Description

Chrysler Caravan, Grand Caravan, Voyager, Grand Voyager, Town & Country Technical Manual

If you’ve ever had a brake job go sideways because an aftermarket manual told you to torque the caliper bracket to 80 ft-lbs when the Chrysler factory spec is 55, you know the pain. I’ve seen it. I’ve fixed it. That’s why this Chrysler Caravan, Grand Caravan, Voyager, Grand Voyager, Town & Country Technical Manual belongs on your workbench, not buried in a browser tab. 607 pages of real Chrysler documentation, not reprints from a third party. You get the same diagrams and procedures the dealer techs use.

VIN decoding, suspension breakdowns, brake specs – it’s all in there. I’ll walk you through what matters so you don’t waste a Saturday guessing.

VIN Plate Decoding: Identify Your Van Before You Start

Page one of the manual dives straight into VIN plate decoding. Country code, assembler, vehicle type, GVWR range, line (Town & Country vs. Caravan vs. Voyager), series, body style (short or long wheelbase), engine – all laid out in tables. Need to confirm if that junkyard 3.3L block matches your van? The VIN chart tells you exactly which engine code belongs to which model year. Use the position numbers (1 through 17) to trace every digit. Don’t guess. Reference the Chrysler VIN Plate Decoding Information for the full breakdown. Related: the Chrysler VIN Plate Decoding Information Manual and Chrysler Caravan Town & Country VIN Decoding Information cover similar ground but this manual is more complete for 1999 NS models.

Front Suspension and Drive Axle Specs

Group 2 covers front suspension and drive. Figure 2-145 shows the front strut assembly with part numbers like 04897451AA. It also lists spring tag codes (ZAB, ZNB, etc.) and suspension sales codes – SDA standard, SDB heavy duty, SDD commercial wagon. You’ll find the exact spring rates by tag number, not a generic “coil spring” line. The front axle drive shafts are in Fig. 2-245. If you’re swapping CV axles on a Grand Voyager AWD or a FWD Town & Country, the exploded view saves you time hunting fastener locations. Torque values? They’re scattered through the diagrams – always double-check the bolt torque listed next to each fastener callout. The manual uses imperial ft-lbs.

Service Brakes: Drum, Disc, and ABS Procedures

Group 5 is where you’ll spend time if you’re doing a brake job. Front brakes (Fig. 5-110), rear drum (Fig. 5-232), rear disc (Fig. 5-240). Each diagram includes the sales code caveats – like BRV for heavy-duty drum or BRE for disc/disc. The power brake booster (Fig. 5-343) and master cylinder (Fig. 5-416) come with line routing. The Anti-Lock Brake Control module is Fig. 5-431. I’ve seen guys swap master cylinders on a Caravan and forget to bench-bleed it. The factory manual calls out the sequence. Brake pedal travel adjustment specs are on the pedal diagram (Fig. 5-645). Use OEM torque on the booster nuts – 20 ft-lbs, not “tighten firmly”.

Trust OEM Torque Values, Not Guesswork

Aftermarket manuals often generalize torque specs. This Chrysler technical manual gives you the exact numbers per application. For example, the parking brake lever (Fig. 4-142) and cables (Fig. 4-147) have specific adjustments. The rear axle torque tube assembly (Fig. 3-130) on AWD models? That’s a 90 ft-lbs bolt pattern, not 75. The differential (Fig. 3-115) fill plug torque is 30 ft-lbs. These specs matter when you’re torquing suspension bolts or drive shaft fasteners. I’ve pulled engines on these vans where the subframe bolts were under-torqued from a previous repair. Don’t be that guy. Manual Transmission identification helps if you’re swapping a manual – rare on these, but the information is in the manual itself. Manual Transmission data is also referenced in Group 3 for rear axle ratios.

Cooling and Electrical: What the Manual Covers

Group 7 tackles cooling: radiators sorted by engine (2.4L, 3.0L, 3.3L-3.8L), water pumps, coolant reserve tank, pulleys, drive belts. The 3.0L radiator (Fig. 7-165) has a different hose routing than the 3.8L (Fig. 7-175). The water pump on the 2.4L (Fig. 7-207) uses a different gasket than the 3.3L (Fig. 7-225). Electrical in Group 8 is massive – starters, alternators, distributor, sensors, relays, battery trays, lamps, and wiring from headlamp to dash. Figure 8-1405 shows instrument panel wiring; Fig. 8-1505 covers body and accessories. If you’re chasing an intermittent power window issue on a Town & Country, the wiring repair section (Fig. 8-1605) shows splice locations and pin numbers. No aftermarket diagram substitutes for that level of detail.

Source Authenticity: OEM vs Aftermarket Documentation

This is a factory Chrysler technical manual, not a compiled PDF from a forum. The 607 pages come from the original 1999 NS service documentation. The VIN table on page 1 is the same one used at Windsor and St. Louis assembly plants. The part numbers are Mopar numbers, not aftermarket equivalents. Suspension spring tags reference Chrysler engineering codes. I’ve used aftermarket manuals that list the wrong brake pad thickness – that doesn’t happen here. Every figure corresponds to a specific Chrysler part number and sales code combination. If you’re working on a Caravan or Voyager from the late ’90s, this is the only source you should trust for torque, clearances, and diagnostic steps.

Frequently Asked Questions

Is this manual for all engine options in the Caravan and Town & Country?

Yes, it covers 2.4L, 3.0L, 3.3L, and 3.8L engines, plus the flex-fuel variant and electric motor option.

Does the manual include complete wiring diagrams for the electrical system?

Group 8 has over 20 wiring figures covering everything from the starter circuit (Fig. 8-105) to the body harness (Fig. 8-1505). Each figure is keyed to component locations and connector pinouts. You’ll find separate diagrams for engine wiring, headlamp-to-dash routing, instrument panel connections, and accessory circuits. The wiring repair section (Fig. 8-1605) even shows approved splice methods. That’s the kind of detail that saves you hours of continuity testing with a multimeter. I’ve used these diagrams to trace a short in a Grand Voyager’s rear lamp circuit – the factory color codes matched exactly. No guessing.

You’ve read the evidence. 607 pages of factory Chrysler specs, torque values, and brake procedures. Don’t torque another caliper bolt by feel. Access the Factory Manual.