mileage CHRYSLER VOYAGER 1996 User Guide

(2) To perform the dipstick tube fluid suction
method, use a suitable fluid suction device (Vaculay
or equivalent).
(3) Insert the fluid suction line into the dipstick
tube.
NOTE: Verify that the suction line is inserted to the
lowest point of the transaxle oil pan. This will
ensure complete evacuation of the fluid in the pan.
(4) Follow the manufacturers recommended proce-
dure and evacuate the fluid from the transaxle.
(5) Remove the suction line from the dipstick tube.
(6) Add 4 Quarts of Mopar ATF Plus 3 Type 7176
transaxle fluid.
(7) Start the engine and allow it to idle for a min-
imum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the
transaxle from park to all gear positions ending in
neutral or park.
(8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ADD mark on the dip-
stick.
(9) Recheck the fluid level after the transaxle is at
normal operating temperature. The level should be in
the HOT range.
TRANSAXLE OIL PAN DROP METHOD
This procedure involves removing the transaxle oil
pan to drain the transaxle fluid.
(1) Bring the vehicle up to normal operating tem-
perature. Drive the vehicle a minimum of 10 miles.
(2) Raise the vehicle on the hoist.
(3) Loosen the transaxle oil pan and drain the
fluid into a suitable container.
(4) Remove the pan and clean all sealant from the
pan and transaxle mating surfaces. Clean the mag-
net and the inside of the pan.
(5) Apply a 1/8 inch bead of Mopar RTV Sealant to
the mounting flange of the transaxle oil pan. Apply
RTV Sealant to the underside of the attaching bolts.
Attach the oil pan to the transaxle. Tighten the bolts
to 19 N²m (165 in. lbs.).
(6) Lower the vehicle and add 4 Quarts of Mopar
ATF Plus 3 Type 7176 transaxle fluid.
(7) Start the engine and allow it to idle for a min-
imum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the
transaxle from park to all gear positions ending in
neutral or park.
(8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ADD mark on the dip-
stick.
(9) Recheck the fluid level after the transaxle is at
normal operating temperature. The level should be inthe HOT range. Drive the vehicle a minimum of 10
miles.
(10) Raise the vehicle on the hoist.
(11) Check for leaks around the transaxle oil pan
sealing surfaces.
(12) Recheck the fluid level. The level should be in
the HOT range.
SEVERE USAGE SERVICE
If the vehicle exhibits any of the following symp-
toms, it is recommended that the transaxle oil and
filter be replaced.
²Transaxle oil discolored
²Transaxle oil has high mileage
²Oil feels grimy when rubbed between fingertips
²Poor shift quality
²Delayed gear engagement
²Vehicle shudder between shifts
TRANSAXLE OIL AND FILTER REPLACEMENT
This procedure involves changing the transaxle
fluid and filter, driving the vehicle for 10 miles and
changing the transaxle fluid a second time.
(1) Bring the vehicle up to normal operating tem-
perature. Drive the vehicle a minimum of 10 miles.
(2) Raise the vehicle on the hoist.
(3) Loosen the transaxle oil pan and drain the
fluid into a suitable container.
(4) Remove the pan and clean all sealant from the
pan and transaxle mating surfaces. Clean the mag-
net and the inside of the pan.
(5) Separate the filter and O-ring from the valve
body. Inspect the O-ring for cuts or improper instal-
lation. This could lead to delayed garage shifts.
(6) Install a new filter. Replace the O-ring as nec-
essary.
(7) Apply a 1/8 inch bead of Mopar RTV Sealant to
the mounting flange of the transaxle oil pan. Apply
RTV Sealant to the underside of the attaching bolts.
Attach the oil pan to the transaxle. Tighten the bolts
to 19 N²m (165 in. lbs.).
(8) Lower the vehicle and add 4 Quarts of Mopar
ATF Plus 3 Type 7176 transaxle fluid.
(9) Start the engine and allow it to idle for a min-
imum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the
transaxle from park to all gear positions ending in
neutral or park.
(10) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ADD mark on the dip-
stick.
(11) Recheck the fluid level after the transaxle is
at normal operating temperature. The level should be
in the HOT range. Drive the vehicle a minimum of
10 miles.
(12) Raise the vehicle on the hoist.
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 17
SERVICE PROCEDURES (Continued)

DIPSTICK TUBE FLUID SUCTION METHOD
(1) When performing the fluid suction method,
make sure the transaxle is at full operating temper-
ature.
(2) To perform the dipstick tube fluid suction
method, use a suitable fluid suction device (Vaculay
or equivalent).
(3) Insert the fluid suction line into the dipstick
tube.
NOTE: Verify that the suction line is inserted to the
lowest point of the transaxle oil pan. This will
ensure complete evacuation of the fluid in the pan.
(4) Follow the manufacturers recommended proce-
dure and evacuate the fluid from the transaxle.
(5) Remove the suction line from the dipstick tube.
(6) Add 4 Quarts of Mopar ATF Plus 3 Type 7176
transaxle fluid.
(7) Start the engine and allow it to idle for a min-
imum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the
transaxle from park to all gear positions ending in
neutral or park.
(8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ADD mark on the dip-
stick.
(9) Recheck the fluid level after the transaxle is at
normal operating temperature. The level should be in
the HOT range.
TRANSAXLE OIL PAN DROP METHOD
This procedure involves removing the transaxle oil
pan to drain the transaxle fluid.
(1) Bring the vehicle up to normal operating tem-
perature. Drive the vehicle a minimum of 10 miles.
(2) Raise the vehicle on the hoist.
(3) Loosen the transaxle oil pan and drain the
fluid into a suitable container.
(4) Remove the pan and clean all sealant from the
pan and transaxle mating surfaces. Clean the mag-
net and the inside of the pan.
(5) Apply a 1/8 inch bead of Mopar RTV Sealant to
the mounting flange of the transaxle oil pan. Apply
RTV Sealant to the underside of the attaching bolts.
Attach the oil pan to the transaxle. Tighten the bolts
to 19 N²m (165 in. lbs.).
(6) Lower the vehicle and add 4 Quarts of Mopar
ATF Plus 3 Type 7176 transaxle fluid.
(7) Start the engine and allow it to idle for a min-
imum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the
transaxle from park to all gear positions ending in
neutral or park.
(8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid levelto 3mm (1/8 in.) below the ADD mark on the dip-
stick.
(9) Recheck the fluid level after the transaxle is at
normal operating temperature. The level should be in
the HOT range. Drive the vehicle a minimum of 10
miles.
(10) Raise the vehicle on the hoist.
(11) Check for leaks around the transaxle oil pan
sealing surfaces.
(12) Recheck the fluid level. The level should be in
the HOT range.
SEVERE USAGE SERVICE
If the vehicle exhibits any of the following symp-
toms, it is recommended that the transaxle oil and
filter be replaced.
²Transaxle oil discolored
²Transaxle oil has high mileage
²Oil feels grimy when rubbed between fingertips
²Poor shift quality
²Delayed gear engagement
²Vehicle shudder between shifts
TRANSAXLE OIL AND FILTER REPLACEMENT
This procedure involves changing the transaxle
fluid and filter, driving the vehicle for 10 miles and
changing the transaxle fluid a second time.
(1) Bring the vehicle up to normal operating tem-
perature. Drive the vehicle a minimum of 10 miles.
(2) Raise the vehicle on the hoist.
(3) Loosen the transaxle oil pan and drain the
fluid into a suitable container.
(4) Remove the pan and clean all sealant from the
pan and transaxle mating surfaces. Clean the mag-
net and the inside of the pan.
(5) Separate the filter and O-ring from the valve
body. Inspect the O-ring for cuts or improper instal-
lation. This could lead to delayed garage shifts.
(6) Install a new filter. Replace the O-ring as nec-
essary.
(7) Apply a 1/8 inch bead of Mopar RTV Sealant to
the mounting flange of the transaxle oil pan. Apply
RTV Sealant to the underside of the attaching bolts.
Attach the oil pan to the transaxle. Tighten the bolts
to 19 N´m (165 in. lbs.).
(8) Lower the vehicle and add 4 Quarts of Mopar
ATF Plus 3 Type 7176 transaxle fluid.
(9) Start the engine and allow it to idle for a min-
imum of one minute. With the parking brake applied,
press your foot on the service brake and cycle the
transaxle from park to all gear positions ending in
neutral or park.
(10) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the ADD mark on the dip-
stick.
21 - 80 TRANSAXLE AND POWER TRANSFER UNITNS
SERVICE PROCEDURES (Continued)

been replaced, you must perform the differential
bearing preload shim adjustment. If the transaxle
case has been replaced, you must perform both pro-
cedures.
GENERAL RULES ON SERVICING BEARINGS
(1) Use extreme care when removing and install-
ing bearing cups and cones. Burrs or nicks on the
bearing seat will give a false end play reading while
gauging for proper shims. Improperly seated bearing
cups and cones are subject to low±mileage failure.
(2) Bearing cups and cones should be replaced if
they show signs of pitting or heat distress. If distress
is seen on either the cup or bearing rollers, both cup
and cone must be replaced.(3) Bearing preload and drag torque specifications
must be maintained to avoid premature bearing fail-
ures. Used (original) bearings may lose up to 50% of
their original drag torque after break in. All bearing
adjustments must be made with no other component
interference or gear intermesh.
(4) Replace bearings as a pair: If one differential
bearing is defective, replace both differential bear-
ings.
(5) Bearing cones must not be reused if removed.
(6) Turning torque readings should be obtained
while smoothly rotating in either direction.
INTERMEDIATE SHAFT BEARING PRELOAD
The intermediate shaft preload must be checked if
the housing, intermediate shaft, bearing plate, bear-
ings, or transaxle case are replaced.
The intermediate shaft bearing preload procedure
must be done with the transaxle out of the vehicle
and on a bench.
(1) Remove end cover (Fig. 226).
(2) Remove 5th shift fork roll pin (Fig. 227).
(3) Use Special Tool 6252 to hold 5th gear. Remove
input shaft 5th gear nut (Fig. 228).
(4) Remove 5th gear synchro snap ring (Fig. 229).
(5) Remove 5th gear synchro, synchro plate, and
fork.
(6) Remove 5th drive gear off of the input shaft
(Fig. 230).
(7) Remove bearing retainer plate (Fig. 231).
(8) Remove bearing preload shim (Fig. 232).
(9) Bolt down the bearing support plate in two
places (verify dowels are in place).
(10) Seat the intermediate bearing cup against the
bearing.
(11) Measure depth of intermediate bearing cup
with dial depth gauge (Fig. 233).
Fig. 224 Crossover Cable Adjustment
Fig. 225 Auxiliary Vent Installation
Fig. 226 End Cover Removed
NS/GSA±598 MANUAL TRANSAXLE 21 - 57
ADJUSTMENTS (Continued)

TIRES AND WHEELS
CONTENTS
page page
TIRES.................................. 1WHEELS................................ 9
TIRES
INDEX
page page
DESCRIPTION AND OPERATION
RADIAL-PLY TIRES....................... 2
REPLACEMENT TIRES.................... 3
SPARE TIRE (TEMPORARY)................ 2
TIRE INFLATION PRESSURES.............. 2
TIRE INFORMATION...................... 1
TIRE PRESSURE FOR HIGH-SPEED DRIVING . . 3
DIAGNOSIS AND TESTING
LEAD CORRECTION CHART................ 4
PRESSURE GAUGES..................... 3
TIRE NOISE OR VIBRATION................ 4TIRE WEAR PATTERNS.................... 4
TREAD WEAR INDICATORS................ 3
SERVICE PROCEDURES
REPAIRING TIRE LEAKS................... 6
TIRE AND WHEEL MATCH MOUNTING........ 6
TIRE AND WHEEL ROTATION (NON-
DIRECTIONAL THREAD PATTERN).......... 6
CLEANING AND INSPECTION
CLEANING TIRES........................ 7
SPECIFICATIONS
TIRE SPECIFICATIONS.................... 8
DESCRIPTION AND OPERATION
TIRE INFORMATION
Tires are designed and engineered for each specific
vehicle. They provide the best overall performance
for normal operation. The ride and handling charac-
teristics match the vehicle's requirements. With
proper care they will give excellent reliability, trac-
tion, skid resistance, and tread life.
Driving habits have more effect on tire life than
any other factor. Careful drivers will obtain, in most
cases, much greater mileage than severe use or care-
less drivers. A few of the driving habits which will
shorten the life of any tire are:
²Rapid acceleration
²Severe application of brakes
²High-speed driving
²Taking turns at excessive speeds
²Striking curbs and other obstacles
Radial ply tires are more prone to irregular tread
wear. It is important to follow the tire rotation inter-
val shown in the section on Tire Rotation. This will
help to achieve a greater tread-life potential.
TIRE IDENTIFICATION
Tire type, size, aspect ratio and speed rating are
encoded in the letters and numbers imprinted on the
side wall of the tire. Refer to the chart to decipher
the tire identification code (Fig. 1).
Performance tires will have a speed rating letter
after the aspect ratio number. The speed rating is not
always printed on the tire sidewall. The letterSindi-
cates that the tire is speed rated up to 112 mph.
²Qup to 100 mph
²Tup to 118 mph
²Uup to 124 mph
²Hup to 130 mph
²Vup to 149 mph
²Zmore than 149 mph (consult the tire manu-
facturer for the specific speed rating)
An All Season type tire will have eitherM+S,M
&SorM±S(indicating mud and snow traction)
imprinted on the side wall.
TIRE CHAINS
This vehicle was designed to allow the use of a
specified type of snow chain on the tires. Only com-
pact snow chains or other traction aidsmeeting SAE
type ªClass Sº specifications may be used.Any style
NSTIRES AND WHEELS 22 - 1

SERVICE PROCEDURES
TIRE AND WHEEL ROTATION (NON-DIRECTIONAL
THREAD PATTERN)
Tires on the front and rear axles operate at differ-
ent loads and perform different functions. For these
reasons, they wear at unequal rates, and tend to
develop irregular wear patterns. These effects can be
reduced by timely rotation of tires. The benefits of
rotation are especially worthwhile. Rotation will
increase tread life, help to maintain mud, snow, and
wet traction levels, and contribute to a smooth, quiet
ride.
The suggested rotation method is the forward-cross
tire rotation method (Fig. 6). This method takes
advantage of current tire industry practice which
allows rotation of radial-ply tires. Other rotation
methods may be used, but may not have all the ben-
efits of the recommended method.
NOTE: Only the 4 tire rotation method may be used
if the vehicle is equipped with a low mileage or tem-
porary spare tire.
REPAIRING TIRE LEAKS
For proper repairing, a radial tire must be removed
from the wheel. Before dismounting the tire from the
wheel, a reference mark should be placed on the tire
at the valve stem location. This reference mark will
ensure that the tire is remounted back on the wheel
in its original position. Repairs should only be made
if the defect, or puncture, is in the tread area (Fig.
7). The tire should be replaced if the puncture is
located in the sidewall.Deflate tire completely before dismounting tire
from the wheel. Use lubrication such as a mild soap
solution when dismounting or mounting tire. Use
tools free of burrs or sharp edges which could dam-
age the tire or wheel rim.
Before mounting tire on wheel, make sure all rust
is removed from the rim bead and repaint if neces-
sary.
Install wheel on vehicle, and progressively tighten
all 5 wheel nuts to a torque of 135 N´m (100 ft. lbs.).
TIRE AND WHEEL MATCH MOUNTING
Wheels and tires are match mounted at the factory.
This means that the high spot of the tire is matched
to the low spot on the wheel rim. This technique is
used to reduce run-out in the wheel/tire assembly.
The high spot on the tire is marked with a paint
mark or a bright colored adhesive label on the out-
board sidewall. The low spot on the rim is identified
with a label on the outside of the rim and a dot or
line on the inside of the rim. If the outside label has
been removed the tire will have to be removed to
locate the dot or line on the inside of the rim.
Before dismounting a tire from its wheel, a refer-
ence mark should be placed on the tire at the valve
stem location. This reference will ensure that it is
remounted in the original position on the wheel.
(1) Measure the total indicator runout on the cen-
ter of the tire tread rib. Record the indicator reading.
Mark the tire to indicate the high spot. Place a mark
on the tire at the valve stem location (Fig. 8).
(2) Break down the tire and remount it 180
degrees on the rim (Fig. 9).
(3) Measure the total indicator runout again. Mark
the tire to indicate the high spot.
Fig. 6 Forward-Cross Tire Rotation Method
Fig. 7 Tire Repair Area
22 - 6 TIRES AND WHEELSNS

WARNING: REPLACEMENT WITH USED WHEELS
IS NOT RECOMMENDED. THE SERVICE HISTORY
OF THE RIM MAY HAVE INCLUDED SEVERE TREAT-
MENT OR VERY HIGH MILEAGE. THE RIM COULD
FAIL WITHOUT WARNING.
TIRE AND WHEEL RUNOUT
NOTE: Runout should always be measured off the
vehicle and on a suitable balance machine.
Radial run out is the difference between the high
and low points on the outer edge of the tire or wheel.
Lateral run out is the total side±to±side wobble of
the tire or wheel.
Radial run out of more than 0.762 mm (.030 inch)
measured at the center line of the tread may cause
the vehicle to shake.
Lateral run out of more than 0.762 mm (.030 inch)
measured at the side of the tire as close to the tread
as possible may cause the vehicle to shake.
Sometimes radial run out can be reduced by relo-
cating the wheel and tire on the wheel studs (See
Method 1). If this does not reduce run out to an
acceptable level, the tire can be rotated on the wheel.
(See Method 2).
METHOD 1 (RELOCATE WHEEL ON HUB)
Check accuracy of the wheel mounting surface;
adjust wheel bearings.
Drive vehicle a short distance to eliminate tire flat
spotting from a parked position.
Verify all wheel nuts are properly torqued (Fig. 2).
Use run out gauge D-128-TR to determine run out
(Fig. 3).
Relocate the wheel on the mounting studs, two
studs over from the original position.
Retighten wheel nuts until all are properly
torqued. This will prevent brake distortion.Check radial run out. If still excessive, mark tire
sidewall, wheel, and stud at point of maximum run
out (Fig. 4) and proceed to Method 2.
METHOD 2 (RELOCATE TIRE ON WHEEL)
Rotating tire on wheel is particularly effective
when there is run out in both tire and wheel.
Remove tire from wheel and remount wheel on hub
in former position.
Check the radial run out of the wheel (Fig. 5). The
radial run out should be no more than 0.5 mm (0.020
inch) for steel wheels and 0.38 mm (0.015 inch) for
cast aluminum wheels.
Check the lateral run out of the wheel (Fig. 6). The
lateral runout should be no more than 0.8 mm (0.032
inch).
If the point of greatest wheel radial run out is near
the original chalk mark, remount the tire on the rim
180 degrees from its original position. Recheck the
run out. If this does not reduce the run out to an
acceptable level, replace the wheel and/or the tire.
Fig. 2 Tightening Wheel Nuts
Fig. 3 Run Out Gauge
Fig. 4 Chalk Marking On Wheel, Tire And Stud
22 - 10 TIRES AND WHEELSNS
DIAGNOSIS AND TESTING (Continued)

HEX
CODEGENERIC
SCAN
TOOL
CODEDRB SCAN TOOL
DISPLAYDESCRIPTION OF DIAGNOSTIC
TROUBLE CODE
20 P0134 Right Rear (or just) Upstream O2S
Stays at CenterNeither rich or lean condition detected from the
oxygen sensor.
21* Engine Is Cold Too Long Engine did not reach operating temperature within
acceptable limits.
23 P0500 No Vehicle Speed Sensor Signal No vehicle speed sensor signal detected during
road load conditions.
24 P0107 MAP Sensor Voltage Too Low MAP sensor input below minimum acceptable
voltage.
25 P0108 MAP Sensor Voltage Too High MAP sensor input above maximum acceptable
voltage.
27 P1297 No Change in MAP From Start to
RunNo difference recognized between the engine MAP
reading and the barometric (atmospheric) pressure
reading from start-up.
28* No Crank Reference Signal at PCM No crank reference signal detected during engine
cranking.
29 P0353 Ignition Coil #3 Primary Circuit Peak primary circuit current not achieved with
maximum dwell time.
2A P0352 Ignition Coil #2 Primary Circuit Peak primary circuit current not achieved with
maximum dwell time.
2B P0351 Ignition Coil #1 Primary Circuit Peak primary circuit current not achieved with
maximum dwell time.
2C* No ASD Relay Output Voltage at
PCMAn Open condition Detected In The ASD Relay
Output Circuit.
2E P0401 EGR System Failure Required change in air/fuel ratio not detected
during diagnostic test.
30* P1697 PCM Failure SRI Miles Not Stored Unsuccessful attempt to update EMR mileage in
the PCM EEPROM.
31 P1698 PCM Failure EEPROM Write
DeniedUnsuccessful attempt to write to an EEPROM
location by the PCM.
39 P0112 Intake Air Temp Sensor Voltage
LowIntake air temperature sensor input below the
maximum acceptable voltage.
3A P0113 Intake Air Temp Sensor Voltage
HighIntake air temperature sensor input above the
minimum acceptable voltage.
3C P0106 Barometric Pressure Out Of Range MAP sensor has a baro reading below an
acceptable value.
3D P0204 Injector #4 Control Circuit Injector #4 output driver does not respond properly
to the control signal.
3E P0132 Right Rear (or just) Upstream O2S
Shorted to VoltageOxygen sensor input voltage maintained above the
normal operating range.
44 P0600 PCM Failure SPI Communications PCM Internal fault condition detected.
45 P0205 Injector #5 Control Circuit Injector #5 output driver does not respond properly
to the control signal.
46 P0206 Injector #6 Control Circuit Injector #6 output driver does not respond properly
to the control signal.
NSEMISSION CONTROL SYSTEMS 25 - 5
DESCRIPTION AND OPERATION (Continued)