Experts often credit the Dodge Caravan with creating the market segment for the now popular minivans. The Caravan launched Chrysler's popular minivan fleet and was the first minivan to enter the world's car markets. If you need encounter steering problems for model years 2001 to 2007 and need to install a new steering rack and pinion gear, you can use the following procedure.
Check your diagnosis before replacing your steering rack. Your symptoms may also be tire wear, poor front-end alignment or problems with the power steering pump.
Lock the steering wheel. It should be in the straight-ahead position. You will also need to drain your power steering fluid and disconnect the battery cables. You will need to support the front end and remove the front wheels.
Disconnect the steering column shaft coupler, power steering cooler hose and outer tie rod ends. Unscrew the rear bushing bolts in the lower control arm and the crossmember bolts. Disconnect the rack and pinion mounting fasteners and the intermediate shaft coupler. You can now swap out the new steering rack for the damaged unit.
Hold the intermediate shaft coupler in position and start the roll pin. Tap it into position with a hammer and finish installing the coupler onto the gear shaft. Slip the removal/installer tool into the roll pin center and attach the knurled nut. Keep the rod stationary while you turn the nut to screw the pin into place.
Reinstall the disconnected components and secure the fluid lines. Make sure you use the right bolts and check your owners' manual for the proper torque. These measurements and bolts may include 135 foot pounds of torque for 14mm steering gear mounting fasteners and 70 foot pounds of torque for 12mm steering gear mounting fasteners; 25 foot pounds of torque for return lines; tighten the crossmember reinforcement bolts to 113 foot pounds for M14 bolts and 78 foot pounds for M12 bolts; 45 foot pounds for the bushing bolts on the lower control arm; 55 foot pounds of torque on the outer tie rod ends; and 21 foot pounds for the pinch bolts on the steering column shaft coupler. When the steering system is reassembled, mount your tires.
Connect the battery cables and replace the power steering fluid. Make sure to bleed any air from the system. Before you drive, inspect the lines for leaking and realign the front end.
