1. Diagnose the Problem:
Before you start, pinpoint the exact issue. Is it:
* Won't open or close at all? This could be a motor, track, or linkage problem.
* Opens/closes slowly or erratically? This points to motor weakness, track binding, or a problem with the roller assembly.
* Makes loud noises? This indicates worn rollers, a track issue, or something loose in the mechanism.
* Door doesn't latch properly? This might be a latch mechanism problem, a striker plate issue, or a misalignment.
2. Common Repairs and How-Tos:
* Lubrication: The most common and often overlooked fix. Use a silicone-based lubricant (like white lithium grease) on the door's rollers, tracks (both top and bottom), and any moving parts of the latch mechanism. Apply sparingly and wipe off excess. This can often solve slow operation and noisy tracks.
* Track Cleaning: Dirt and debris build up in the tracks, causing binding. Use a stiff brush, compressed air, and a shop vacuum to thoroughly clean the tracks. Pay attention to the area where the rollers ride.
* Roller Replacement: The rollers are common wear items. If they're worn, cracked, or damaged, they need replacing. This usually involves removing the door panel (see below) to access the rollers. You'll need to find replacement rollers specific to your van's year and model.
* Motor Issues: If the motor is weak or failing, it may need repair or replacement. This is a more involved repair and often requires specialized tools and electrical knowledge. Testing the motor's voltage and amperage might be needed to diagnose if it's the motor or the wiring.
* Latch Mechanism: Examine the latch mechanism and striker plate. Adjust the striker plate if it's misaligned. If parts are broken or worn, they'll need replacing.
* Linkage: The linkages connecting the handle to the latch mechanism can become worn or dislodged. Inspect these for damage and repair or replace as needed.
* Wiring Issues: Check all wiring connections to the motor and other components for loose or broken wires.
3. Removing the Interior Door Panel:
Accessing many of the internal components requires removing the interior door panel. This typically involves:
1. Removing the screws: These are usually hidden under trim pieces and around the armrest area.
2. Disconnecting the wiring harnesses: Carefully disconnect any electrical connectors for power windows, locks, etc.
3. Popping the panel off: There are usually clips holding the panel in place. Gently pry it away from the door, starting at the edges. Work carefully to avoid breaking the clips.
4. Finding Parts:
You can find replacement parts at auto parts stores (like AutoZone, Advance Auto Parts), online retailers (like Amazon, eBay), or salvage yards. Always specify your van's year, make, model, and trim level when ordering parts.
5. When to Call a Professional:
If you're uncomfortable working on your vehicle's mechanical systems, or if the problem is beyond simple maintenance, it's best to take your van to a qualified mechanic. Electrical problems and complex mechanical repairs should be handled by professionals.
Important Note: Before undertaking any repair, consult a repair manual specific to your 1996 Chrysler Town & Country LXi. A repair manual will provide detailed diagrams, instructions, and torque specifications to ensure you perform the repair correctly and safely.
