Chrysler Town & Country 1996-2005 Repair Service Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Town & Country Generation: Third Generation (GS Platform) Production Years Covered: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005 Codes Platform Code: GS 👋 Introduction Market Position Segment: Full-size Minivan Target Audience: Families, DIY mechanics, professional automotive technicians Competitive Analysis Key Competitors: Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture/Vans Key Features Vehicle Highlights: Spacious interior, comfortable ride, versatile seating configurations, Stow 'n Go seating (introduced later in the generation), available all-wheel drive (later models). Manual Value Proposition Value To Owner: Empowers owners to perform comprehensive maintenance, diagnose issues accurately, and complete repairs, saving significant costs on dealership servicing. 📋 Manual Details Coverage Areas Engine Coverage: 3.3L V6 (EGA), 3.8L V6 (L32) Transmission Coverage: 4-speed Automatic (41TE, 42LE) Chassis Systems: Suspension, Steering, Brakes, Exhaust, Cooling, Fuel Electrical Systems: Lighting, Instrumentation, Audio, Power Accessories, Powertrain Control Modules (PCM), Body Control Modules (BCM), ABS, Airbags Body And Interior: Body panels, Doors, Seats, HVAC, Trim, Glass Page Count Estimated Pages: 2000+ Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Complete coverage of 3.3L and 3.8L V6 engines, including disassembly, inspection, assembly, and troubleshooting of all internal components, cooling system, fuel system, and exhaust system. Drivetrain: Detailed information on the 4-speed automatic transmissions (41TE and 42LE), including hydraulic circuits, valve body operation, electronic controls, and overhaul procedures. Suspension And Steering: Front and rear suspension components (struts, shocks, control arms, sway bars), steering gear, power steering system, and wheel alignment specifications. Braking System: Front and rear disc brakes (including ABS components), brake fluid specifications, bleeding procedures, component replacement, and hydraulic system diagnostics. Electrical And Diagnostics: Comprehensive wiring diagrams, fuse box locations, component testing procedures, diagnostic trouble codes (DTCs), PCM/BCM functions, and diagnostic tool usage. Procedures Included Maintenance Procedures: Oil changes, filter replacements, spark plug service, coolant flushes, brake fluid changes, air filter replacement, and belt inspection/replacement. Repair Procedures: Engine component replacement (pistons, rings, bearings, valves), transmission overhaul, brake caliper/rotor replacement, strut/shock replacement, and power steering pump replacement. Troubleshooting Guides: Systematic diagnostic flowcharts for common drivability issues, electrical faults, HVAC problems, and braking system malfunctions. Diagnostics And Testing: Detailed procedures for using scan tools, multimeter testing, oscilloscope usage for sensor and actuator diagnostics, and pressure testing. Technical Depth Depth: Expert level, covering everything from routine maintenance to complete engine and transmission rebuilds, including advanced electronic system diagnostics and component-level troubleshooting. 📊 Manual Specifications File Format Quality: High-resolution PDF, enabling clear viewing and printing of diagrams and text. Searchability: Text-searchable PDF allows for quick navigation to specific topics and components. Print Quality Printability: Designed for printing, with clear layouts and organized sections for easy reference. Binding Type Binding Type: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Code 1: EGA Engine Description 1: 3.3L (3301cc) SOHC V6, Cast Iron Block, Aluminum Cylinder Heads Bore Stroke 1: 93.0 mm x 81.0 mm Compression Ratio 1: 9.0:1 Horsepower 1: 158 hp @ 4700 rpm (approximate, varies by year) Torque 1: 190 lb-ft @ 3300 rpm (approximate, varies by year) Optional Engine Engine Code 2: L32 Engine Description 2: 3.8L (3778cc) SOHC V6, Cast Iron Block, Aluminum Cylinder Heads Bore Stroke 2: 96.0 mm x 86.0 mm Compression Ratio 2: 9.3:1 Horsepower 2: 180 hp @ 4400 rpm (approximate, varies by year) Torque 2: 235 lb-ft @ 3200 rpm (approximate, varies by year) Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (87 Octane Recommended) Cooling System Coolant Type: Mopar OAT (Organic Acid Technology) Antifreeze/Coolant, or equivalent HOAT Coolant Capacity: 12.7 Quarts (12.0 Liters) 🔧 Transmission Standard Transmission Type: 4-Speed Automatic Transaxle Transmission Model 1: 41TE Transmission Model 2: 42LE (with specific enhancements) Features Gear Ratios: Detailed in manual, typically includes first gear around 2.84:1, second around 1.57:1, third around 1.00:1, overdrive around 0.69:1, and reverse around 2.20:1. Fluid Specifications Transmission Fluid: ATF+4 (Automatic Transmission Fluid +4) or equivalent Fluid Capacities Fluid Capacity Dry: 8.0 Quarts (7.6 Liters) Fluid Capacity Refill: 6.0 Quarts (5.7 Liters) 📐 Dimensions Exterior Length: 197.1 - 201.0 inches (4905 - 5106 mm) (varies by year/trim) Width: 76.5 inches (1943 mm) Height: 67.4 - 69.1 inches (1712 - 1755 mm) (varies by year/trim) Wheelbase: 119.3 inches (3030 mm) Cargo Cargo Volume Behind 3Rd Row: Approx. 38.2 cu ft Cargo Volume Behind 2Nd Row: Approx. 76.5 cu ft Cargo Volume Max Seats Folded: Approx. 150.1 cu ft Weights Curb Weight: 4,100 - 4,400 lbs (1860 - 2000 kg) (varies by engine/trim) Gross Vehicle Weight Rating Gvwr: 5,750 - 6,000 lbs (2608 - 2722 kg) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 4 Stars (1996-2000 models, some variations) NHTSA Front Impact Passenger: 4 Stars (1996-2000 models, some variations) IIHS Side Impact: Acceptable...

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Type: Car

Vendor:

Sku: 69225

Collections: ALL Chrysler Marine

Availability: In stock

Tags: 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 Car Chrysler Marine Misc Outboard Engines Town & Country

Product variants

Description

🏷️ Basic Information

Identification

Make:

Chrysler

Model:

Town & Country

Generation:

Third Generation (GS Platform)

Production Years Covered:

1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005

Codes

Platform Code:

👋 Introduction

Market Position

Segment:

Full-size Minivan

Target Audience:

Families, DIY mechanics, professional automotive technicians

Competitive Analysis

Key Competitors:

Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture/Vans

Key Features

Vehicle Highlights:

Spacious interior, comfortable ride, versatile seating configurations, Stow 'n Go seating (introduced later in the generation), available all-wheel drive (later models).

Manual Value Proposition

Value To Owner:

Empowers owners to perform comprehensive maintenance, diagnose issues accurately, and complete repairs, saving significant costs on dealership servicing.

📋 Manual Details

Coverage Areas

Engine Coverage:

3.3L V6 (EGA), 3.8L V6 (L32)

Transmission Coverage:

4-speed Automatic (41TE, 42LE)

Chassis Systems:

Suspension, Steering, Brakes, Exhaust, Cooling, Fuel

Electrical Systems:

Lighting, Instrumentation, Audio, Power Accessories, Powertrain Control Modules (PCM), Body Control Modules (BCM), ABS, Airbags

Body And Interior:

Body panels, Doors, Seats, HVAC, Trim, Glass

Page Count

Estimated Pages:

2000+

Manual Type

Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain:

Complete coverage of 3.3L and 3.8L V6 engines, including disassembly, inspection, assembly, and troubleshooting of all internal components, cooling system, fuel system, and exhaust system.

Drivetrain:

Detailed information on the 4-speed automatic transmissions (41TE and 42LE), including hydraulic circuits, valve body operation, electronic controls, and overhaul procedures.

Suspension And Steering:

Front and rear suspension components (struts, shocks, control arms, sway bars), steering gear, power steering system, and wheel alignment specifications.

Braking System:

Front and rear disc brakes (including ABS components), brake fluid specifications, bleeding procedures, component replacement, and hydraulic system diagnostics.

Electrical And Diagnostics:

Comprehensive wiring diagrams, fuse box locations, component testing procedures, diagnostic trouble codes (DTCs), PCM/BCM functions, and diagnostic tool usage.

Procedures Included

Maintenance Procedures:

Oil changes, filter replacements, spark plug service, coolant flushes, brake fluid changes, air filter replacement, and belt inspection/replacement.

Repair Procedures:

Engine component replacement (pistons, rings, bearings, valves), transmission overhaul, brake caliper/rotor replacement, strut/shock replacement, and power steering pump replacement.

Troubleshooting Guides:

Systematic diagnostic flowcharts for common drivability issues, electrical faults, HVAC problems, and braking system malfunctions.

Diagnostics And Testing:

Detailed procedures for using scan tools, multimeter testing, oscilloscope usage for sensor and actuator diagnostics, and pressure testing.

Technical Depth

Depth:

Expert level, covering everything from routine maintenance to complete engine and transmission rebuilds, including advanced electronic system diagnostics and component-level troubleshooting.

📊 Manual Specifications

File Format

Quality:

High-resolution PDF, enabling clear viewing and printing of diagrams and text.

Searchability:

Text-searchable PDF allows for quick navigation to specific topics and components.

Print Quality

Printability:

Designed for printing, with clear layouts and organized sections for easy reference.

Binding Type

Binding Type:

N/A (Digital PDF Download)

Paper Type

Paper Type:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

Engine Description 1:

3.3L (3301cc) SOHC V6, Cast Iron Block, Aluminum Cylinder Heads

Bore Stroke 1:

93.0 mm x 81.0 mm

Compression Ratio 1:

9.0:1

Horsepower 1:

158 hp @ 4700 rpm (approximate, varies by year)

Torque 1:

190 lb-ft @ 3300 rpm (approximate, varies by year)

Optional Engine

Engine Code 2:

Engine Description 2:

3.8L (3778cc) SOHC V6, Cast Iron Block, Aluminum Cylinder Heads

Bore Stroke 2:

96.0 mm x 86.0 mm

Compression Ratio 2:

9.3:1

Horsepower 2:

180 hp @ 4400 rpm (approximate, varies by year)

Torque 2:

235 lb-ft @ 3200 rpm (approximate, varies by year)

Fuel System

Fuel Delivery:

Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 Octane Recommended)

Cooling System

Coolant Type:

Mopar OAT (Organic Acid Technology) Antifreeze/Coolant, or equivalent HOAT

Coolant Capacity:

12.7 Quarts (12.0 Liters)

🔧 Transmission

Standard

Transmission Type:

4-Speed Automatic Transaxle

Transmission Model 1:

Transmission Model 2:

42LE (with specific enhancements)

Features

Gear Ratios:

Detailed in manual, typically includes first gear around 2.84:1, second around 1.57:1, third around 1.00:1, overdrive around 0.69:1, and reverse around 2.20:1.

Fluid Specifications

Transmission Fluid:

ATF+4 (Automatic Transmission Fluid +4) or equivalent

Fluid Capacities

Fluid Capacity Dry:

8.0 Quarts (7.6 Liters)

Fluid Capacity Refill:

6.0 Quarts (5.7 Liters)

📐 Dimensions

Exterior

Length:

197.1 - 201.0 inches (4905 - 5106 mm) (varies by year/trim)

Width:

76.5 inches (1943 mm)

Height:

67.4 - 69.1 inches (1712 - 1755 mm) (varies by year/trim)

Wheelbase:

119.3 inches (3030 mm)

Cargo

Cargo Volume Behind 3Rd Row:

Approx. 38.2 cu ft

Cargo Volume Behind 2Nd Row:

Approx. 76.5 cu ft

Cargo Volume Max Seats Folded:

Approx. 150.1 cu ft

Weights

Curb Weight:

4,100 - 4,400 lbs (1860 - 2000 kg) (varies by engine/trim)

Gross Vehicle Weight Rating Gvwr:

5,750 - 6,000 lbs (2608 - 2722 kg)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

4 Stars (1996-2000 models, some variations)

NHTSA Front Impact Passenger:

4 Stars (1996-2000 models, some variations)

IIHS Side Impact:

Acceptable (varies by year and specific testing)

Active Features

Standard on most models, 4-wheel disc brakes with ABS available and standard on later models.

Traction Control:

Optional on some models, standard on later high-trim models.

Passive Features

Airbags Front:

Driver and passenger front airbags standard throughout the generation.

Airbags Side:

Optional side curtain airbags available on later models.

Seatbelts:

All seating positions equipped with three-point seat belts. Lower Anchors and Tethers for Children (LATCH) system included.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with cassette and/or CD player. Optional Infinity speaker systems available.

Rear Seat Entertainment:

Optional rear-seat entertainment systems, including video screens and headphone jacks, were available on higher trims or as dealer accessories.

Driver Assistance

Cruise Control:

Standard on most models.

Connectivity

Original Connectivity:

Limited by era; typically basic audio controls, power accessories. Later models may have optional remote keyless entry.

🔧 Maintenance

Service Intervals

Oil Change Interval:

3,000-7,500 miles (5,000-12,000 km) or 6-12 months, depending on driving conditions and oil type used (refer to manual for specifics).

Engine Air Filter:

Replace every 30,000 miles (48,000 km) or as needed based on inspection.

Spark Plugs:

Replace every 100,000 miles (160,000 km) with recommended iridium or platinum plugs.

Transmission Fluid Flush:

Recommended every 30,000-60,000 miles (48,000-96,000 km), or more frequently under severe usage. Consult manual for specific procedure and fluid type.

Fluid Specifications

Engine Oil Viscosity 3.3L:

5W-30

Engine Oil Viscosity 3.8L:

5W-30 or 10W-30 (depending on climate, refer to manual)

Engine Oil Capacity 3.3L:

3.9 Quarts (3.7 Liters) with filter change

Engine Oil Capacity 3.8L:

4.0 Quarts (3.8 Liters) with filter change

Power Steering Fluid:

ATF+4 (Automatic Transmission Fluid +4) or equivalent

Brake Fluid:

DOT 3

Known Issues

Common Problem 1:

Transmission issues: Torque converter shudder, solenoid pack failures, and internal wear are common. Requires meticulous diagnostic procedures detailed in the manual.

Common Problem 2:

Cooling system leaks: Water pump seals, hose deterioration, and radiator leaks can occur. Proper inspection and replacement guidance are crucial.

Common Problem 3:

Power sliding door mechanisms: Can experience binding or failure due to wear and lubrication issues. The manual covers adjustments and common repairs.

Common Problem 4:

CV Axle failure: Torn boots leading to joint damage. Requires replacement of axle assembly.

📚 Vehicle History

Brand Heritage

Manufacturer:

Chrysler Corporation, later DaimlerChrysler.

Model Evolution

Introduction Year:

1996 (for this generation)

Major Updates:

Facelift in 2001 with updated styling, interior, and powertrain enhancements. Introduction of Stow 'n Go seating in 2005 model year.

Production

Assembly Locations:

Windsor, Ontario, Canada; St. Louis, Missouri, USA (for some models/years)

🏆 Awards & Recognition

Recognitions

Initial Reception:

The first generation of the Town & Country was critically acclaimed for its innovation in the minivan segment, setting benchmarks for space and versatility.

Family Car Awards:

While specific awards for this generation might vary by publication and year, the Town & Country consistently ranked as a strong contender in family vehicle categories due to its practicality.