2005 Dodge Caravan Headliner

R&R is basically obvious, but here's what I learned.

• Wiring harness connects at bottom of passenger side door column, therefore must remove door openings lower trim and column trim
• Recline seats and remove headrests
• I removed the deteriorating foam by scraping and brushing (no foam for the new material).  The replacement fabric I used was not headliner fabric, but looks fine.  Lay out the fabric on the cleaned headliner board, fold it in the middle, spray the board and fabric with adhesive, glue it down, then repeat for the other half
• I used one can of 3M 38808 Headliner & Fabric Adhesive (18.1oz).  This was barely enough.  I used two coats rather than the specified three, but since my fabric is very lightweight, I think it will be OK long term.  Next time I would look for something less expensive that I could use more of.  I would also leave some extra fabric in the front, and fold it around the front edge (this is the only edge that is not covered by weatherstripping and/or trim)
• Clip the map light assembly into it's supporting tray before installing the headliner
• Some of the upper trim that had to pull out to remove will sort of be in the way during replacement, but can move it out of the way as necessary
• Can initially hold the headliner up with just the three plastic retainers

2005 Dodge Caravan radiator replacement

There is a problem when trying to lift the condenser up slightly to detach it from the radiator.  The condenser has tabs that sit in hooks near the bottom of the radiator frame sides.  There are plastic air dams that clip to the sides of the radiator between it and the condenser.  On the passenger side, the hard plastic part of the air dam stops the refrigerant tubes from being lifted up with condenser.  On the drivers side the transmission cooler hoses hit the radiator drain area.  I was finally able to get things unhooked and the old radiator out without fully understanding the problem.  When reinstalling, I removed the fascia so I could see what was the problem.  This allowed me to move the side air dam for clearance with the refrigerant tubes while installing.

It is not at all difficult to remove the fascia.  Take it off as an assembly with the grill and underside plastic fairing.  The headlights must be removed for access to a nut holding the fascia to the body.  Must also remove a vertical screw that access from the front of the wheelwell.