Dodge Caravan 1991-1995 Body Panel & Frame Bolt Torque Specifications
Dodge Caravan 1991-1995

Dodge Caravan 1991-1995 Body & Frame Bolt Torque Specifications

This page provides detailed torque specifications for various body bolts on the 1991-1995 Dodge Caravan (2nd generation). Includes torque values for doors, fenders, bumpers, and other body panels.

Updated

Important Information

Safety guidelines and reference information for proper torque application

Quick Reference Guide
ft-lbs → Nm
× 1.356
ft-lbs → kg-m
× 0.138
Nm → ft-lbs
× 0.738
in-lbs → ft-lbs
× 0.083

Common Torque Patterns

Star Pattern

Used for wheels and other circular bolt patterns

Star Pattern torque pattern diagram showing proper bolt tightening sequence
Cross Pattern

Used for gaskets and cover plates

Cross Pattern torque pattern diagram showing proper bolt tightening sequence
Sequential Pattern

Used for head bolts and other critical components

Sequential Pattern torque pattern diagram showing proper bolt tightening sequence

Common Mistakes to Avoid

Over-tightening

Exceeding the specified torque value can stretch or break fasteners, damage threads, or crack components.

Prevention:

Always use a calibrated torque wrench and follow specifications exactly.

Incorrect Torque Sequence

Tightening bolts in the wrong order can cause uneven pressure distribution and potential leaks or damage.

Prevention:

Follow the manufacturer's specified torque sequence pattern.

Dirty Threads

Dirt, rust, or old thread locker can affect torque readings and proper fastener tension.

Prevention:

Clean and inspect all threads before assembly. Use new thread locker if specified.

Reusing TTY Bolts

Torque-to-yield bolts are designed to stretch and must not be reused.

Prevention:

Always replace TTY bolts with new ones. They are single-use only.

Dry vs. Lubricated

Not accounting for whether torque specs are for dry or lubricated fasteners can lead to incorrect tension.

Prevention:

Check if specs are for dry or lubricated threads. Use specified lubricant when required.

Recommended Tools

Torque Wrench (1/4" Drive)

Range: 2-25 ft-lbs
Small fasteners, delicate components

Torque Wrench (3/8" Drive)

Range: 10-100 ft-lbs
Most common automotive fasteners

Torque Wrench (1/2" Drive)

Range: 30-250 ft-lbs
Large fasteners, wheels

Angle Gauge

Torque-to-yield (TTY) bolts

Torque Wrench Care

  • Calibrate annually or after 5,000 clicks
  • Store at lowest setting
  • Keep clean and lubricated

Search Specifications

Search by component name, bolt size, or description

Torque Calculator

Convert between different torque units

Front End And Hood

Torque specifications for components in the front end of the vehicle, including the hood, fenders, bumper, grille and radiator support.

1

Hood Hinge Bolts

M8 x 1.25
Torque Value
18 ft-lbs (24 N·m)
Important Notes
Proper torque ensures smooth hood operation and alignment. These are safety-critical fasteners. Industry standard for M8 grade 8.8 bolt.
2

Hood Latch Bolts

M6 x 1.0
Torque Value
7 ft-lbs (9.5 N·m)
Important Notes
Proper torque ensures the hood latches securely. This is a safety-critical component. Industry standard for M6 grade 8.8 bolt.
3

Fender Bolts

M8 x 1.25
Torque Value
18 ft-lbs (24 N·m)
Important Notes
Proper torque prevents rattling and maintains panel alignment. Industry standard for M8 grade 8.8 bolt.
4

Front Bumper Mounting Bolts

M10 x 1.5
Torque Value
30 ft-lbs (40 N·m)
Important Notes
Correct torque ensures the bumper is securely mounted for impact protection. This is a safety-critical component. Estimated based on similar Dodge models and industry standard for M10 grade 8.8 bolt.
5

Grille Mounting Bolts

M6 x 1.0
Torque Value
7 ft-lbs (9.5 N·m)
Important Notes
Secures the grille to the core support and fenders. Helps with proper alignment. Estimated based on similar models and industry standard for M6 grade 8.8 bolt.
6

Radiator Support Bolts

M8 x 1.25
Torque Value
18 ft-lbs (24 N·m)
Important Notes
Secure the radiator support to the frame. Provides structural integrity to the front end. Industry standard for M8 grade 8.8 bolt.

Doors

Torque specifications for door components, including hinges, latches, handles, and check straps.

1

Door Hinge Bolts

M10 x 1.5
Torque Value
35 ft-lbs (47 N·m)
Important Notes
These are critical bolts securing the door to the body. Proper torque ensures smooth door operation, alignment, and prevents sagging. These are safety-critical fasteners. Industry standard for M10 grade 8.8 bolt.
2

Door Latch Bolts

M8 x 1.25
Torque Value
18 ft-lbs (24 N·m)
Important Notes
These bolts secure the door latch to the door. Proper torque ensures the door latches securely. This is a safety-critical component. Industry standard for M8 grade 8.8 bolt.
3

Door Handle Bolts

M6 x 1.0
Torque Value
7 ft-lbs (9.5 N·m)
Important Notes
These secure the door handle to the door. Proper torque ensures smooth handle operation. Industry standard for M6 grade 8.8 bolt.
4

Door Check Strap Bolts

M8 x 1.25
Torque Value
18 ft-lbs (24 N·m)
Important Notes
These secure the check strap to the door and body. Proper torque prevents damage and ensures the door opens and closes smoothly. Industry standard for M8 grade 8.8 bolt.

Rear End And Tailgate

Torque specifications for components in the rear end of the vehicle, including the tailgate, bumper, and liftgate/hatch struts.

1

Tailgate Hinge Bolts

M10 x 1.5
Torque Value
35 ft-lbs (47 N·m)
Important Notes
These secure the tailgate to the body. Proper torque is essential for smooth operation and preventing the tailgate from sagging or opening unexpectedly. This is a safety-critical component. Estimated based on similar Dodge models and industry standard for M10 grade 8.8 bolt.
2

Tailgate Latch Bolts

M8 x 1.25
Torque Value
18 ft-lbs (24 N·m)
Important Notes
These bolts secure the tailgate latch to the tailgate and body. Proper torque is essential for reliable latching and preventing unexpected opening. This is a safety-critical component. Industry standard for M8 grade 8.8 bolt.
3

Rear Bumper Mounting Bolts

M10 x 1.5
Torque Value
30 ft-lbs (40 N·m)
Important Notes
These secure the bumper to the frame/body. Proper torque is crucial for impact protection. This is a safety-critical component. Estimated based on similar Dodge models and industry standard for M10 grade 8.8 bolt.
4

Liftgate/Hatch Strut Bolts

M8 x 1.25
Torque Value
18 ft-lbs (24 N·m)
Important Notes
Secures the gas struts to the body and liftgate. Proper torque ensures the struts function correctly and liftgate operates safely. Industry standard for M8 grade 8.8 bolt.

Interior

Torque specifications for interior components, including seats, seat belts, dash, center console, and steering column.

1

Seat Mounting Bolts

M10 x 1.5
Torque Value
35 ft-lbs (47 N·m)
Important Notes
These bolts are critical for occupant safety. They secure the seats to the floor pan. Proper torque ensures the seats remain securely mounted in the event of an accident. These are safety-critical fasteners. Industry standard for M10 grade 8.8 bolt, also consistent with similar Dodge models.
2

Seat Belt Anchor Bolts

M10 x 1.5
Torque Value
40 ft-lbs (54 N·m)
Important Notes
These bolts are extremely critical for safety. They secure the seat belts to the body. Proper torque is essential to ensure the seat belts function correctly in the event of an accident. These are safety-critical fasteners. Industry standard for seat belt anchor bolts, and is consistent with similar Dodge vehicles.
3

Dash Mounting Bolts

M6 x 1.0 or M8 x 1.25
Important Notes
These bolts secure the dashboard to the body. While not directly safety-critical, loose bolts will cause rattles. Use 7 ft-lbs (9.5 N·m) for M6 bolts and 18 ft-lbs (24 N·m) for M8 bolts. Estimated based on similar Dodge models, industry standard for M6 and M8 grade 8.8 bolts.
4

Center Console Bolts

M6 x 1.0
Torque Value
7 ft-lbs (9.5 N·m)
Important Notes
These bolts secure the center console to the floor and dashboard structure. Proper torque prevents rattles. Estimated based on similar models and industry standard for M6 grade 8.8 bolt.
5

Steering Column Bolts

M10 x 1.5
Torque Value
35 ft-lbs (47 N·m)
Important Notes
These bolts are essential to securing the steering column to the body. Correct torque ensures safe operation of the steering and is a safety critical component. Industry standard for M10 grade 8.8 bolt.

Body Panels And Miscellaneous

Torque specifications for body side moldings, rocker panels, and other miscellaneous body components.

1

Body Side Molding Bolts/Clips

Various
Torque Value
5 ft-lbs (7 N·m)
Important Notes
These secure the body side moldings. Note this is very light, typically these are clips and fasteners - this is a guideline for smaller screws. Proper torque prevents damage to the moldings and surrounding panels. Estimated and based on industry standard for small self-tapping screws used on body panels.
2

Rocker Panel Bolts

M6 x 1.0
Torque Value
7 ft-lbs (9.5 N·m)
Important Notes
Secure rocker panels to the body. Proper torque prevents panel rattles and secure fitment. Estimated based on similar Dodge models, industry standard for M6 grade 8.8 bolts.

Troubleshooting Guide

Common issues, diagnostic steps, and prevention guidelines

Common Issues

Bolt stretching, stripped threads, uneven torque patterns

Loose Components

Symptoms:
  • Rattling or vibration noises
  • Visible movement in components
  • Uneven panel gaps
Solutions:
  • Clean threads and mounting surfaces
  • Replace damaged fasteners
  • Apply proper torque in sequence
  • Use thread locker if specified

Stripped Fasteners

Symptoms:
  • Unable to achieve proper torque
  • Fastener spins freely
  • Visible thread damage
Solutions:
  • Use thread repair kit if appropriate
  • Install thread insert (HeliCoil)
  • Replace component if threaded hole is damaged
  • Upgrade to higher grade fastener if recommended

Overtightened Components

Symptoms:
  • Cracked or deformed parts
  • Broken fasteners
  • Compressed gaskets or seals
Solutions:
  • Replace damaged components
  • Use new fasteners
  • Follow proper torque sequence
  • Verify correct torque specifications

Diagnostic Steps

Visual inspection, torque verification, thread assessment

1

Visual Inspection

Inspect the affected area for any visible signs of damage or wear

  • Check for cracks or deformation
  • Look for signs of excessive wear
  • Verify proper fastener installation
2

Torque Verification

Verify the torque applied to the fasteners

  • Check the torque wrench calibration
  • Verify the torque specification
  • Compare the applied torque to the specification
3

Thread Assessment

Assess the condition of the threads

  • Check for signs of thread damage
  • Verify the thread type and size
  • Check for proper thread engagement

Prevention Guidelines

Best practices, maintenance tips, tool care

Best Practices

  • Always follow the recommended torque specification
  • Use the correct type and size of fasteners
  • Verify the torque wrench calibration regularly

Maintenance Tips

  • Regularly inspect the affected area for signs of wear or damage
  • Replace damaged or worn-out components promptly
  • Keep the work area clean and organized

Tool Care

  • Regularly clean and maintain the torque wrench
  • Store the torque wrench in a dry and secure location
  • Verify the torque wrench calibration before each use

Frequently Asked Questions

Find answers to common questions about torque specifications

Q1

Why are proper torque specifications important for body bolts?

Proper torque ensures the body panels are securely fastened to the vehicle's frame, preventing rattles, vibrations, and potential loosening over time. Under-tightening can lead to panels shifting or falling off, while over-tightening can strip threads or damage the panels and mounting points. It also helps maintain structural integrity in case of an impact.

Q2

What happens if I over-tighten a body bolt?

Over-tightening can stretch or break the bolt, strip the threads in the receiving nut or panel, and potentially deform the body panel. This can lead to a weakened joint that may fail. In many cases, an over-torqued bolt will need to be drilled and re-tapped, or the receiving part may have to be replaced.

Q3

What happens if I under-tighten a body bolt?

Under-tightening can lead to the bolt loosening over time due to vibration and movement. Loose body panels can rattle, create unwanted noises, and eventually detach. This is a common reason for body alignment issues and can lead to increased wear on mounting points.

Q4

Do I need to use new bolts when reinstalling body panels?

While not always mandatory, using new bolts is highly recommended, especially for critical body components. Old bolts can be stretched or weakened from previous use or corrosion, and they may not achieve the required torque reliably. New bolts will ensure proper clamping force and reduce the chance of future loosening or failure.

Q5

Do I need to use any threadlocker when reinstalling body bolts?

Generally, threadlocker isn't required for most body bolts unless specifically indicated in the vehicle's service manual. However, if you are dealing with recurring loosening issues or bolts in a high-vibration area, a light-strength (e.g., blue) threadlocker can be beneficial. Be cautious with high-strength threadlockers as they may make the bolts difficult to remove later.

Environmental Considerations

Temperature, humidity, and seasonal effects on torque specifications

Temperature Effects

Includes: High Heat, Cold Weather, Thermal Cycling

Temperature can significantly impact torque values and fastener behavior

Cold Weather

Effects:
  • Increased material brittleness
  • Higher torque required due to thread contraction
  • Reduced thread lubricant effectiveness
Recommendations:
  • Allow components to warm to room temperature when possible
  • Consider using winter-grade thread lubricants
  • Check torque values more frequently during winter months

Hot Weather

Effects:
  • Thermal expansion of components
  • Decreased friction in threads
  • Accelerated lubricant breakdown
Recommendations:
  • Check torque when components are at normal operating temperature
  • Use temperature-resistant thread lockers
  • Consider re-torquing after heat cycles

Humidity and Corrosion

Covers: Rust Prevention, Salt Exposure, Moisture Control

Moisture and corrosion can affect fastener integrity and torque values

High Humidity

Effects:
  • Accelerated corrosion formation
  • Reduced friction coefficient
  • Potential thread seizing
Prevention:
  • Use corrosion-resistant fasteners
  • Apply appropriate anti-seize compounds
  • Maintain proper protective coatings

Salt Exposure

Effects:
  • Rapid corrosion development
  • Thread damage
  • Seized fasteners
Prevention:
  • Regular underbody washing
  • Use of sacrificial anodes where appropriate
  • Application of protective coatings

Seasonal Maintenance

Spring, Summer, Fall, and Winter maintenance schedules

Spring

  • Inspect for winter damage
  • Clean and protect exposed fasteners
  • Check torque on critical components

Summer

  • Monitor heat-affected components
  • Check expansion-related loosening
  • Inspect cooling system mounts

Fall

  • Prepare for winter conditions
  • Apply corrosion protection
  • Verify all fasteners are properly torqued

Winter

  • More frequent inspection of critical fasteners
  • Check for salt damage
  • Monitor suspension component torque

Related Resources

Tools, service procedures, and technical bulletins

Recommended Tools

Torque Wrench (1/2" Drive)

A calibrated torque wrench is essential for applying accurate torque to body bolts. A 1/2" drive is recommended for the common range of torque values encountered.

  • Click-type mechanism for audible feedback
  • Wide torque range (e.g., 20-150 ft-lbs)
Learn more

Torque Wrench (3/8" Drive)

A smaller 3/8" drive torque wrench may be needed for lower torque body components and in tighter spaces.

  • Click-type mechanism for audible feedback
  • Lower torque range (e.g., 5-80 ft-lbs)
Learn more

Socket Set (Metric)

A set of metric sockets, including common sizes found on Dodge Caravans, is necessary for removing and tightening bolts.

  • Variety of sizes (e.g., 10mm, 12mm, 13mm, 15mm, 17mm)
  • 6-point sockets recommended
Learn more

Socket Extensions

Socket extensions of various lengths are often needed to access bolts in tight spots.

  • Various lengths (e.g., 3", 6", 10")
  • Durable steel construction
Learn more
Service Procedures

Body Panel Bolt Torque Procedure

This procedure outlines how to correctly torque body panel bolts on a 1991-1995 Dodge Caravan.

  • 1. Identify the specific body panel and the bolt to be torqued. Consult a service manual for bolt location.
  • 2. Consult the torque specification for the specific bolt. See table below for common locations.
  • 3. Select the correct size socket and torque wrench. Attach any needed extensions.
  • 4. Loosely install the bolt into its hole. Avoid fully tightening at this stage.
  • 5. Using the torque wrench, tighten the bolt to the specified torque. Apply a smooth, steady force.
  • 6. Listen for the click or observe the torque wrench indicator to verify correct torque.
  • 7. Repeat this process on all other bolts for that panel using any specified sequence if necessary.
View full procedure

Bumper Mounting Bolt Torque Procedure

This procedure outlines how to correctly torque bumper mounting bolts on a 1991-1995 Dodge Caravan.

  • 1. Identify the specific bumper mounting bolts to be torqued. Consult a service manual for bolt location.
  • 2. Consult the torque specification for the specific bolt. See table below for common locations.
  • 3. Select the correct size socket and torque wrench. Attach any needed extensions.
  • 4. Loosely install the bolt into its hole. Avoid fully tightening at this stage.
  • 5. Using the torque wrench, tighten the bolt to the specified torque. Apply a smooth, steady force.
  • 6. Listen for the click or observe the torque wrench indicator to verify correct torque.
  • 7. Repeat this process on all other bolts for the bumper.
View full procedure

Door Hinge Bolt Torque Procedure

This procedure outlines how to correctly torque door hinge bolts on a 1991-1995 Dodge Caravan.

  • 1. Identify the specific door hinge bolts to be torqued. Consult a service manual for bolt location.
  • 2. Consult the torque specification for the specific bolt. See table below for common locations.
  • 3. Select the correct size socket and torque wrench. Attach any needed extensions.
  • 4. Loosely install the bolt into its hole. Avoid fully tightening at this stage.
  • 5. Using the torque wrench, tighten the bolt to the specified torque. Apply a smooth, steady force.
  • 6. Listen for the click or observe the torque wrench indicator to verify correct torque.
  • 7. Repeat this process on all other hinge bolts on the door.
View full procedure
Technical Service Bulletins

Body Panel Bolt Corrosion Issues

1998-06-15

Some 1991-1995 Dodge Caravan models may exhibit premature corrosion of body panel bolts, leading to reduced clamping force and potential loosening.

1991-1995 Dodge Caravan

Resolution: Inspect all body panel bolts for corrosion. Replace corroded bolts with new, properly coated fasteners. Apply anti-seize compound to bolt threads during reinstallation. Verify all bolts are torqued to specification. Recommended torque for most body panel bolts is between 15-25 ft-lbs.

Bumper Bolt Loosening and Alignment

1996-03-20

Reports of bumper bolt loosening and misalignment on 1991-1995 Dodge Caravan. This bulletin addresses the proper procedure for tightening bumper bolts and aligning bumper to chassis.

1991-1995 Dodge Caravan

Resolution: Check all bumper mounting bolts and ensure they are tightened to the correct torque specification. The recommended torque is between 35-50 ft-lbs for most bumper to frame mounting bolts. Use correct shims if necessary to achieve alignment. Recheck torque after a brief period of driving

Door Hinge Bolt Failure

1997-11-01

Some 1991-1995 Dodge Caravans have reported door hinge bolt failure due to fatigue. Inspection and replacement of bolts is crucial

1991-1995 Dodge Caravan

Resolution: Inspect door hinge bolts for cracks and elongation. Replace with new bolts that meet or exceed OEM specification. Recommended torque is between 20-30 ft-lbs for door hinge bolts.

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