key CHRYSLER VOYAGER 2004 Owners Manual

INSTALLATION
(1) Install the lock cylinder housing in the bottom
of the steering column lining up the mounting holes.
(2) Install the self-tapping lock cylinder housing
mounting screws through the top of the column into
the housing (Fig. 26). Tighten the two mounting
screws to a torque of 11 N´m (100 in. lbs.).
(3) Connect both tilt mechanism springs back onto
their mounting posts making sure the spring hooks
engage the grooves in the posts (Fig. 25).
(4) Ensure that the ignition switch and the actua-
tor shaft in the lock cylinder housing are in the ON
position.
(5) Carefully install the ignition switch over the
actuator shaft (Fig. 27). The switch will snap over
the retaining tabs on the housing.(6) Install the ignition switch mounting screw (Fig.
23).
(7) Install the key cylinder halo lamp on the lock
cylinder housing.
(8) Install the vehicle wiring harness connector
onto the key cylinder halo lamp (Fig. 22).
(9) Install the key cylinder (with key in it turned
to the ON position) by sliding it straight into the lock
cylinder housing aligning the retaining tab on the
key cylinder with the hole in the lock cylinder hous-
ing.
(10) Turn the key to the OFF position and remove
the key.
(11) Connect the shifter/ignition interlock link to
the lever on the lock cylinder housing by aligning the
Fig. 24 Ignition Switch Retaining Tabs
1 - IGNITION SWITCH
2 - LOCK CYLINDER HOUSING
3 - RETAINING TABS
Fig. 25 Tilt Mechanism Spring Removal/Installation
1 - SPRINGS
2 - POST
3 - GROOVE
Fig. 26 Lock Cylinder Housing Mounting Screw
Location
1 - SPRINGS
2 - MOUNTING SCREWS
Fig. 27 Ignition Switch Installation
1 - IGNITION SWITCH
2 - ACTUATOR SHAFT
3 - RETAINING TABS
RSCOLUMN19-19
LOCK CYLINDER HOUSING (Continued)

retaining tab on the lever with the ramp on the link
(Fig. 20), then pushing the two together.
(12) Install the metal cover in place below the
shifter/ignition interlock linkage using the two
screws (Fig. 19).
(13) Install the steering column fixed shroud on
the steering column (Fig. 18) using its 2 mounting
screws.
(14) Install the trim bezel on the instrument panel
above the steering column. The trim bezel is
mounted to the instrument panel using 2 screws (one
on each side of the column) and retaining clips.
(15) Install the lower and upper steering column
shrouds. (Refer to 19 - STEERING/COLUMN/
LOWER SHROUD - INSTALLATION)
(16) Install the knee blocker reinforcement plate
(Fig. 17).
(17) Connect the parking brake release link to the
release handle.
(18) Install the data link diagnostic connector to
the mounting hole in the reinforcement plate.
(19) Install the lower steering column cover/knee
blocker (Fig. 17).
(20) Connect the negative (ground) cable to the
battery terminal.
KEY/LOCK CYLINDER
DESCRIPTION
The lock cylinder is inserted in the end of the
housing opposite the ignition switch.
OPERATION
The ignition key rotates the cylinder to 5 different
detents (Fig. 28) :
²Accessory
²Off (lock)
²Unlock
²On/Run
²Start
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove steering column cover retaining
screws.
(3) Remove screws holding steering column
shrouds and remove lower shroud.
(4) Place key cylinder in RUN position. Depress
lock cylinder retaining tab on the bottom of the lock
housing and remove key cylinder.
INSTALLATION
(1) Install key in lock cylinder. Turn key to run
position (retaining tab on lock cylinder can be
depressed).
(2) The shaft at the end of the lock cylinder aligns
with the socket in the end of the housing. To align
the socket with the lock cylinder, ensure the socket is
in the Run position (Fig. 29) .
(3) Align the lock cylinder with the grooves in the
housing. Slide the lock cylinder into the housing
until the tab sticks through the opening in the hous-
ing.
(4) Turn the key to the Off position. Remove the
key.
(5) Install lower steering column shroud.
(6) Install steering column cover.
(7) Connect negative cable to battery.
Fig. 28 Ignition Lock Cylinder Detents
Fig. 29 Socket in Lock Cylinder Housing
1 - LOCK CYLINDER HOUSING
2 - SOCKET
19 - 20 COLUMNRS
LOCK CYLINDER HOUSING (Continued)

REMOVAL - RHD GEAR
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much fluid as
possible from the power steering fluid reservoir.
CAUTION: Locking the steering column in the
straight-ahead position will prevent the clockspring
from being accidentally over-extended when the
steering column is disconnected from the interme-
diate steering coupler.
(3) Position the steering wheel in the STRAIGHT-
AHEAD position. Lock the steering wheel in place
using a steering wheel holding tool.
(4) With the ignition key in the locked position
turn the steering wheel to the left until the steering
wheel is in the locked position.
(5) With the vehicle on the ground, disconnect the
steering column shaft coupler from the steering gear
intermediate coupler (Fig. 2).
(6) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(7) Remove front wheel and tire assemblies.
(8) If power steering cooler equipped, remove a
hose at power steering cooler and allow fluid to
drain.
(9) Remove 2 bolts attaching power steering cooler
to cradle crossmember reinforcement (Fig. 3).
(10) On both sides of vehicle, remove nut attaching
outer tie rod end to steering knuckle (Fig. 4).Remove nut by holding tie rod end stud with a
socket while loosening and removing nut with
wrench.
(11) Remove both tie rod ends from steering
knuckles using Puller, Special Tool C-3894±A (Fig. 5).
(12) Remove the lower control arm rear bushing
retainer bolts located on each side of each lower con-
trol arm rear bushing.
NOTE: The bolts fastening the cradle crossmember
reinforcement are of two different thread sizes. Note
the location of the various sizes.
(13) Remove the bolts attaching the cradle cross-
member reinforcement to the front suspension cradle
crossmember (Fig. 6). Remove the 2 bolts fastening
the reinforcement and rear of cradle crossmember to
the body of the vehicle. Remove the reinforcement.
(14) If the vehicle is equipped with All-Wheel-
Drive, remove the power transfer unit (Refer to 21 -
TRANSMISSION/TRANSAXLE/POWER TRANSFER
UNIT - REMOVAL).
(15) Remove the power steering fluid pressure and
return hoses from the power steering gear (Fig. 10).
(16) Remove the routing clamp bolt securing the
power steering fluid hoses to the rear of the cradle
crossmember (Fig. 11). Allow the hoses to hang down
out of the way.
(17) Remove the heat shield from the steering gear
(Fig. 10).
(18) Remove the 2 bolts and nuts mounting the
steering gear to the front suspension cradle.
Fig. 9 Removing Roll Pin From Intermediate Coupler
1 - INTERMEDIATE COUPLER
2 - KNURLED NUT
3 - SUSPENSION CRADLE
4 - REMOVER SPECIAL TOOL 6831A
5 - STEERING GEAR
6 - NUT
7 - ROLL PIN
8 - THREADED ROD
Fig. 10 RHD Gear Heat Shield And Hose Fittings
1 - HEAT SHIELD
2 - CRADLE CROSSMEMBER
3 - RETURN HOSE FITTING
4 - PRESSURE HOSE FITTING
5 - POWER STEERING GEAR
RSGEAR19-31
GEAR (Continued)

Misassembled synchronizer components also cause
shifting problems. Incorrectly installed synchronizer
sleeves, keys, balls, or springs can cause shift prob-
lems.
NOISY OPERATION
Transaxle noise is most often a result of worn or
damaged components. Chipped, broken gear or syn-
chronizer teeth, and brinnelled, spalled bearings all
cause noise.
Abnormal wear and damage to the internal compo-
nents is frequently the end result of insufficient
lubricant.
SLIPS OUT OF GEAR
Transaxle disengagement may be caused by mis-
aligned or damaged shift components, or worn teeth
on the drive gears or synchronizer components. Incor-
rect assembly also causes gear disengagement. Check
for missing snap rings.
LOW LUBRICANT LEVEL
Insufficient transaxle lubricant is usually the
result of leaks, or inaccurate fluid level check or refill
method. Leakage is evident by the presence of oil
around the leak point. If leakage is not evident, the
condition is probably the result of an underfill.
If air±powered lubrication equipment is used to fill
a transaxle, be sure the equipment is properly cali-
brated. Equipment out of calibration can lead to an
underfill condition.
CLUTCH PROBLEMS
Worn, damaged, or misaligned clutch components
can cause difficult shifting, gear clash, and noise.
A worn or damaged clutch disc, pressure plate, or
release bearing can cause hard shifting and gear
clash.
REMOVAL
REMOVAL - 2.4L GAS
(1) Raise hood.
(2) Disconnect gearshift cables from shift levers/
cover assembly (Fig. 10).
(3) Remove gearshift cable retaining clips from
mounting bracket (Fig. 10). Remove cables and
secure out of way.
(4) Remove three (3) right engine mount bracket-
to-transaxle bolts (Fig. 11).
(5) Raise vehicle on hoist.
(6) Remove front wheel/tires and halfshafts.
(7) Drain transaxle fluid into suitable container.
(8) Remove front harness retainer and secure har-
ness out of way.
Fig. 10 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
Fig. 11 Transaxle Right Mount and Bracket
1 - MOUNT BRACKET
2 - BOLT (3)
3 - MOUNT
4 - BOLT (1)
RST850 MANUAL TRANSAXLE21-31
T850 MANUAL TRANSAXLE (Continued)

SYNCHRONIZER
DESCRIPTION
The T850 transaxle uses two styles of synchronizer
assemblies; a conventional single-cone style is used
for the 5th/Reverse and 3rd/4th applications (Fig.
277), and a dual-cone style for the 1st/2nd gear appli-
cation (Fig. 278).
DISASSEMBLY
Place synchronizer in a clean shop towel and wrap.
Press on inner hub. Carefully open up shop towel
and remove springs, balls, keys, hub, and sleeve.
CLEANING
CLEAN
Do not attempt to clean the blocking rings in sol-
vent. The friction material will become contaminated.
Place synchronizer components in a suitable holder
and clean with solvent. Air dry.
INSPECTION
INSPECT
Proper inspection of components involve:
²
Teeth, for wear, scuffed, nicked, burred, or broken
teeth
²Keys, for wear or distortion
²Balls and springs, for distortion, cracks, or wear
If any of these conditions exist in these compo-
nents, replace as necessary.
ASSEMBLY
(1) Position synchronizer hub onto work bench.
Hub is non-directional.
(2) Install springs into hub slot.
(3) Insert key into hub and spring.
(4) Apply petroleum jelly to the hole in the key.
Insert balls into each key.
(5) Slide sleeve over the hub and depress balls as
you carefully slip the sleeve into position.
Fig. 276 Shift Fork/Shaft Components
1 - 5/R FORK
2 - SHAFT/LINK ASSEMBLY
3 - LINK
4 - 3/4 FORK
5 - 1/2 FORK
Fig. 277 3/4-5/R Synchronizer Assembly
1 - SLEEVE
2 - HUB
3 - BLOCKER RING (2)
4 - SPRING (3)
5 - KEY (3)
6 - BALL (3)
21 - 114 T850 MANUAL TRANSAXLERS
SHIFT FORK AND SHAFT (Continued)

VEHICLE SPEED SENSOR
REMOVAL
(1) Raise vehicle on hoist.
(2)
Disconnect the speed sensor connector (Fig. 279).
CAUTION: Clean area around speed sensor before
removing to prevent dirt from entering the transaxle
during speed sensor removal.
(3) Remove speed sensor retaining bolt (Fig. 279).
(4) Remove speed sensor from transaxle.
CAUTION: Carefully remove vehicle speed sensor
so that sensor drive gear does not fall into trans-
axle. Should sensor drive gear fall into the trans-
axle during sensor removal, drive gear must be
reattached to sensor.
(5) Remove speed sensor drive gear from speed
sensor.
INSTALLATION
(1) Install pinion gear to speed sensor (Fig. 279).
(2) Using a NEW o-ring, install the speed sensor
to the transaxle (Fig. 279).
(3) Install the bolt and torque to 7 N´m (60 in.
lbs.).
(4) Connect speed sensor connector (Fig. 279).
(5) Lower vehicle and road test to verify proper
speedometer operation.
Fig. 278 1/2 Synchronizer Assembly
1 - SLEEVE
2 - REACTOR RING (2)
3 - HUB
4 - BLOCKER RING (2)
5 - SLEEVE
6 - FRICTION CONE (2)
7 - SPRING (3)
8 - KEY (3)
9 - BALL (3)
Fig. 279 Speed Sensor and Pinion Removal/
InstallationÐTypical
1 - CONNECTOR
2 - SENSOR
3 - O-RING
4 - GEAR
RST850 MANUAL TRANSAXLE21 - 115
SYNCHRONIZER (Continued)

(4) Install knee bolster (Fig. 220).
(5) Install instrument panel lower silencer (Fig.
221).
(6) Install gear shift cable to transaxle upper
mount bracket (Fig. 222). An audible ªclickº should
be heard.
(7) Connect gear shift cable end to transaxle man-
ual valve lever (Fig. 222).
(8) Adjust gearshift cable. (Refer to 21 - TRANS-
MISSION/TRANSAXLE/AUTOMATIC - 41TE/GEAR
SHIFT CABLE - ADJUSTMENTS)
(9) Install speed control servo into position.
(10) Install battery.
(11) Install battery shield.
(12) Connect battery cables.
ADJUSTMENTS
GEARSHIFT CABLE ADJUSTMENT
VERIFICATION
(1) Place gearshift lever in gated park (P).
(2) Attempt to move vehicle by rocking back and
forth on level ground. If vehicle does not move,
attempt to start engine. If engine starts, the park
position is correct.
(3) Set parking brake.
(4) Turn key to on/run and depress brake pedal.
Place gearshift lever in neutral (N).
(5) Attempt to start engine. If engine starts in
both neutral (N) or park (P), gearshift cable is
adjusted properly. No adjustment is required.
(6) If engine does not start in either park (P) or
neutral (N), perform adjustment procedure.
Fig. 220 Knee Bolster
1 - KNEE BOLSTER
Fig. 221 Instrument Panel Lower Silencer
1 - INSTRUMENT PANEL LOWER SILENCER
Fig. 222 Gearshift Cable at Transaxle
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
21 - 206 41TE AUTOMATIC TRANSAXLERS
GEAR SHIFT CABLE (Continued)

ADJUSTMENT
(1) Park the vehicle on level ground and set the
parking brake.
(2) Place the gearshift lever in gated park (P) and
remove ignition key.
(3) Loosen the cable adjustment screw at the
transaxle manual valve lever (Fig. 223).
(4) Pull the gearshift lever fully forward to the
park detent position.
(5) Release the park brake, then rock the vehicle
to assure it is in park. Reset the park brake.
(6) Tighten the cable adjustment screw to 8 N´m
(70 in. lbs.). Gearshift cable should now be properly
adjusted.
(7) Verify adjustment by using the verification pro-
cedure.
HOLDING CLUTCHES
DESCRIPTION
Two hydraulically applied multi-disc clutches are
used to hold planetary geartrain components station-
ary while the input clutches drive others. The 2/4
and Low/Reverse clutches are considered holding
clutches and are contained at the rear of the trans-
axle case. (Fig. 224).
OPERATION
NOTE: Refer to the ªElements In Useº chart in Diag-
nosis and Testing for a collective view of which
clutch elements are applied at each position of the
selector lever.
2/4 CLUTCH
The 2/4 clutch is hydraulically applied in second
and fourth gears by pressurized fluid against the 2/4
clutch piston. When the 2/4 clutch is applied, the
front sun gear assembly is held or grounded to the
transaxle case.
LOW/REVERSE CLUTCH
The Low/Reverse clutch is hydraulically applied in
park, reverse, neutral, and first gears by pressurized
fluid against the Low/Reverse clutch piston. When
the Low/Reverse clutch is applied, the front planet
carrier/rear annulus assembly is held or grounded to
the transaxle case.
Fig. 223 Gearshift Cable Adjustment
1 - GEARSHIFT CABLE ADJUSTMENT SCREW
2 - GEARSHIFT CABLE
Fig. 224 2/4 and Low/Reverse Clutches
1 - FRONT PLANET CARRIER/REAR ANNULUS
2 - 2/4 CLUTCH
3 - L/R CLUTCH
4 - REAR PLANET CARRIER/FRONT ANNULUS
5 - REAR SUN GEAR
6 - FRONT SUN GEAR ASSEMBLY
RS41TE AUTOMATIC TRANSAXLE21 - 207
GEAR SHIFT CABLE (Continued)

INSTALLATION
(1) Using Tool C-4193, install oil pump seal (Fig.
290).
(2) Install transaxle to vehicle (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC - 41TE
- INSTALLATION).
SHIFT INTERLOCK SOLENOID
DESCRIPTION
The Brake/Transmission Shift Interlock system
consists of an electro-magnetic solenoid mounted to
the steering column (Fig. 291). The solenoid's plunger
consists of an integrated hook, which operates the
shift lever pawl (part of shift lever assembly), and a
plunger return spring (Fig. 292). The solenoid also
has an integrated bracket, which facilitates fastening
to the steering column.
OPERATION
The Brake/Transmission Shift Interlock (BTSI) Sole-
noid prevents the transmission shift lever from being
moved out of PARK (P) unless the brake pedal is
applied. The BTSI solenoid is hardwired to and con-
trolled by the Intelligent Power Module (IPM). Battery
voltage is applied to one side of the solenoid with the
ignition key is in either the OFF, ON/RUN, or START
positions (Fig. 293). The ground side of the solenoid is
controlled by a driver within the IPM. It relies on volt-
age supplied from the stop lamp switch to the stop
lamp sense circuit within the IPM to tell when the
brake pedal is depressed. When the brake pedal is
depressed, the ground circuit opens, de-energizing the
solenoid. When the brake pedal is released, the ground
circuit is closed, energizing the solenoid.
When the ignition key is in either the OFF,
ON/RUN, or START positions, the BTSI solenoid is
energized, and the solenoid plunger hook pulls the
shift lever pawl into position, prohibiting the shift
lever from moving out of PARK (P) (Fig. 294). When
the brake pedal is depressed, the ground circuit
opens, de-energizing the solenoid. This moves the
gearshift lever pawl out of the way (Fig. 295), allow-
ing the shift lever to be moved into any gear position.
Fig. 290 Install Oil Pump Seal
1 - TOOL C-4193
2 - HANDLE TOOL C-4171
Fig. 291 Brake/Transmission Shift Interlock (BTSI)
Solenoid Location
1 - BTSI SOLENOID
Fig. 292 Solenoid Plunger and Return Spring
1 - PLUNGER
2 - RETURN SPRING
3 - BTSI SOLENOID
RS41TE AUTOMATIC TRANSAXLE21 - 233
SEAL - OIL PUMP (Continued)

A conventional mechanical interlock system is also
used. This system manually prohibits shifter move-
ment when the ignition switch is in the LOCK or
ACC positions. Solenoid operation is not required in
these key positions.
For intended BTSI system operation, refer to the
following chart:
ACTION EXPECTED RESPONSE
1. Turn key to the9OFF9
position.1. Shifter CAN be shifted
out of park with brake
pedal applied.
2. Turn key to the
9ON/RUN9position.2. Shifter CANNOT be
shifted out of park.
3. Turn key to the
9ON/RUN9position and
depress the brake pedal.3. Shifter CAN be shifted
out of park.
4. Leave shifter in any
gear and try to return key
to the9LOCK9or9ACC9
position.4. Key cannot be
returned to the9LOCK9or
9ACC9position.
5. Return shifter to
9PARK9and try to remove
the key.5. Key can be removed
(after returning to9LOCK9
position).
6. With the key removed,
try to shift out of9PARK9.6. Shifter cannot be
shifted out of9PARK9.
NOTE: Any failure to meet these expected
responses requires system adjustment or repair.
Fig. 293 Ignition Key/Switch Positions
1 - ACC
2 - LOCK
3 - OFF
4 - ON/RUN
5-START
Fig. 294 Pawl Engaged to Shift Lever
1 - GEAR SHIFT LEVER
2 - GEAR SHIFT LEVER PAWL
Fig. 295 Pawl Disengaged From Shift Lever
1 - GEAR SHIFT LEVER
2 - GEAR SHIFT LEVER PAWL
21 - 234 41TE AUTOMATIC TRANSAXLERS
SHIFT INTERLOCK SOLENOID (Continued)