T&C..car is warmed up, it makes a noise at about 1700-1750 rpm..horn…

Moan/Fog Horn Like Sound While Turning During Slow Speed Or Parking Lot Maneuvers.

This bulletin involves installing a finned power steering fluid cooler package and if

necessary, a steering gear.

2005 (RS) Town & Country/Caravan

The vehicle operator may describe a moan/fog horn like sound while turning during slow

speed or parking lot maneuvers. The sound may occur throughout the steering range, off

center, but not at the wheel stops.

If the vehicle operator describes the Symptom/Condition, perform the Repair Procedure.

1 04743473AE Line, Power Steering Return, With Cooler

AR (1) 04766250AF Gear, Power Steering

With Flat Floor

AR (1) 04766270AC Gear, Power Steering

With Stow 'n Go^TM (Sales Code CWZ)

AR 05013457AA Oil, Automatic Transmission - ATF+4

1. Open the hood.

2. Remove the cap from the power steering fluid reservoir.

3. Using a siphon pump/suction gun, remove as much power steering fluid as possible

from the power steering fluid reservoir.

4. Remove and save the constant tension spring clamp securing the power steering

return line hose to the power steering fluid reservoir.

5. Remove the rubber hose portion of the power steering return line from the power

steering fluid reservoir fitting.

6. Drain the power steering fluid reservoir into an appropriate container.

7. Raise the vehicle on an appropriate hoist.

8. Remove the fuel vapor canister.

9. Locate the bracket connecting the power steering return line cooler loop to the cradle

reinforcement plate (Fig. 1).

1 - SUSPENSION CRADLE

2 - J/U NUT CLIP (DISCARD)

3 - CRADLE REINFORCEMENT PLATE

4 - FUEL VAPOR CANISTER

5 - COOLER LOOP MOUNTING FASTENERS (SAVE FOR FINNED COOLER INSTALLATION)

6 - PRESSURE LINE

7 - COOLER LOOP (DISCARD)

8 - SWAY BAR

10. Remove the fasteners connecting the cooler line to the reinforcement plate. Save the

fasteners for use in Step #17.

11. Locate the bracket connecting the power steering pressure line to the cradle

reinforcement plate (Fig. 1).

12. Remove the fastener connecting the bracket to the reinforcement plate. Save the

fastener for use in Step #18.

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13. Remove and discard the J/U nut clip on the bracket.

14. Locate and unscrew the tube nut connecting the power steering return line to the

steering gear pinion housing.

15. Drain the remaining fluid into an appropriate container and discard the loop cooler line

that was removed from the vehicle.

16. Install the new power steering return line, p/n 04743473AE. Attach the power steering

return line tube nut to the steering gear pinion housing and tighten to 27.1 - 35.0 N·m

(240 - 310 in. lbs.).

17. Reuse the fastener removed in Step #10. Install the fastener into the left weld nut on

the cooler fin pack bracket and the left hole in the cradle reinforcement plate. Tighten

the fastener to 9 - 11.3 N·m (80-100 in. lbs.) (Fig. 2).

1 - FINNED COOLER FASTENERS (INSTALLED POINTING UPWARD)

2 - SWING THE PRESSURE LINE CLAMP BACK INTO POSITION WITHOUT THE J/U NUT

3 - FINNED COOLER

18. Line up the pressure line bracket and the right weld nut in the cooler fin pack bracket.

Reuse the fastener removed in Step #12. Install the fastener through the right hole in

the cradle reinforcement plate, the fin pack bracket and the pressure line bracket.

Tighten the fastener to 9 - 11.3 N·m (80-100 in. lbs.) (Fig. 2).

19. Install the fuel vapor canister.

20. Lower the vehicle.

21. Install the constant tension spring clamp removed in Step #4 onto the rubber hose on

the power steering return line. Slide the clamp so that it is 3 inches from the end of the

rubber hose.

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22. Push the end of the rubber hose portion of the power steering return line onto the

power steering fluid reservoir suction port. Secure the hose by sliding the constant

spring tension clamp installed on the hose in the last step, to within 6 mm (0.25 in.) of

23. Fill the power steering system. Refer to Steering/Pump - Standard Procedure at the

end of this bulletin.

24. Test drive the vehicle in the parking lot. Determine if the sound, as describe in the

Symptom/Condition section of this bulletin, is still present.

25. If the sound is no longer present. The repair is complete. If the sound is still present,

replace the steering gear using the appropriate part number according to the Parts

Required table above. Refer to the service information available in TechCONNECT.

Refer to 19 - Steering/Gear - Removal and Installation.

26. Fill the power steering system. Refer to Steering/Pump - Standard Procedure below.

Read the fluid level through the side of the power steering fluid reservoir. The fluid level

should be within "FILL RANGE" when the fluid is at a temperature of approximately 21°C

to 27°C (70°F to 80°F).

1. Wipe the filler cap and area clean, then remove the cap.

2. Fill the fluid reservoir to the proper level and let the fluid settle for at least two (2)

minutes.

3. Start the engine and let run for a few seconds, then turn the engine off.

4. Add fluid if necessary. Repeat the above steps until the fluid level remains constant

after running the engine.

5. Raise the front wheels off the ground.

6. Start the engine.

7. Slowly turn the steering wheel right and left, lightly contacting the wheel stops.

8. Add fluid if necessary.

9. Lower the vehicle, then turn the steering wheel slowly from lock-to-lock.

10. Stop the engine. Check the fluid level and refill as required.

11. If the fluid is extremely foamy, allow the vehicle to stabilize a few minutes, then repeat

the above procedure.

Reimbursable within the provisions of the warranty.

19-50-16-91 Tube/Cooler, Power Steering Return - Replace

and Test

0.6 Hrs.

19-00-01-94 Tube/Cooler, Power Steering Return - Replace, 3.6 Hrs.

19-011-04 -4-

Test Drive & Gear Power Steering - Replace

NOTE: Includes Reset Toe

68 Noisy

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