My 1994 Dodge Caravan 3.0 V6 Base Project

[Matt86]

Here she is, day one:
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_3037.jpg

Stats:
1994 Dodge Caravan Base Model (Former Fleet vehicle)
Windsor built Canadavan!
3.0 V6
A670 3-speed leaky automatic
Cruise, tilt, AC and thats it!

Bought on 8/10/2008 for $500 from some old fat guy.

129K when purchased, now has 136K

First modification was rear tinted windows! I got tired of having to drive around in a fish bowl.

Since the old guy never took good care of it, I had to replace the following due to mileage/age/broken:

Drivers side hub & CV Axle (twice)
Complete tune-up (All original ignition parts!)
Valve cover gaskets
Timing belt
Water pump
Hoses
Serp. Belt
All three motor mounts
Rear shocks
Drivers seat (broken by old fat guy)

Added stuff/modifications:
Overhead information center
Factory CD/Cassette stereo
New dash speakers
Tranny cooler
New front bumper
CB Radio :thumb:
Hubcap delete

I have a set of white Snowflake wheels from a Spirit ES to install, just need the $$$ for some new rubber!


It rides very nice and smooth, runs excellent. Not bad for still being under $1,000 in parts including the purchase price of the van.

As she sits now:
http://i49.photobucket.com/albums/f270/mpmatt2/Pull%20A%20Part%20Lithonia%203%2029%2009/IMG_3962.jpg

The beast behind the blue cloud of oil smoke:
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4031.jpg

Now, the big project is to delete that automatic. Dispite the fact it shift perfect, it leaks and is a huge drag on the V6 making my 99' Neon soo much faster.

So, I have this stuff:
http://i49.photobucket.com/albums/f270/mpmatt2/Pull%20A%20Part%20Lithonia%203%2029%2009/IMG_3964.jpg

A543 from a 97K Dodge Daytona IROC
A set of perfect axles from the same IROC
Shifter, cables, clutch pedal assembly and cross member from a 94' Voyager
A computer from a 1994 Dodge Shadow ES 3.0 5-spd

Now, I have to put it all in..which I will have to find the time for!

[Dodge Aries K]

Hurry up and get some time! I want to see it happen.

[Vigo]

Its gonna be a huge upgrade when you get done. My 90 van is already setup for the 543, and i have the 3.0, harness+comp, and accessories etc from a 93 van i just parted. Im picking up a 3" exhaust later today.

3.0/543 minivans ftw!

[Matt86]

I'm going to start cleaning up the IROC A543. New seals, end pan gasket, really want to get all that old fluid out of there. Also, need to degrease the case. That sucker was covered in crap.

[Matt86]

So I finished working on the fourth snowflake wheel.

This is what it looked like before:
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4032.jpg

After a strip, prime and a coat or two of white Wheel Paint:
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4041.jpg

Just got to get two more tires and put these babys on!

[Big_P]

Matt you are going to LOVE a 3.0 5 speed Caravan. It's QUICK! ;)

[jory]

3.0s are great especially with the 5 speed. Indestructible! And the power delivery is great, torque on command. You might want to return those car axles however because they won't fit your van. Your automatic axles will slide into the 543 no problem :thumb:

[Matt86]

I'll use the Daytona axles and build my own with the longer minivan shafts, if not I'll see if I can find a decent factory set at the yard. The reman axles that are on there now are JUNK.

[Ondonti]

those wheels sure look better.

[Mario]

So I finished working on the fourth snowflake wheel.

This is what it looked like before:
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4032.jpg

After a strip, prime and a coat or two of white Wheel Paint:
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4041.jpg

Just got to get two more tires and put these babys on!

Wheel paint? Is there anything different about the paint? I'd like to re-do my red snowflakes on the spirit.


those wheels sure look better.

I agree. They are almost blinding. Nice job.

[Matt86]

The wheel paint is much thicker, almost exactly like the factory coating.

[Vigo]

Ive always thought white was the best color on snowflakes, and white wheels on white cars look good. I think this will turn out very well.

[Matt86]

Yes, it will be a nice upgrade from the steelies, just have to get some $$$ for a few new tires.

I really wish a C/V would show up at one of the yards....I want to get those nice big truck mirrors, viynl front floors and seats.

Meanwhile, I'm slowly gathering the remaining parts and refurbishing the A543 for the big 5-speed swap.

[Vigo]

...I want to get those nice big truck mirrors, viynl front floors and seats.

I think the rubber flooring is the most desirable part that came on cv's, personally.. Id love to have one in good condition :)

[turbovanman²]

Sorry, car axles won't work, they are 1 inch or so shorter. You need to reuse your stock auto axles.

Other than that, nice work, :nod:

[WickedShelby88]

I think he meant to use the van axle shafts with the ends from the car if I read that correctly?

[Matt86]

Oh....A670...how I hate thee....

The mystery ATF leak continues, before it would occur randomly, but now it's leaving puddles on the ground all the time.

The only solution:

Remove A670-Install A543. I have Friday and Sat off, and depending on the weather, I'll have to do the swap.

Since I can't afford new tires for the Snowflakes, I've thrown a set of K-car hub caps on and a bug guard...all from the junkyard:
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4083.jpg

[Vigo]

i absolutely detest the bug guard, to be honest. If you want it for functionality, i propose getting a protective film type that doesnt butcher the looks.

Good luck with the 543 swap. Mount the shifter and pedals before you take anything else apart in case you get stuck, that way it will still be mobile if and when you run out of time and need it again.

[turbovanman²]

I think he meant to use the van axle shafts with the ends from the car if I read that correctly?

Well he said this-


I'll use the Daytona axles and build my own with the longer minivan shafts, if not I'll see if I can find a decent factory set at the yard. The reman axles that are on there now are JUNK.

And this- ;)


A543 from a 97K Dodge Daytona IROC
A set of perfect axles from the same IROC
Shifter, cables, clutch pedal assembly and cross member from a 94' Voyager
A computer from a 1994 Dodge Shadow ES 3.0 5-spd

[Matt86]

i absolutely detest the bug guard, to be honest. If you want it for functionality, i propose getting a protective film type that doesnt butcher the looks.

Good luck with the 543 swap. Mount the shifter and pedals before you take anything else apart in case you get stuck, that way it will still be mobile if and when you run out of time and need it again.

I plan on mounting the shifter and pedals at least this week, I still have to gather a few more parts for the swap.

as far as the bug guard..it was free and covers up the peeling/chipping paint on the hood...

One of the yards also finally got in a C/V, but both mirrors were trashed and the viynl floors were trashed too....:mad:

[WickedShelby88]

Check your trans pan. That was what was leaking on my A670. At least that would get you by if you fixed it. Otherwise is it wet around the axle area?

[Matt86]

It's coming from the front seal. The pan is bone dry along with the axle seals. No sense on replacing it when I can just get rid of the evil red fluid and stick that sexy A543 in there!

To add to the to do list, the hood release broke today....back to the junkyard!

[WickedShelby88]

Front pump leak no bueno. 543 will definitely liven things up a bit!

[Matt86]

Progress as of Friday:

http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4098.jpg
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4099.jpg
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4100.jpg
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4103.jpg

Got the shifter & cables, clutch pedal assembly and clutch cable installed. Wiring up the clutch switch was easy, the pigtail was there, just had a bypass wire installed.

Also installed my fat IROC Daytona gas pedal!

Hopefully, next Friday the A670 will be out!

[blk86trbo]

Also installed my fat IROC Daytona gas pedal!

Oh yeah, that's dead sexy!

Was just thinking that the brake and clutch pedal pads were pretty worn out...are you sure that trans has 97K?

Overall things look great Matt! Again, thanks for the pics :thumb:

[Matt86]

Thanks Paul

I have to pick up the flywheel from the machine shop tomorrow (I dropped it off Saturday just a few minutes before they closed), I also have to run back to the yard with that IROC that's been very generous at donating parts. I need a few miscellaneous things.

[Matt86]

Going over the wiring diagrams, I have to find a way to ground the neutral safety wire, but open the circuit to allow the cruise control to work. Can I just splice in to the clutch start wire?

[Big_P]

I *think* you can, Matt.

[Dodge Aries K]

I believe if you ground the neutral safety switch out and if your van already has the pigtail for the clutch switch in it (which is suprising) it should work fine. Otherwise I believe that the manual transmission PCM doesn't check that to be grounded for cruise control operation.

[Matt86]

I can't tap in to the clutch switch, as it's power side switched, I'd have to add another switch, but I'm thinking along Karls idea that since my van already has the clutch switch, I think I'd be okay just grounding the wire. I'll have to give it a shot

[Dodge Aries K]

Worse comes to worse... as a temporary fix you can add a momentary button switch that you have to push so the van will let you start it... you could call it ghetto brand security system ;)

[Matt86]

Also picked up the flywheel from the machine shop:
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4104.jpg

I also went to the Pull-a-Part and got a new coolant inlet tube from a low mileage 93' A604 Dodge Spirit, as the one from the IROC was pretty nasty:
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4105.jpg

Hopefully Tomorow I'm dropping the A670!

[Matt86]

Good progress today,

Got the old crossmember out, the A670 out and the A543 installed..I had to call it a day because I have to go to work..but very good progress, I started around 10 am, and had the automatic out by noon.

What a mess...
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4110.jpg

Gone forever!!! Stupid automatic
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4111.jpg

Popped a new rear main in:
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4113.jpg

Shiny flywheel and new clutch installed:
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4118.jpg

After a lot of frustration, sore arms and backs....and a lot of cursing..the A543 went in:
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4119.jpg


Tomorow I'm going to finish the wiring, install the new crossmember, new axles, fill the tranny and radiator....and roll on!

[blk86trbo]

Again, good pics to document your project! I bet you can't wait :clap:

[Ondonti]

good move on the coolant pipe. A bad one can make life terrible trying to seal it up.

[Matt86]

A543 swap has been a success!

Total time: 2 days between work, about 13 hours invested, but that includes many breaks, trips to the parts store and other things.

The easy part:

Removing the old Automatic...took about an hour

The hard part:

everything else

I had a few set backs, first I had installed the front sway bar upside down so it made some god awful clunking noises, I fixed that..

The alignment is way way way out of wack. Need to get it realigned.

Current issue is the coolant tube o-ring is leaking. I'll get one from the dealer tomorow

Have to wire up the "neutral saftey switch" switch so I can have cruise control again.

I also deleted the column shifter and the PRND indicator with the approperate delete pieces.

But the difference between the A670 and the A543 is night and day. Holy crap, this thing has NO problems spinning the front tires...(thank goodness I put in diff savers!)..it as a ton of low-end torque which my Neon lacks....the van seems like a whole different beast. Its soo much faster now.

THANKS for all your help everyone here on Turbo Mopar...ya'll rock!

[jory]

Pulling out of the driveway after a fresh 5 speed swap is a great feeling. The fun is never going to end with that 543. the 3.0 is a good motor and runs forever. attached to a 5 speed it is a little monster for sure. Your junkyard has some good prices too. A transmission here will cost $110 out the door, $25 less if you bring a core.

[135sohc]

A transmission here will cost $110 out the door, $25 less if you bring a core.

Thats the whole bs thing with junkyards up this way. you go to the junkyard to get something and that should be it. no core charge or any of that other crap. otherwise it defeats the whole purpose of going there :mad:

[Vigo]

Ahh, good motivation for my project. I pulled open my 543 i have sitting here and it LOOKS like it will work.. and i just remembered i need to get some wiring diagrams for the swap! good thing i looked at your thread!

Congrats

[Matt86]

I love Pull-a-Part, the A543 was only $45.00 with a $8.00 core, which I never bothered to turn in.

I've got a new o-ring for the coolant tube, but I won't have a chance to work on the van until next week as I work all weekend.

I also need front struts BADILY. One is totally blown out and the other is in rough shape. I'm waiting for a nice set to show up at the yard so I can finally get the front end all aligned

Once I get all the little issues taken care of, I want to drive it and see the mileage improvement. I've been getting a 21-24 MPG average. Next time I drive the van up to IL, I expect to get some killer mileage. I'm able to get 44 in the Neon with the AC on.

[Dodge Aries K]

...and I look forward to seeing that van again dude. That thing is awesome.

[WickedShelby88]

Awesome fuel mileage. I actually didn't think my 3.0 voyager was a slouch even with just the A670. I've surprised plenty of folks with it. I can't imagine one with a turboed 3.0, 543 with OBX and some drag radials on the street. Sounds like the 543 is the perfect combo mopar should of made in the vans! I would love to ride in that thing whenever you get back up here to Illinois. Looks like a clean swap. Good work! So is that the original bumper cover or what? Looks to have the fog light holes. I definitely want to get the fogs and sport cover for my voyager LX as well as maybe some PT cruiser GT wheels. Those would look nice on that van.

[Matt86]

More bugs have popped up.

I fixed the o-ring, but another more serious issue came up/

Driving in town, the van was shifting great, then all of the sudden, the van was hard to shift in to thrid and fourth, then as an attempt to downshift back to thrid, I couldn't get in to any gear.

I was able to coast in to a parking lot, I shut the van off and attempted to get in gear, no luck. I inspected the cables on the outside and all was good, I got in the van and tried again, she went in to first and I was able to drive to a parts store parking lot. I removed the shifter bezel and sprayed the shifter assembly with some lube, as it seemed like it was binding up.

It would shift in to gears when not running, but when running it wouldn't, but then it just started working again and shifted fine the whole way home and is fine since.

I double checked the shift and clutch cables, all seems well.

Any ideas as to what caused this?

[Dodge Aries K]

Triple check your shifter cables for kinks as well as make sure the clutch cable is good. I don't remember for certain but you might want to spray some lube on the ends of the shifter cables where they go into the sheath to lubricate the cables a bit.

[Vigo]

I can't imagine one with a turboed 3.0, 543 with OBX and some drag radials on the street.

no need to.. theres videos of such a van up on streetfire or youtube, minus the drag radials. its a 95 grand caravan too..


did the resistance in the clutch pedal change while the shifting issue was occurring?

[Matt86]

did the resistance in the clutch pedal change while the shifting issue was occurring?

The clutch pedal felt just fine.

I'll check the cables again, it really seemed like the shifter was just binding up.

[jory]

I just went through something like that on my friends daytona. He mixed up the tranny mount bolts and drove a long one into the selector housing. It was fun replacing that.

[Matt86]

After cleaning and regreasing the shifter assembly, so far no issues. It shifts pretty smoothly now, unless under heavy accleration, it can be a bit stiff to go in to thrid, but that's probably the rear bobble strut being worn. I lubed up all the cables and checked all the bushings. I took it on many abusive test drives, lots of tire abuse ;) , it's holding up very well even with the crappy alignment.

I finished up the interior:
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4124.jpg
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4127.jpg

I love that picture...5 speed minivans ROCK!

I was hoping to get the steering column covers from the 5-speed van at the yard, but they crushed it last week.... :( . I just took the column shifter off and slid the black plastic up to cover it.

Interesting story involving the van occured this week.

I stopped in at a shop at a former co-worker works at (his brother in-law owns it), we talked and he was very impressed, amazed, and humored with my work he offered me a job...which I took :thumb: .

[135sohc]

Thats great. looks right in place there :thumb:
I have the same Dodge floormats in the car.

[Matt86]

Thanks...

I'm eventually going to delete the carpet and replace it with rubber floor C/V style!

I also want to put a new shifter in, maybe one from a RAM or Dakota....something big and truck like.

[Matt86]

I finally got a matching shifter console! I had to drive 800 miles to get it :) . I was actually up in IL for Neons 2009 when I stumbled across a 93' Caravan at the yard that had it. I also got some more goodies like some non-blown Pioneer speakers, 52MM 88' Caravan throttle body and some other things

http://i49.photobucket.com/albums/f270/mpmatt2/Misc/IMG_4325.jpg

[Matt86]

installed the new shifter console. Much better:

http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4350.jpg
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4356.jpg

The fleet:
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4359.jpg

[blk86trbo]

Yeah that new base looks much better than the other one...get those darn snowflakes mounted next!

[Matt86]

Yes! Snowflakes must go on!

I need to address the alignment first, I want to replace both outer tie rod ends as the boots are torn and they do have some play in them.

I installed my upgraded junkyard speakers to replace the factory blown crap..

I ditched the bugflector on the front as it cracked somehow while I was away for a week.

[Dodge Aries K]

No rust by you, that should be an easy job hopefully.

[WickedShelby88]

How does that shifter feel? Looks like they sit kind low stock. I've been thinking a 5 speed 3.0 van would be a great towing machine. The A670 in my van has towed and pushed a few vehicles in its day and didn't seem to mind.

[Matt86]

It shifts okay, better with new booger bushings. The A543 seems to be more cumbersome to shift then the T-350 in my Neon. I think a nice short throw would be a good fix! I've been driving the van daily now since my commute is 5 miles away, rather then 22.

A 5-speed badge courtsey of the jap-scrap section at pull-a-part:
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4363.jpg


R/T neon badges on the front doors:
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4361.jpg

No more bugflector:
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4368.jpg

http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4366.jpg
Need to find a nice rear bumper..but the yards put wheel stands under them...so they are ruined and impossible to remove.

[Vigo]

uhh.. im doubting you'll find many fans of the misplaced/misleading sticker approach here.

But what we really want to see now is van vs neon drag race on video. :D

[Matt86]

I really want to add woodgrain to the van. The paint isn't great, and if I actually took the time to wash it, it would probably all peel off.

The van is faster then the Neon now, that V6 really woke up with the A543. The Neon is a lot more fun though...only if the Neon had a V6 :)

[Aries_Turbo]

you ricer! ;)

was that the factory entry and exit points for the shifter cables right in front of the shifter? the cables like to be kept as straight as possible for shift smoothness.

sounds like a temporary clutch issue was keeping the thing hung up that one day. hopefully everything is fine in there.

also make sure the shifter cables stay away from the exhaust manifolds.

looks good.

i put that same grey shifter console in a 88 reliant that i swapped a 3.0L/543 into. :)

Brian

[Matt86]

The factory exit points were there, I did have to drill holes and make some modifications to allow the cables to fit properly.

Almost 2000 miles on the swap and it's been great.

Update 7/5/09

I found a set of nearly new-still shiny Monroe Sensatrac struts on a 95' Town & Country at Pull-a-Part and grabbed them. The van also had new axles, brakes, wheel bearings, rear shocks (Reflex's). I was almost tempted to do the big brake 5X114.3 wheel swap too.

Mine struts were OEM 94' and blown....badily:
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4415.jpg

The Caravan now ride soo much better, smoother, and quieter with the Sensatracs plus the Town & Country 'Touring' Springs are a bit nicer then my BASE springs.

It even sits up like it should:
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4416.jpg
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4417.jpg

before it leaned badly to the left as that strut was blown.

I also got the column shifter delete bezel from Pull-a-Part too, now my interior swap is complete:
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4414.jpg

[Vigo]

looking good.

I decided to do the turbo 2.5 swap on my van first as i had all the parts on hand, but havent driven it yet.

I guess it gives me more time to perfect my 3.0 swap parts pile before i ever start.

[blk86trbo]

Looks great Matt, you've done a good job...makes me wish I had a 2nd gen van. All I have to ask is...Where are the white snowflakes?

Ha ha LOL!

[Matt86]

Them there white snowflakes are sitting in my basement awating some tires! The 205/60/15s are too small and two of them don't hold air....I need to find some new tires....hopefully white lettered!

[Vigo]

white lettered... hmmmmm..

If not for that id say get 215/60r15 falken ze912s, $55/pc at tires-easy.com and great ratings.

I actually have a set but havent driven on them much so no feedback really.

[Subliminal]

Nice project! I always wanted to make my caravan a 5 speed, but it just didn't end up happening...

For tires, I say get some of these babies:

http://www.streetperformance.com/ART/PRODUCTS/101831/67797.jpg

$72 each at the tirerack..man I love those tires..they're like old school hot rodders! ;)

[Vigo]

I really like the looks of those tires, and they drive sporty compared to many TRUCK tires, but on a car they're mediocre at best.

Not to mention ive personally seen all sorts of problems with those, mostly sidewall bulges.

but the looks are definitely cool and old school.

id check out these, though
http://www.tirerack.com/tires/tires.jsp?tireMake=Firestone&tireModel=Firehawk+Indy+500

A much more modern-tech tire with really good ratings. I have also heard that they handle well for a truck tire. they have 215/65r15 whish is perfect for a van and 6" wide wheels for $80/pc i think.

[Matt86]

I'd really like to have some white letter tires, but I can't afford them right now...I've been searching on craigslist for a decent set of 205/70/15's but no luck. I'll have to hit up the used tire joints around town.

Meanwhile, I aligned the van monday and have been driving it daily.

It's a huge improvement with the new struts, the front end dosn't bounce all over and it tracks nice and straight. Even with high RPM shifts, there isn't as much front end dump & jump.

Now I need to replace the rear drivers leaf spring as the shackle that holds them together is very loose causing it to rattle. I've tried everything to re-secure it, even wrapped it in duct tape which worked very well :)

I think there is an AWD van at the yard, I think those have stronger springs.

MPGs are really good, averaging about 25 around town and a killer 30 on the interstate....with the AC on!

[Vigo]

holy smack 30? wow you're right up there with my tbi van. Sure you got the right speedo gear?

What final drive is your 543?

[skitzo_inc]

Very nice! It looks good, but I don't approve of the sticker mods. Adding 50 HP per sticker aside, no beuno.

[Matt86]

I finally cleaned out the van! What a project that was....I also washed it for the first time since August 2008, removed the R/T badges and such to make it more traditional looking, though I did add some simple 3.0 V6 badges from a Lebaron:
http://i49.photobucket.com/albums/f270/mpmatt2/Misc/bugabago.jpg

Next big step for the ol' van is emissions, I have to take the test next month. She passed with flying colors last year with the original plugs, wires, cap & rotor that had 129K on them...I'm sure the emissions testing guys will be confused when the state computer pulls it up as an automatic....;)

Now I've decided to do some body work to it. First I have to ditch the mismatched krylon'd front bumper and beat up dented up rear bumper. There was a fairly clean set of bumpers on a van at the Junkyard last month..I just hope they are still there and in good shape.

And YES...the snowflakes will eventually be mounted soon!

[Ondonti]

if you have any problems passing, just retard the timing a few degrees and try again.

[Matt86]

it should pass, at least I hope it does! It runs great, gets a nice 28-30 mpg with the five speed.

Updates:

Pull-a-Part was very nice to me today, there was a 94' Voyager SE there with a set of great looking bumpers which I grabbed:

http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4427.jpg
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4426.jpg

Much better then the mis matched Krylon'd front bumper and the smashed up rear bumper. I also wetsanded the foggy right headlight and gave it a coat of clear coat. Looking better already. Next-Snowflakes! Since my right front tire has a nice sidewall bubble forming on it.

[Vigo]

good tires are an investment nobody ever regrets. :)

[Big_P]

Adam: I have BFGoodrich Radial T/A's on my Cruiser (you can see it in the pic) and they're pretty friggin' good. Not quite as good in snow as the snow tires I had, but I like them. It's very good in the rain, too.

[Matt86]

Well, looks like I have one more bump in the way of getting my pretty snowflakes mounted....the Interstate battery from 2003 is dead...oh well, I'll have to buy a new one tomorow.

[Matt86]

She passed the emissions test with flying colors! The inspector thought the five speed minivan was badass. Now...since shes good for another year...maybe I'll finally get some new tires.

[blk86trbo]

Dammit Matt, I thought this was gonna be an update with pics of them snowflakes mounted!!!

Ha ha, glad to hear you passed the emissions test :thumb:

[Matt86]

Finally got the snowflakes mounted and on the van, it's been pouring out all day today else I'd have the wheels cleaned up and some better pics:
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4448.jpg
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4449.jpg

I've got Perelli's up front, some good quality generic's in the back. The tires are bigger then the stock 195/70/14's so it rides a bit higher and softer. I love it!

[Aries_Turbo]

beautiful!! :)

Brian

[Vigo]

looking good!

[blk86trbo]

Oh yeah, it was worth the wait! Nice :thumb:

[Ondonti]

needs a drop now

[Matt86]

Minivan=Mega mover!

Just moved out of the folks house earlier this month. That's where this van really paid for it's self. Moved 90% of my stuff, including furniture in about four trips fully loaded, two of them using the roof rack. Amazingly the van still had plenty of power and got 30 MPG. Much better then a Uhaul van.

With the unit totally loaded down the rear suspension sure shut up. I normally have no rear seats in it.

Going on 3,000 miles since the A543 swap and I've never looked back....I love it!

[blk86trbo]

Vans rule, glad to see it worked well with your move.

Personally, I like the tall stance...around here it helps with the snowdrifts :thumb:

[Matt86]

I haven't done much with the Scaravan, but I finally did an oil change after 6500 miles. Supertech 10W-40 and a bottle of super slop leak stop. 3.0 loves it. It has a few leaks that I'm just to lazy to fix (oil pan and probably the rear main).

I did try the 94' 3.0 5-speed Shadow PCM I had, well it came out of a questionable car with 240K on it. Turns out the radiator fan control part is fried and wouldn't turn on the fan, so the stock PCM is back in.

The fleet:
http://i49.photobucket.com/albums/f270/mpmatt2/Fleet/IMG_4511.jpg

I hope to add a Turbo Spirit ES to the fleet next weekend!

[Vigo]

you can get an adjustable thermostatic fan controller to run the stock relay for $20. I love those things.

[Matt86]

I thought about it, infact I know I have one laying around from my old Acclaim, but I'd rather keep it stock. I have no issues with the automatic PCM, other then I have to flip another switch to turn on the cruise control/anti theft (neutral saftey by-pass). I'll just keep my eyes out for another 93-94 V6 5 speed car at the yards.

[Matt86]

Finally solved my neutral saftey switch issue. I got under the dash and made a custom switch that is engaged when the clutch is depressed, same as the clutch start switch but since I'm running the automatic computer I have to fool it to think the cars in park when started, but in gear when driving so I can have cruise control. As far as code 37, I could care less! Gotta love OBD I!

http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4518.jpg

Extra Neon clutch start switch and scrap metal = $0.00. Love it!

Also added something for those junkyard runs:
http://i49.photobucket.com/albums/f270/mpmatt2/Misc/IMG_4516.jpg

Mounted in the back.

[blk86trbo]

That's pretty neat Matt, good job!

[Ondonti]

what is your switch wired to? I don't like pushing in the clutch during starts for the sake of my thrust bearings.
I always just had a switch for the cruise.

Get a 5 speed computer! I enjoy the extra 400 rpms.

[Vigo]

did the wipey rack! :D

Also the auto neutral safety switch just grounds the coil side of the starter relay.

So basically connect the wire on the ground side of the coil circuit of your starter relay and it will work whenever you want :)

[Matt86]

The switch is wired to the neutral saftey switch. When depressed it tells the computer its in park or neutral to start. The other switch is the factory clutch interlock start switch (oddly enough, prewired for it). Since im running the automatic computer, I have to override the neutral saftey switch so I can have cruise control. Else I'd just keep it grounded.

I wish I could find a 5 speed computer, but it has to be from a 93-94 vehicle. I had one from a Shadow with 250K on it and the fan driver was fried so it wouldn't turn the fan on.

[Ondonti]

92 also works.

[TurboII]

wow man great work to the van. Very sharp!

[Matt86]

Well..as luck would have it

After a successful trip to Nashville TN and back (480 miles) today the axles started to act up again with typical inner joint ware...so it shakes on acceleration and thunks on turns. Crap reman axles! This will be set #3!

[WickedShelby88]

I'm guessing motor mounts are fairly new? Are those axles the same as for a TBI 5 speed van?

[Reaper1]

Nice project! :thumb:

[Matt86]

Replaced the bad axle and it's nice and smooth again. The mounts are all new aside from the bobble strut which was second hand.

The axles are the same ones from when I had the 3 speed in it. Gotta love interchangability!

[jory]

That is a sweet @$$ van matt, awesome work.

[Matt86]

Thanks!

It was a little slow at the shop today so I installed my class III trailer hitch! What a PITA! EZ-Install my @$$!!!!

[Dodge Aries K]

Oh boy... that's something I get to look forward to... except it's a class IV.

[WickedShelby88]

Replaced the bad axle and it's nice and smooth again. The mounts are all new aside from the bobble strut which was second hand.

The axles are the same ones from when I had the 3 speed in it. Gotta love interchangability!

Cool! Glad it wasn't too bad then. I think I need to change one of my axles as well as I get a bit of a vibration under acceleration in my old van.

[Matt86]

Went to Pull-a-Part again today to find a 1992 Lebaron GTC 3.0 A543:
http://i49.photobucket.com/albums/f270/mpmatt2/Pull%20A%20Part%20Conley%2012%2013%2009/papdec4.jpg

It was in pretty rough shape but I did get the PCM and throttle body out of it. I'll have to try the PCM next week but from what I've looked at the 92 one should work. I already installed the throttle body as it has the stronger spring so take offs are much easier now. Too bad it was pouring out all day else I'd get more done.

[blk86trbo]

Went to Pull-a-Part again today to find a 1992 Lebaron GTC 3.0 A543:
http://i49.photobucket.com/albums/f270/mpmatt2/Pull%20A%20Part%20Conley%2012%2013%2009/papdec4.jpg

It was in pretty rough shape but I did get the PCM and throttle body out of it. I'll have to try the PCM next week but from what I've looked at the 92 one should work. I already installed the throttle body as it has the stronger spring so take offs are much easier now. Too bad it was pouring out all day else I'd get more done.

Man what I would give to find a complete 92 GTC with the 6 button Traveller...I'd completely rewire one of my Daytona's to use it!

[Matt86]

This one had the 6 button Traveler in it. If you want it I could grab it along with the necessary hardware for it next time.

[Matt86]

Updates

Class III trailer hitch installed, no fun!
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4536.jpg

FREE upgraded seats from a 1994 Grand Voyager LE, power drivers side:
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4540.jpg
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4542.jpg

http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4543.jpg

Much more comfortable then the crummy base model seats. One of the used car dealers I work with had a 94 Grand Voyager LE AWD-fully loaded they were going to send to the junkyard due to a dead A604 and a few other issues, so they said it would be no problem to swap my base seats in to it for the nice, plush, LE seats.

[WickedShelby88]

Dang wish I had cash and an opportunity like that. My van would love AWD. Looking great though Matt!!! LE seats are definitely very nice compared to the base model ones. I like the lumbar lever as well. As to the lebaron you found I would love to actually see one of those on the road and running. That would be the best cruiser IMO. Can't beat the V6 5 speed combo.

[TurboII]

your missing one thing THO.....arm rest!!! i cant drive a car that doesnt have an arm rest...
its so much more comfortable on long trips!!! lol nice work man thats a sweet van!!

[Matt86]

They do have arm rests, I actually swapped my viynl base ones to the new seats as they were in better shape.

Great upgrade....so much more comfortable. Plus the power feature is very nice as well as the lumbar support.

I noticed in the cold weather my base seats would be hard as a rock...Chrysler experimental memory foam stuff....

The donor van was a long wheel base van, if it was a short wheel base AWD, I would grab it and take all the AWD stuff!

[TurboII]

i would think that the seat would have a arm rest like a captain seat?
i could of swore my uncles van had one

Joey

[Dodge Aries K]

The Subaru's have spoiled me... I'd love to put AWD on my van but I don't know how well that'll work with the 5 speed transmission. Wouldn't the only difference between the SWB and LWB units be the driveshaft?

[Matt86]

The Caravan has been problem free with the five speed for over a year now, until today:
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/caravanhalendoor.jpg

The door latch broke off inside the door and tore the sheet metal where it mounts due to the hinge pins being soo worn thanks to the fat bloke I bought the van off of using the door to get in and out. Plus me putting off installing new pins for the past three years may have contributed to it......so off to the yard this weekend to get a new door.

[Vigo]

Yes im pretty sure the only difference between short and long wheelbase AWD vans would be the driveshaft, and the only difference between a long driveshaft and a short driveshaft is a driveshaft shop. Handy, huh?

[Matt86]

Finally replaced my broken leaf springs! Got these from a 1994 Caravan ES with the towing package, they are the heavy duty units.

http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4956.jpg
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4957.jpg
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_4961.jpg

No more saggy assend! Aparently the old broken worn springs were causing my torque steer issues. The van rides totally different now...and much quieter!

Not too bad to install, had to cut just one of the clamp things. I love not having to deal with rust anymore! everything came out and apart so nicely.

I need to replace the shocks, the cheapos I put in there are dead after 2 years.

There was a bit of a hold up, the springs I got came from an ABS van, my van dosn't have ABS so I had to swap the little bracket for the rear porporting valve.

[Vigo]

Looking good, glad you're still improving it little by little!

My friend StraX22 here is building a 2nd gen 95 van to swap in all his turbo 2.5 stuff from the 89 that got wrecked. Picked up a 523 swap for it too, should be pretty fun! Here's a hanful of pics/info

http://www.turbo-mopar.com/forums/showthread.php?t=43834&page=4

Your clean 2nd gen example is one to live up to..

Have you towed anything yet?

[Matt86]

Thanks!

As clean as it looks, it hasn't been washed in about a year and the inside is totally filthy. It's really a truck/junkyard runner, my 99 Grand Voyager is too nice to use as a truck. I will clean it out one day, I have the old door, a set of control arms, a bunch of loose tools, random van/neon/Volvo parts, garbage, and now a set of dead leaf springs. I need to dump that stuff off at the scrap yard.

I towed a 1992 Nissan Stanza with it on a car dolley. It really had no problem hauling it, infact it did quite well. Dispite the rear suspension was falling apart at the time, other then that no issues. Braking was okay, still better then my 3rd gens underpowered brakes.

I'll probably end up towing a 2nd gen Intrepid sometime soon, I'd love to see how well the new springs take to it.

It's a great van, I love it. Super reliable, starts everytime. Freezing cold AC, great highway MPG, and pretty quick!

[Matt86]

Passed emissions test today with flying colors!

A group photo excluding the 02' Intrepid SE 2.7 which is dead...
http://i49.photobucket.com/albums/f270/mpmatt2/Fleet/IMG_5031.jpg

[Vigo]

looking good.

[Matt86]

Thanks! Both minivans will be used in full duty when I move at the end of the month, but that's after I tow a Pontiac Slutfire to the junkyard this weekend!

Once I'm settled in I'll finally get around to installing the right PCM in to the Caravan. It's from a 92 Lebaron GTC, I just have to rewire the cooling fan as the Lebaron PCM controls it much differently.

[Vigo]

I just finally installed my van hitch yesterday. It wasnt complicated, but it was hard.. the hardest part of course being holding the damn 50 lb thing up there somehow while i marked the spots to drill! >: o

[Matt86]

I did mine at work on the lift, and it wasn't an exact fit so having air tools and a welder sure helped :)

[Vigo]

Yeh mine actually came off the 97 grand caravan my brother traded in during cash for clunkers, so it wasnt exact either. That van was a miracle machine and most of what was still good from it is still living on... :)

[Matt86]

Finally installed the rear sway bar. Bolted right on to the frame but used the suggested exhaust clamps to secure it to the axle. Works perfect
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_5178.jpg

Restored my hazy headlights....the cheapass way. Some sandpaper and a can of clear spray
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_5180.jpg

http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_5181.jpg

[Vigo]

Lookin good!!

Care to comment on what difference the sway bar made?

[Ondonti]

Cool Trick on the headlights :)

[Vigo]

If im starting with some pretty bad ones i start with 600, then 1000, 1500, 2000, and polishing compound.

If they're not bad i start with 1000.

What kind of grits did you use?

[Matt86]

I noticed a difference with the sway bar. It seems to handle much better around corners as where it would normally feel like it's going to roll over it now feels much more stable and less touchy. On the highway is the biggest difference. Where it would normally feel like the rear end was wondering on it's own, it now feels much more soild and stable.


I think I used 1000 grit, I really don't know. I just found a sanding block my landlord left laying around and went to town. The fix works well, usually lasts a year or more.

[turbovanman²]

Finally installed the rear sway bar. Bolted right on to the frame but used the suggested exhaust clamps to secure it to the axle. Works perfect
http://i49.photobucket.com/albums/f270/mpmatt2/1994%20Dodge%20Caravan/IMG_5178.jpg


You guys are lucky, I don't have the threaded nuts in the frame like you do, :(

[Matt86]

Yep, sure made life easy! My Neon was the same way. I love bolt ons....makes up for all the hell that "direct fit" trailer hitch was....ugh

[Dodge Aries K]

Hmm... rear sway bar. Must locate for Voyager!

[Matt86]

I found mine on a Caravan ES. The higher end vans have them, I noticed a few on other better equipped vans at the yard

[j4278h]

all second gen caravan sports had the rear sway bar also

[bill440cars]

Awesome Project! I haven't been around here much and am getting caught up. I saw this and it reminded me of when I had a '94 Grand Voyager LE that the trans "Died on" and ended up selling it for little of nothing. I'd have given ANYTHING to have been able to do what YOU did. Mine had the 3.3 Chrysler engine that ran like a top. I just got through going through your entire thread w/ all of the posts and it SURE made me wish I could have done Mine that way. Oh Well Mine's Gone (couldn't afford to build on it, at the time) and Yours Isn't. So, Enjoy and keep us posted on Progress.

[Vigo]

Well, the good news is that any van like this with a broken auto trans can be had for a few hundred bucks. If you get good deals on everything you should be able to put together a running 3.0/5spd van for about $1k.