support vehicle with safety stands.
4. Disconnect rear park assist wire connector, if equipped. (Scheme 6)
5. Remove the three screws attaching rear fascia to rear fascia brackets on right side and left side. (Scheme 7)and (Scheme 8).
6. Remove the four plastic push pin attaching bottom of rear fascia to fascia support.
7. Remove rear fascia from vehicle by lifting sides of fascia up and outboard to release from rear fascia brackets. 1 - REAR FASCIA 2 - PUSH PINS 3 - REAR BUMPER REINFORCEMENT 4 - REAR FASCIA BRACKET 1 - SIDE TRIM 2 - STEP PAD 3 - REAR FASCIA 4 - PARK ASSIST SENSOR
8. Remove park assist sensor, if necessary. (Scheme 9)«(Refer to ELECTRICAL/CHIME/BUZZER/PARK ASSIST SENSOR - INSTALLATION)»(ref-248899-S14006211402007022700000).

Scheme 9

1. Install park assist sensor(s), if necessary. see scheme 8 «(Refer to ELECTRICAL/CHIME/BUZZER/PARK ASSIST SENSOR - INSTALLATION)»(ref-248899-S14006211402007022700000). 1 - PARK ASSIST SENSOR 2 - LOCKING CLIP
2. Hoist and support vehicle with safety stands.
3. Position rear fascia on vehicle. see scheme 9and see scheme 10.
4. Connect the rear park assist wire connector, if equipped. see scheme 11
5. Engage front edge of fascia under the liftgate tower. Install screw in liftgate tower right side and left side.
6. Engage sides of fascia to top and front edge of the rear fascia brackets. NOTE: Verify fascia is still engaged under the liftgate. Ensure acceptable and consistent gap between liftgate and fascia.
7. Install three screws attaching rear fascia to rear fascia brackets, right side and left side.
8. Install the four plastic push pins attaching bottom of rear fascia to fascia support.
9. Lower vehicle.
10. Install the two screws attaching the upper fascia to the fascia support.

1. Remove rear bumper fascia. «(Refer to FRAMES & BUMPERS/BUMPERS/REAR FASCIA - REMOVAL)»(ref-248897-S21656916742007022700000)
2. Support rear bumper reinforcement on a suitable lifting device.
3. Remove the four nuts attaching rear bumper reinforcement to frame rail extensions. (Scheme 10)
4. Remove rear bumper reinforcement from vehicle.

Scheme 10

1. Support rear bumper reinforcement using a suitable lifting device to lift into position.
2. Position rear bumper reinforcement on vehicle.
3. Install the four nuts attaching rear bumper reinforcement to frame rail extensions and tighten to 27 N.m (20 ft. lbs.) torque. (Scheme 10)
4. Install rear bumper fascia. «(Refer to FRAMES & BUMPERS/BUMPERS/REAR FASCIA - INSTALLATION)»(ref-248897-S40320818372007022700000).

The scuff pad may not be salvageable during the removal process. The scuff pad should be replaced if damaged or broken. Check availability before servicing. The scuff pad serviceability is improved if the rear fascia is to be removed for service.

Note. If the rear fascia is to be removed for other service issues or If the scuff pad is to be reused use the steps below.

1. Remove rear bumper fascia. «(Refer to FRAMES & BUMPERS/BUMPERS/REAR FASCIA - REMOVAL)»(ref-248897-S21656916742007022700000)
2. Using a trim stick, pry up the rear edge of the scuff pad while squeezing the rear locking tabs from underneath the fascia to release the rear edge of scuff pad from the rear bumper fascia. Pull the scuff pad up and squeeze the remaining tabs to release the remaining of the scuff pad. (Scheme 11) NOTE: If the rear fascia is to not to be removed for other service issues use the step below.
3. Using a trim stick, pry up the rear edge of the scuff pad to release tabs from the rear bumper fascia and pull scuff pad to release the forward tabs. (Scheme 11)

Scheme 11

1. Verify that there are fifteen slots in the fascia.
2. Place scuff pad in position. (Scheme 11)
3. Align and insert the center forward tab.
4. Align the remaining tabs and press into the slots, starting in the center and working outboard.
5. Assure all tabs are fully engaged into the fascia.
6. If rear bumper fascia has been removed install. «(Refer to FRAME & BUMPERS/BUMPERS/REAR FASCIA - INSTALLATION)»(ref-248897-S40320818372007022700000).

The front cradle crossmember must be installed in the design location to achieve proper front end suspension alignment. If the cradle crossmember is removed without applying reference marks on the frame rails, align the cradle crossmember according to the dimensions provided in this group.

Note. If the caged nuts in the frame rails become damaged and cannot be reused, a replacement nut can be obtained through Mopar(R). (Scheme 12)

Scheme 12

1. Disconnect battery negative cable.
2. Remove steering column lower cover from instrument panel «(Refer to BODY/INSTRUMENT PANEL/STEERING COLUMN OPENING COVER - REMOVAL)»(ref-248887-S35097004782007022700000).
3. Remove steering column cover backing plate «(Refer to BODY/INSTRUMENT PANEL/STEERING COLUMN COVER BACKING PLATE - REMOVAL)»(ref-248887-S31163616442007022700000).
4. Position steering so front wheels are straight ahead. CAUTION: Do not rotate steering wheel after disengaging lower coupling from steering gear, damage to air bag clock spring can result.
5. Remove clinch bolt attaching steering column coupling to steering gear shaft. (Scheme 13)
6. Remove steering column coupling from telescoping steering gear shaft.
7. Hoist vehicle and support on safety stands.
8. Position a drain pan under power steering pump and oil return hose coupling.
9. Using a hose pinch-off pliers (C-4390), pinch power steering oil return hose off between the crossmember coupling and the pump.
10. Loosen hose clamp at the cradle crossmember coupling.
11. Disconnect return hose from metal tube.
12. While holding pressure relief valve nut on back of power steering pump, Remove flare nut attaching high pressure hose to back of pump.
13. Remove high pressure hose from pump.
14. Allow power steering fluid to drain into pan.
15. Remove bolts attaching anti-lock brake sensor leads to cradle crossmember.
16. Position anti-lock brake leads out of the way.
17. Disconnect stabilizer bar links from ends of stabilizer bar.
18. Disconnect lower ball joints from lower steering knuckles (Refer to «LOWER BALL JOINT»(ref-248906-S02336576972007022700000) ).
19. Remove the rear engine mount heat shield. (Scheme 14)
20. Remove through bolt attaching rear engine mount to cradle crossmember. (Scheme 15)
21. Using paint or grease pencil, mark outline of cradle crossmember on frame rails to aid installation.
22. Support cradle crossmember on suitable lifting device. (Scheme 17)
23. Remove bolts attaching crossmember to front frame rails. (Scheme 16)
24. Remove cradle crossmember from vehicle. (Scheme 17)

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Note. If cradle crossmember requires replacement. Refer to SUSPENSION , to transfer suspension components and STEERING , to transfer steering components.

1. Support crossmember on suitable lifting device. (Scheme 17)
2. Position crossmember to vehicle.
3. Loosely install bolts attaching cradle crossmember to front frame rails.
4. Place upper half of bushing on top of crossmember aligned to receive square tube protruding upward from lower bushing half.
5. Align crossmember to previously made marks on frame rails.
6. Tighten bolts attaching cradle crossmember to frame rails.
7. Install through bolt attaching rear engine mount to cradle crossmember and tighten to 68 N.m (50 ft. lbs.) torque. (Scheme 15)
8. Install the rear mount heat shield. (Scheme 14)
9. Connect lower ball joints to steering knuckles (Refer to «LOWER BALL JOINT»(ref-248906-S02336576972007022700000) )
10. Connect stabilizer bar links to ends of stabilizer bar.
11. Install bolts attaching anti-lock brake sensor leads to cradle crossmember.
12. Install high pressure hose to pump.
13. Connect return hose to metal tube.
14. Tighten hose clamp at the cradle crossmember coupling.
15. Remove pinch-off pliers.
16. Position steering so front wheels are straight ahead.
17. Install steering column coupling to telescoping steering gear shaft.
18. Install clinch bolt attaching steering column coupling to steering gear shaft.
19. Install steering column cover backing plate «(Refer to BODY/INSTRUMENT PANEL/STEERING COLUMN COVER BACKING PLATE - INSTALLATION)»(ref-248887-S28875990042007022700000)
20. Install steering column lower cover from instrument panel «(Refer to BODY/INSTRUMENT PANEL/STEERING COLUMN OPENING COVER - INSTALLATION)»(ref-248887-S25860076732007022700000).
21. Connect battery negative cable.

1. Using paint or grease pencil, mark outline of cradle crossmember on frame rails.
2. Loosen bolts attaching crossmember to frame rails.
3. Remove bolt on bushing that requires replacement.
4. Allow cradle crossmember to drop down enough to gain clearance for bushing removal.
5. Remove bushing from vehicle.

1. Apply rubber lubrication or soap to replacement bushing.
2. Insert lower half of bushing into square hole in cradle crossmember.
3. Place upper half of bushing on top of crossmember aligned to receive square tube protruding upward from lower bushing half.
4. Squeeze bushing halves together to ensure they are properly mated.
5. Lift cradle crossmember upward to close gap between the bushing and frame.
6. Verify that lower bushing is fully seated into cradle crossmember and upper bushing.
7. Install bolt attaching bushing and crossmember to frame rail hand tight.
8. Align cradle crossmember to reference marks on frame rails.
9. Tighten cradle crossmember to frame rails attaching bolts to 163 N.m (120 ft. lbs.) torque.