CHRYSLER VOYAGER 1996 Service Manual

ELECTRONIC GEAR INDICATOR DISPLAY DIAGNOSIS
CONDITIONPOSSIBLE
CAUSESCORRECTION
NO DISPLAY 1. Internal Cluster
Failure.1. (a) Perform Cluster Self Diagnostic Test and check for fault
codes.
²If PRND3L passes the dim test and segment check and fault
codes 110 or 111 don't appear in the odometer display then
failure is not in the cluster. Look for another possible cause of
failure.
²If PRND3L doesn't work go to Step (b).
²If fault code 110 is displayed in the odometer, go to Step (b)
²If fault code 905 is displayed use a scan tool to check
electronic TCM.
(b) Remove cluster from instrument panel and verify that
PRND3L assembly is properly connected to main pc board. If
OK, go to Step (c). If not OK, reconnect PRND3L assembly to
main pc board.
(c) Replace PRND3L assembly. Go to Step (d).
(d) Connect cluster into instrument panel wiring harness.
Place it back into the proper position in the instrument panel.
DO NOT COMPLETELY INSTALL CLUSTER TO INSTRUMENT
PANEL UNTIL UNIT IS TESTED. Go to Step (e).
(e) Perform Self Diagnostic Test. If OK, continue installation. If
not OK, go to Step (f).
(f) Replace main cluster pc board and use a scan tool to
calibrate cluster. If not OK, look at another possible cause for
the PRND3L failure.
NSINSTRUMENT PANEL AND SYSTEMS 8E - 15
DIAGNOSIS AND TESTING (Continued)

CONDITIONPOSSIBLE
CAUSESCORRECTION
ERRATIC DISPLAY 1. Internal Cluster
Failure.1. (a) Perform Cluster Self Diagnostic Test and check for fault
codes.
²If PRND3L passes the dim test and segment check and fault
codes 110 or 111 don't appear in the odometer display then failure
is not in the cluster. Look for another possible cause of failure.
²If PRND3L doesn't work go to Step (b).
²If fault code 110 is displayed in the odometer, go to Step (f).
²If fault code 111 is displayed in the odometer display then use a
scan tool to calibrate cluster.
²If fault code 905 is displayed use a scan tool to check electronic
TCM.
(b) Remove cluster from instrument panel and verify that odometer
assembly is properly connected to main pc board. If OK, go to
Step (c). If not OK, reconnect PRND3L assembly to main pc board.
(c) Replace PRND3L assembly. Go to Step (d).
(d) Connect cluster into instrument panel wiring harness. Place it
back into the proper position in the instrument panel. DO NOT
COMPLETELY INSTALL CLUSTER TO INSTRUMENT PANEL
UNTIL UNIT IS TESTED. Go to Step (e).
(e) Perform Self Diagnostic Test. If OK, continue installation. If not
OK, go to Step (f).
(f) Replace main cluster pc board and use a scan tool to calibrate
cluster. If not OK, look at another possible cause for the PRND3L
failure.
2. Bad CCD Bus
Message from the
Electronic
Transmission
Control Module
(TCM).2. Use a scan tool to check the electronic TCM. Refer to the
electronic TCM section of the manual to properly diagnose and
repair.
ALL SEGMENTS
ARE ON1. No CCD bus
message from the
electronic
Transmission
Control Module
(TCM).1. (a) Perform Cluster Self Diagnostic test. If PRND3L passes test
go to Step (b). If PRND3L fails test go to Step (c).
(b) Check electronic TCM using a scan tool. Refer to the electronic
TCM section of the manual to properly diagnose and repair.
(c) Replace PRND3L assembly. Connect cluster into instrument
panel wiring harness. Place it back into the proper position in the
instrument panel. DO NOT COMPLETELY INSTALL CLUSTER TO
INSTRUMENT PANEL UNTIL UNIT IS TESTED. Go to Step (d).
(d) Perform Self Diagnostic Test. If OK, continue installation. If not
OK, go to Step (e).
(e) Replace main cluster pc board and use a scan tool to calibrate
cluster. If not OK, look at another possible cause for the PRND3L
failure.
8E - 16 INSTRUMENT PANEL AND SYSTEMSNS
DIAGNOSIS AND TESTING (Continued)

TRACTION CONTROL SWITCH
(1) Remove over steering column bezel. Refer to
Over Steering Column Bezel. Removal procedures.
(2) Using an ohmmeter check for continuity read-
ing between pins. Refer to Switch Continuity Table.
REMOVAL AND INSTALLATION
CONVENIENCE BIN - CUP HOLDER
REMOVAL
(1) Pull the convenience bin open (Fig. 3).
(2) Push lock tab at rear center downward.
(3) Pull the convenience bin - cup holder from
track in instrument panel.(4) Remove convenience bin - cup holder.
INSTALLATION
For installation, reverse the above procedures.
CONVENIENCE BIN LAMP
If the lamp is not used refer to (Fig. 4).
REMOVAL
(1) Pull out and remove the convenience bin - cup
holder. Refer to Convenience Bin - Cup Holder
removal in this section.
MECHANICAL TRANSMISSION RANGE INDICATOR (PRND21) DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
INDICATOR DOES NOT
SHOW PROPER GEAR
OR NO INDICATION.Mis-adjusted. 1. (a) Verify transmission shift system correctly
adjusted.
(b) Verify correct routing and attachment of PRNDL
cable and guide tube.
(c) Re-adjust PRNDL indicator in Neutral using adjuster
wheel below steering column.
INDICATOR DOES NOT
FOLLOW GEAR SHIFT
LEVER.Not attached. 1. (a) Verify indicator cable connected to shift lever pin
in the groove.
(b) Verify indicator clip secure and attached to steering
column/transmission shift cable bracket and clip not
broken. If broken, replace clip on indicator.
INDICATOR DOES NOT
MAKE FULL TRAVEL (ªPº
< > ª1º).1. Cable dislodged from
its path on the indicator
base.1. Verify correct attachment of indicator cable to shift
lever pin (under hoop of trans. shift cable) and clip onto
steering column/shift cable bracket.
2. Incorrect attachment of
cable to shift lever pin.2. Verify indicator travel by pulling on cable gently over
full travel range. If still problem, remove cluster and
lens to access indicator base and confirm cable path
per attached sketch.
Fig. 2 Traction Control Switch Connector
SWITCH CONTINUITY TABLE
SWITCH POSITION CONTINUITY BETWEEN
ACTUATED PINS 1 AND 3
ILLUMINATION PINS 2 AND 3
Fig. 3 Convenience Bin ± Cup Holder
NSINSTRUMENT PANEL AND SYSTEMS 8E - 17
DIAGNOSIS AND TESTING (Continued)

(2) Insert the trim stick (special tool #C-4755)
between access cover and radio bezel, above conve-
nience bin - cup holder.
(3) Carefully pry the access cover from the instru-
ment panel (Fig. 5).
(4) Separate the access cover from the vehicle.
(5) Using needle-nose pliers, carefully squeeze the
vertical metal legs of the lamp hood.
(6) Lift the lamp hood upward from the cup holder
tray.
(7) Carefully pull the lamp and wiring rearward
from the instrument panel (Fig. 6).
(8) Pull the lamp hood from the lamp socket.
(9) Pull bulb from socket.
INSTALLATION
For installation, for reverse the above procedures.
CONVENIENCE BIN TRACK
REMOVAL
(1) Remove the convenience bin - cup holder. Refer
to Convenience Bin - Cup Holder Removal and
Installation procedure in this section.
(2) Remove the screw access cover from the bottom
of the radio bezel (Fig. 5).(3) Remove the center bezel.
(4) Remove the convenience bin track attaching
screws and pull the convenience bin track rearward
to disengage the rear guide studs from instrument
panel (Fig. 7).
(5) Disengage the clip holding convenience bin
lamp to track.
(6) Remove the convenience bin track.
INSTALLATION
For installation, reverse the above procedures.
BODY CONTROL MODULE (BCM)
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove lower steering column cover and knee
blocker reinforcement.
Fig. 4 Unused Convenience Bin Lamp Socket
Location
Fig. 5 Convenience Bin Access Cover
Fig. 6 Convenience Bin Lamp Bulb
Fig. 7 Convenience Bin Track
8E - 18 INSTRUMENT PANEL AND SYSTEMSNS
REMOVAL AND INSTALLATION (Continued)

(3) Disconnect two wire connectors from bottom of
Body Control Module (BCM)
(4) Remove bolts holding Junction Block to dash
panel mounting bracket (Fig. 8).
(5) Remove Junction Block from mounting bracket.
(6) Remove screws holding Body Control Module to
Junction Block.
(7) Slide Body Control Module downward to disen-
gage guide studs on Junction Block from channels on
BCM mounting bracket.
(8) Remove Body Control Module from Junction
Block.
INSTALLATION
For installation, reverse the above procedures.
INSTRUMENT CLUSTER LENS - MECHANICAL
TRANSMISSION RANGE INDICATOR (PRND21)
REMOVAL
(1) Remove the instrument cluster and disconnect
the range indicator cable at both attaching points.
Refer to Instrument Cluster with Mechanical Trans-
mission Range Indicator Reval and Installation pro-
cedures.
(2) Remove the screws holding the cluster lens to
the rear shell from around perimeter of lens.
(3) Remove the lens from the cluster, guide the
shift indicator cable through cluster shell.
(4) Remove the screws holding the shift indicator
to the lens.
INSTALLATION
(1) Install the shift indicator and screws to cluster
lens.
(2) Position the lens on cluster and carefully guide
the shift indicator cable and guide through cluster
opening.
(3) Install the cluster lens and screws to the rear
shell around perimeter of lens.
(4) Install the instrument cluster.
INSTRUMENT CLUSTER ELECTRONIC ODOMETER
AND TRANSMISSION RANGE INDICATOR
REMOVAL
(1) Remove instrument cluster.
(2) Remove cluster lens.
(3) Disconnect wire connector from odometer and
transmission range indicator.
(4) Remove screws holding odometer and transmis-
sion range indicator to cluster shell.
(5) Remove odometer and transmission range indi-
cator from cluster.
INSTALLATION
(1) Install odometer and transmission range indi-
cator and attach to cluster shell.
(2) Connect wire connector into odometer and
transmission range indicator.
(3) Install cluster lens.
(4) Install instrument cluster.
GLOVE BOX
REMOVAL (FIG. 4)
(1) Open glove box (Fig. 9).
(2) Disengage clip holding checkstraps to glove box
door.
(3) Pivot glove box downward and disengage hinge
hooks from instrument panel.
(4) Remove glove box.
INSTALLATION
(1) Place glove box in position.
(2) Engage hinge hooks into instrument panel and
pivot glove box upward.
(3) Engage clip to hold checkstraps to glove box
door.
(4) Close glove box door.
GLOVE BOX LAMP AND SWITCH
REMOVAL
(1) Open glove box door (Fig. 10).
(2) Using a trim stick, lightly pry glove box lamp/
switch from instrument panel.
(3) Disengage wire connector from glove box lamp
and switch.
Fig. 8 Body Control Module Location
NSINSTRUMENT PANEL AND SYSTEMS 8E - 19
REMOVAL AND INSTALLATION (Continued)

(4) Remove glove box lamp and switch.
(5) Remove lamp (Fig. 11).
INSTALLATION
For installation, reverse the above procedures.
GLOVE BOX LOCK STRIKER
REMOVAL
(1) Open glove box door (Fig. 12).
(2) Disengage clip holding checkstraps to glove box
door.
(3) Remove screws holding lock striker to instru-
ment panel.
(4) Remove glove box lock striker.
INSTALLATION
For installation, reverse the above procedures.
HEADLAMP SWITCH
REMOVAL
(1) Remove instrument cluster bezel (Fig. 13).
(2) Remove screws holding the headlamp switch
bezel to cluster bezel.
(3) Disconnect the wire connectors from the head-
lamp switch and wire connector from the power mir-
ror switch.
(4) Remove headlamp switch bezel from cluster
bezel.
INSTALLATION
For installation, reverse the above procedures.
Fig. 9 Glove Box
Fig. 10 Glove Box Lamp and Switch
Fig. 11 Glove Box Lamp
Fig. 12 Glove Box Lock Striker
Fig. 13 Headlamp Switch
8E - 20 INSTRUMENT PANEL AND SYSTEMSNS
REMOVAL AND INSTALLATION (Continued)

HEADLAMP SWITCH LAMP(S)
REMOVAL
(1) Remove instrument cluster bezel.
(2) Disconnect wire connectors.
(3) Remove headlamp switch bezel from instru-
ment cluster bezel.
(4) Rotate bulb socket counterclockwise one quar-
ter turn (Fig. 14).
(5) Pull bulb socket from headlamp switch.
INSTALLATION
For installation, reverse the above procedures.
HVAC CONTROL LAMP
REMOVAL
(1) Remove radio bezel and HVAC Control (Fig.
15).
(2) Remove rear cover from HVAC control.
(3) Rotate bulb socket counterclockwise one quar-
ter turn.
(4) Pull bulb socket from HVAC.
INSTALLATION
For installation, reverse the above procedures.
INSTRUMENT CLUSTER BACK PANEL
REMOVAL
(1) Remove instrument cluster.
(2) Remove screws holding back panel to instru-
ment cluster (Fig. 16).
(3) Remove back panel.
INSTALLATION
For installation, reverse the above procedures.
INSTRUMENT CLUSTER BEZEL
REMOVAL
(1) Remove steering column cover.
(2) Remove over steering column bezel (Fig. 17).
(3) Remove left end cover.
(4) Remove screw at left end of cluster bezel and
headlamp switch.
Fig. 14 Headlamp Switch Lamp
Fig. 15 HVAC Control Lamps
Fig. 16 Instrument Cluster Back Panel
Fig. 17 Instrument Cluster Bezel
NSINSTRUMENT PANEL AND SYSTEMS 8E - 21
REMOVAL AND INSTALLATION (Continued)

(5) Remove screws holding cluster bezel to instru-
ment panel from each side of steering column.
(6) Disconnect clip holding cluster bezel to instru-
ment panel from above right vent louver.
(7) Separate cluster bezel from instrument panel.
(8) Disconnect wire connectors from back of the
bezel.
INSTALLATION
(1) Connect wire connectors into back of the bezel.
(2) Place cluster bezel in position on instrument
panel. Use care not to place hands on louvers.
(3) Connect clips to hold cluster bezel to instru-
ment panel. Use care not to add pressure on the A/C
louvers to seat the cluster bezel clips.
(4) Install screws to hold cluster bezel to instru-
ment panel on each side of steering column.
(5) Install screw at left end of cluster bezel and
headlamp switch.
(6) Install left end cover.
(7) Install over steering column bezel.
(8) Install lower steering column cover.
INSTRUMENT CLUSTER LAMPS
REMOVAL
(1) Remove the instrument cluster. Refer to Instru-
ment Cluster Removal procedure.
(2) Locate the lamp (Fig. 18).
(3) Remove the lamps from cluster with a 1/4 turn
twist.
INSTALLATION
For installation, reverse the procedures.
INSTRUMENT CLUSTER LENS
REMOVAL
(1) Remove the instrument cluster.
(2) Remove the screws holding the lens to the
instrument cluster (Fig. 19).
(3) Remove the lens from cluster.
INSTALLATION
For installation, reverse the procedures.
Fig. 18 Cluster Lamp Location
Fig. 19 Instrument Cluster Lens
8E - 22 INSTRUMENT PANEL AND SYSTEMSNS
REMOVAL AND INSTALLATION (Continued)

INSTRUMENT CLUSTER PRINTED CIRCUIT BOARD
REMOVAL
(1) Remove the instrument cluster.
(2) Remove the instrument cluster back panel.
(3) Disconnect the electronic cluster wire connector
from the printed circuit board (Fig. 20).
(4) Remove the screws holding wire connector
insulator to the instrument cluster shell and the
printed circuit board.
(5) Remove the screws holding printed circuit
board to the cluster shell.
(6) Remove the printed circuit board from the clus-
ter.
INSTALLATION
For installation, reverse the above procedures.
After installing the print circuit board it will have to
be calibrated using a scan tool (DRB III). Refer to the
proper Body Diagnostic Procedure Manual for cali-
bration procedures.
NOTE: Speedometer and/or Tachometer will not
operate properly until all gauges have been cali-
brated
INSTRUMENT CLUSTER SUBDIAL
REMOVAL
(1) Remove the instrument cluster.
(2) Remove the cluster lens.
(3) Disconnect the temperature/fuel gauge and the
tachometer terminals from the connectors in cluster
by pulling the subdial straight away from the cluster
(Fig. 21).
(4) Remove the subdial from the cluster.
INSTALLATION
For installation, reverse the above procedures.
INSTRUMENT CLUSTER SUBDIALÐMECHANICAL
TRANSMISSION RANGE INDICATOR
REMOVAL
(1) Remove instrument cluster.
(2) Remove screws holding cluster lens to the rear
shell from around perimeter of lens.
(3) Remove lens from cluster, guide shift indicator
cable through cluster shell.
(4) Remove gauge subdial from cluster.
INSTALLATION
(1) Position gauge subdial on cluster.
(2) Position lens on cluster, guide shift indicator
cable through cluster shell.
(3) Install cluster lens and screws to the rear shell
around perimeter of lens.
(4) Install instrument cluster.
INSTRUMENT CLUSTER WITH ELECTRONIC
TRANSMISSION RANGE INDICATOR
REMOVAL
(1) Remove instrument cluster bezel (Fig. 22).
(2) Remove screws holding instrument cluster to
instrument panel.
(3) Rotate top of cluster outward.
(4) Remove instrument cluster from instrument
panel.
(5) Disconnect wire connector from back of instru-
ment cluster.
(6) Remove instrument cluster.
INSTALLATION
(1) Place instrument cluster in instrument panel,
bottom first.
Fig. 20 Instrument Cluster Printed Circuit Board
Fig. 21 Instrument Cluster Subdial
NSINSTRUMENT PANEL AND SYSTEMS 8E - 23
REMOVAL AND INSTALLATION (Continued)

(2) Connect wire connector into back of instrument
cluster.
(3) Position instrument cluster in instrument
panel.
(4) Install instrument cluster mounting screws to
instrument panel.
(5) Install instrument cluster bezel.
INSTRUMENT CLUSTER WITH MECHANICAL
TRANSMISSION RANGE INDICATOR
REMOVAL
(1) Remove the lower steering column cover.
(2) Remove the metal knee blocker panel.
(3) Disconnect the transmission range indicator
cable end from shift lever by flexing the HOOP on
the transmission shift cable rearward and slip the
indicator cable loop off the lever pin (Fig. 23).
(4) Disconnect the clip holding the indicator cable
to the steering column/transmission shift cable
bracket.
(5) Remove the instrument cluster bezel.
(6) Rotate top of the cluster rearward.
(7) Disconnect the wire connector from back of the
instrument cluster.
(8) Remove the instrument cluster carefully while
guiding the range indicator cable and guide tube
through the opening to avoid any damage (Fig. 24).
INSTALLATION
(1) Verify the free travel of the range indicator
cable from P to 1 by gently pulling on the cable and
relaxing the cable. DO NOT SNAP THE CABLE
ONCE IT IS PULLED.
(2) Position the instrument cluster in instrument
panel and route the indicator cable and guide tube
through the opening in the instrument panel. Posi-tion the cluster by leading the bottom in first, con-
nect the wire connector, and rotate upward.
(3) Install the screws to hold the instrument clus-
ter to the instrument panel.
(4) Install the instrument cluster bezel.
(5) Connect the clip to hold the indicator cable to
steering column/transmission shift cable bracket. The
indicator cable and guide tube should BOW towards
the passenger side of the vehicle (Fig. 25).
(6) Connect indicator cable loop end to shift lever
by flexing the hoop on the transmission shift cable
rearward, then slip the indicator cable loop over the
shift lever pin and into the groove.
(7) Assuming the transmission shift system is
properly adjusted, place the shift lever in neutral N
position.
NOTE: The parking brake should have been
engaged for safety purposes.
Fig. 22 Instrument Panel ±Electronic Transmission
Range IndicatorFig. 23 Range Indicator
Fig. 24 Removing and Installing Cluster
8E - 24 INSTRUMENT PANEL AND SYSTEMSNS
REMOVAL AND INSTALLATION (Continued)