Chrysler Town & Country 1996-2005 Factory Service Manual
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🏷️ Basic Information Identification Make: Chrysler Model: Town & Country Model Years Covered: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005 Codes Platform: NS (1996-2000), RS (2001-2007) 👋 Introduction Market Position Segment: Minivan Target Audience: Families, people needing ample cargo and passenger space Competitive Analysis Key Competitors: Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture/Vans Key Features Design Philosophy: Family-oriented utility, comfortable ride, versatile interior Distinctive Features By Generation: NS generation: Available Quad Seats, Stow 'n Go seating introduced in later RS generation. RS generation: Redesigned exterior and interior, available Stow 'n Go, upgraded powertrains. 📋 Manual Details Coverage Areas Engine Coverage: 3.3L V6 (EGA), 3.8L V6 (EGH) Transmission Coverage: 4-speed Automatic (41TE, 42LE) Major Systems: Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical, HVAC, Body, Interior, Emissions Control Page Count Estimated Pages: Over 2500 Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine removal/installation, cylinder head, valve train, pistons, connecting rods, crankshaft, timing, oil pump, oil pan, lubrication system Engine Fuel System: Fuel pump, fuel injectors, fuel filter, fuel pressure regulator, throttle body, evaporative emissions (EVAP) system Engine Cooling And Exhaust: Radiator, water pump, thermostat, cooling fan, exhaust manifold, catalytic converter, muffler Transmission Automatic: Transmission removal/installation, internal components, valve body, torque converter, clutch packs, seals, fluid service Drivetrain: Front axle, CV joints, drive shafts, differential (integrated with transmission) Suspension: Front struts, rear shocks, control arms, ball joints, bushings, sway bars Steering: Power steering pump, steering gear, tie rods, steering column, alignment specifications Brakes: Front and rear disc brakes, brake calipers, brake pads, rotors, master cylinder, brake booster, ABS system (Antilock Braking System) diagnostics and repair Electrical System: Battery, alternator, starter, ignition system, lighting, power windows, power locks, mirrors, horn, wiring diagrams, fuses, relays HVAC System: Air conditioning, heater core, blower motor, refrigerant system, climate control module, diagnostic procedures Body And Interior: Body panels, doors, hood, tailgate, bumpers, seats, interior trim, instrument panel, roof rack system Emissions Control: Catalytic converter, oxygen sensors, EGR system, EVAP system, emissions related diagnostic trouble codes (DTCs) Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement Diagnostics: Symptom-based troubleshooting, diagnostic trouble code (DTC) retrieval and interpretation, component testing procedures, use of diagnostic scan tools Repair: Step-by-step repair instructions for all major systems, component replacement, adjustments, and calibrations Overhaul: Complete engine and transmission overhaul procedures, including disassembly, inspection, and reassembly Installation: Component installation procedures, including accessories and optional equipment Technical Depth Depth: Comprehensive - Covers routine maintenance to major component overhauls and diagnostics Diagnostics Level: Advanced, including sensor data interpretation and system diagnostics Diagrams: Detailed wiring diagrams, vacuum schematics, and exploded views 📊 Manual Specifications File Format Format: PDF Searchability: Searchable text content Printability: Printable pages Print Quality Resolution: High-resolution scans for clear diagrams and text Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine 1: 3.3L (201 ci) OHV V6 (EGA) Engine 2: 3.8L (230 ci) OHV V6 (EGH) Performance 3.3L Horsepower: Approx. 158-170 hp (depending on year) 3.3L Torque: Approx. 190-205 lb-ft (depending on year) 3.8L Horsepower: Approx. 180-215 hp (depending on year) 3.8L Torque: Approx. 230-270 lb-ft (depending on year) Fuel System Fuel Delivery: Multi-port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (87 Octane Recommended) Engine Management ECM Model: Various NGC (Next Generation Controller) or earlier variants 🔧 Transmission Standard Type: 4-speed Automatic Transaxle Model Code 1: 41TE (FWD) Model Code 2: 42LE (FWD) Optional Optional Transmission: N/A (All models equipped with automatic) Features Overdrive: Yes, 4th gear Transmission Fluid Type: ATF+4 (Chrysler Mopar) Transmission Fluid Capacity: Approximately 9-11 quarts (depending on drain and fill vs. overhaul) 📐 Dimensions Exterior Wheelbase Ns: 119.3 inches Wheelbase Rs: 119.8 inches Length: Approximately 196-201 inches (depending on year and trim) Width: Approximately 78.8 inches Height: Approximately 68.8 inches Weights Curb Weight: Approximately 4,000 - 4,500 lbs Gross Vehicle Weight Rating Gvwr: Approximately 5,500 - 5,800 lbs Towing Capacity: Up to 3,500 lbs (with optional tow package) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: Not consistently rated across all years; often received 4-star ratings in early models. NHTSA Front Impact Passenger: Not consistently rated across all years; often received 4-star ratings in early models. IIHS Side Impact: Varies by year; some models rated 'Acceptable'. Active Features ABS: Standard on most models, optional on early base trims. Traction Control: Optional on some models, standard on later high-trim levels. Passive Features Airbags: Front driver and passenger airbags standard; side airbags optional on later models. Seatbelts: All seating positions, with front pretensioners. Child Seat Anchors: LATCH system introduced in later models (RS generation). 💡 Technology Features Infotainment Audio System: AM/FM stereo with cassette and CD player, optional Infinity audio system. Navigation: Optional factory...
NS generation: Available Quad Seats, Stow 'n Go seating introduced in later RS generation. RS generation: Redesigned exterior and interior, available Stow 'n Go, upgraded powertrains.
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement
Diagnostics:
Symptom-based troubleshooting, diagnostic trouble code (DTC) retrieval and interpretation, component testing procedures, use of diagnostic scan tools
Repair:
Step-by-step repair instructions for all major systems, component replacement, adjustments, and calibrations
Overhaul:
Complete engine and transmission overhaul procedures, including disassembly, inspection, and reassembly
Installation:
Component installation procedures, including accessories and optional equipment
Technical Depth
Depth:
Comprehensive - Covers routine maintenance to major component overhauls and diagnostics
Diagnostics Level:
Advanced, including sensor data interpretation and system diagnostics
Diagrams:
Detailed wiring diagrams, vacuum schematics, and exploded views
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Searchable text content
Printability:
Printable pages
Print Quality
Resolution:
High-resolution scans for clear diagrams and text
Binding Type
Type:
N/A (Digital Download)
Paper Type
Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine 1:
3.3L (201 ci) OHV V6 (EGA)
Engine 2:
3.8L (230 ci) OHV V6 (EGH)
Performance
3.3L Horsepower:
Approx. 158-170 hp (depending on year)
3.3L Torque:
Approx. 190-205 lb-ft (depending on year)
3.8L Horsepower:
Approx. 180-215 hp (depending on year)
3.8L Torque:
Approx. 230-270 lb-ft (depending on year)
Fuel System
Fuel Delivery:
Multi-port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 Octane Recommended)
Engine Management
ECM Model:
Various NGC (Next Generation Controller) or earlier variants
🔧 Transmission
Standard
Type:
4-speed Automatic Transaxle
Model Code 1:
41TE (FWD)
Model Code 2:
42LE (FWD)
Optional
Optional Transmission:
N/A (All models equipped with automatic)
Features
Overdrive:
Yes, 4th gear
Transmission Fluid Type:
ATF+4 (Chrysler Mopar)
Transmission Fluid Capacity:
Approximately 9-11 quarts (depending on drain and fill vs. overhaul)
📐 Dimensions
Exterior
Wheelbase Ns:
119.3 inches
Wheelbase Rs:
119.8 inches
Length:
Approximately 196-201 inches (depending on year and trim)
Width:
Approximately 78.8 inches
Height:
Approximately 68.8 inches
Weights
Curb Weight:
Approximately 4,000 - 4,500 lbs
Gross Vehicle Weight Rating Gvwr:
Approximately 5,500 - 5,800 lbs
Towing Capacity:
Up to 3,500 lbs (with optional tow package)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
Not consistently rated across all years; often received 4-star ratings in early models.
NHTSA Front Impact Passenger:
Not consistently rated across all years; often received 4-star ratings in early models.
IIHS Side Impact:
Varies by year; some models rated 'Acceptable'.
Active Features
ABS:
Standard on most models, optional on early base trims.
Traction Control:
Optional on some models, standard on later high-trim levels.
Passive Features
Airbags:
Front driver and passenger airbags standard; side airbags optional on later models.
Seatbelts:
All seating positions, with front pretensioners.
Child Seat Anchors:
LATCH system introduced in later models (RS generation).
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with cassette and CD player, optional Infinity audio system.
Navigation:
Optional factory navigation system available on higher trims in later years.
Rear Seat Entertainment:
Optional DVD player and rear-seat screens available in the RS generation.
Driver Assistance
Cruise Control:
Standard on most models.
Parking Sensors:
Optional on later models.
Connectivity
Power Outlets:
12V power outlets for accessories.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-7,500 miles (depending on oil type and driving conditions, refer to manual for specifics).
Transmission Fluid Change:
Every 30,000-60,000 miles (recommended by many technicians, check manual for OEM recommendations).
Spark Plug Replacement:
Approximately 60,000-100,000 miles (depending on plug type - copper vs. platinum/iridium).
Coolant Flush:
Every 30,000-60,000 miles or 2-4 years.
Fluid Specifications
Engine Oil:
API certified SAE 5W-30 or 10W-30 (refer to specific year/engine in manual).
Engine Coolant:
Chrysler HOAT (Hybrid Organic Acid Technology) or IAT (Inorganic Acid Technology) coolant, typically Mopar OAT or G-05.
Power Steering Fluid:
ATF+4 (Chrysler Mopar) or equivalent.
Known Issues
Engine Mounts:
Premature wear of engine and transmission mounts leading to vibration and noise.
Transmission Hard Shifting:
Common issue with the 41TE/42LE transmission, often related to valve body wear, solenoid issues, or low fluid.
Power Sliding Doors:
Malfunctions in the power sliding door motors, tracks, or control modules.
Alternator Failure:
Alternators can fail prematurely on some models.
Rear Hatch Struts:
Loss of pressure in rear liftgate struts.
Wiper Motor Failure:
Front windshield wiper motor failure.
Ac System Leaks:
Leaking O-rings and seals in the A/C system.
📚 Vehicle History
Brand Heritage
Brand:
Chrysler, a division of Fiat Chrysler Automobiles (FCA), formerly DaimlerChrysler and Chrysler Corporation.
Model Evolution
Generation 1 Ns:
1996-2000. Shared platform with Dodge Grand Caravan and Plymouth Voyager. Introduced the concept of integrated child seats and a removable center console.
Generation 2 Rs:
2001-2007. All-new platform, significantly revised styling, introduction of Stow 'n Go seating system (standard on many trims), available rear-seat entertainment.
Production
Manufacturing Location:
Windsor Assembly Plant, Windsor, Ontario, Canada
Production Period:
1996-2005
🏆 Awards & Recognition
Recognitions
Wards 10 Best Engines:
The 3.8L V6 engine was recognized by Ward's Communications as one of the 10 Best Engines multiple times during this period for its smooth operation and power delivery.
Consumer Reports:
Consumer Reports ratings varied by year and specific model, but the Town & Country was generally considered a competent, if not class-leading, minivan.
Ratings
Jd Power Dependability:
Dependability ratings were often mid-pack compared to competitors like Toyota and Honda.
Certifications
Emissions Certification:
Meets Federal EPA and California CARB emissions standards as applicable for the model year.
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