Town & Country Van AWD V6-230 3.8L VIN L SMFI (1998)
7.
Remove the 2 bolts and loosen the third that attach the Antilock Brake System (ABS) Hydraulic Control Unit (HCU) to the front suspension
cradle, as shown in Figure 9. Then rotate the HCU rearward to allow access to cradle plate attaching nut and bolt just forward of the HCU.
8.
Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension cradle. Separate the cradle plate from the vehicle.
9.
Using an 18 mm crowfoot, remove both P/S fluid lines from the steering gear (Figure 10).
10.
Remove the 3 bolts and nuts attaching the steering gear to the front suspension cradle and lower the steering gear enough to allow access to the
intermediate coupler roll pin.
11.
Install Special Tool 6381 A through the center of the roll pin and secure the tool with the knurled nut (Figure 11). Hold the threaded rod stationary
while turning the nut to pull the roll pin out of the intermediate coupler. Remove the special tool from the intermediate coupler.
12.
Separate the intermediate coupler from the steering gear shaft and remove the steering gear from the vehicle.
13.
Position the revised steering gear (P/N 4874878) into the front suspension cradle, leaving room to install the intermediate coupler.
14.
Start the roll pin into the intermediate coupler by tapping it with an appropriate hammer, then install the intermediate coupler onto the shaft of the
steering gear.
15.
Install Special Tool 6381A through the center of the roll pin and secure the tool with the knurled nut (Figure 11). Hold the threaded rod stationary
while turning the nut to push the roll pin into the intermediate coupler. Remove the special tool from the intermediate coupler.
16.
Attach the steering gear to the front suspension cradle with the 2 right side mounting bolts removed in step 10, revised left side bolt (P/N
6504585), and 3 three nuts removed in step 10. Torque the bolts/nuts to 183 Nm (135 ft. lbs.).
17.
Attach the P/S fluid lines to the proper fitting on the steering gear (Figure 9). Torque the P/S fluid line tube nuts to 31 Nm (275 in.lbs.).
18.
Install the tie rod end into the steering knuckle and install the attaching nut onto the stud of the tie rod end finger tight. Hold the tie rod end stud
stationary with an 11/32 in. socket and torque the nut with a crowfoot to 54 Nm (40 ft. lbs.). Repeat for the other side.
19.
Attach the cradle plate to the front suspension cradle using the 10 bolts/nuts removed in step 8. Torque the bolts/nuts to 165 Nm (123 ft. lbs.).
20.
Position a gear type clamp (P/N 6032839) over the P/S fluid return hose and push the hose onto the steel tube portion of the return line. Be sure
the hose and clamp are positioned past the upset bead on the steel tube and torque the clamp to 1.5-2.5 Nm (14-22 in. lbs.).
