brake light CHRYSLER VOYAGER 1996 Workshop Manual

8W-45 BODY CONTROL MODULE
Component Page
A/C Heater Control..................8W-45-5, 6
Ash Receiver Lamp....................8W-45-5
Automatic Day/Night Mirror.............8W-45-8
Back-Up Switch.......................8W-45-9
Battery.............................8W-45-9
Body Control Module . .8W-45-2, 3, 4, 5, 6, 7, 8, 9, 10
BS02...............................8W-45-9
BS10...............................8W-45-8
BS30...............................8W-45-9
Clockspring..........................8W-45-3
Combination Flasher/DRL Module........8W-45-5
Controller Anti-Lock Brake..............8W-45-6
CS03...............................8W-45-8
Data Link Connector...................8W-45-3
Door Lock Relay......................8W-45-7
Door Unlock Relay....................8W-45-7
Driver Door Ajar Switch................8W-45-7
Driver Door Arm/Disarm Switch..........8W-45-8
Driver Door Lock Switch..............8W-45-6, 8
Driver Door Unlock Relay...............8W-45-7
Driver Power Mirror..................8W-45-10
Driver Power Window Switch............8W-45-6
Engine Coolant Temperature Sensor.......8W-45-9
Engine Oil Pressure Switch..............8W-45-7
ES01...............................8W-45-9
ES02...............................8W-45-9
Front Cigar Lighter/Power Outlet.........8W-45-5
Front Reading Lamps/Switch............8W-45-8
Front Wiper Switch....................8W-45-4
Fuel Tank Module...................8W-45-7, 9
Fuse 1 (JB)..........................8W-45-3
Fuse 2 (JB)..........................8W-45-2
Fuse 3 (JB)..........................8W-45-3
Fuse 6 (JB)..........................8W-45-2
Fuse 19 (PDC)........................8W-45-4
Fuse 22 (PDC)........................8W-45-3
Fuse 28 (PDC)........................8W-45-2
G100...............................8W-45-9
G103...............................8W-45-9
G300............................8W-45-2, 10
G302...............................8W-45-9
Glove Box Lamp......................8W-45-8
Headlamp Dimmer Switch..............8W-45-5
Headlamp Switch...............8W-45-2, 3, 4, 5
Hood Ajar Switch.....................8W-45-7
Horn Relay..........................8W-45-3
HVAC Control........................8W-45-6
Ignition Switch.....................8W-45-2, 5
Instrument Cluster....................8W-45-5
Junction Block...........8W-45-2, 3, 4, 5, 6, 7, 10
Key-In Halo Lamp....................8W-45-10Component Page
Left Mid Reading Lamp................8W-45-8
Left Rear Door Ajar Switch..............8W-45-8
Left Rear Reading Lamp................8W-45-8
Left Visor/Vanity Mirror Lamps..........8W-45-8
Liftgate Ajar Switch...................8W-45-7
Liftgate Arm/Disarm Switch.............8W-45-6
LJ01 B17..........................8W-45-4, 6
Low Beam Relay......................8W-45-5
Low Coolant Level Switch...............8W-45-9
Low Washer Fluid Switch...............8W-45-3
Memory Seat/Mirror Module...........8W-45-2, 6
Message Center.....................8W-45-5, 6
Park Lamp Relay.....................8W-45-3
Passenger Door Ajar Switch.............8W-45-7
Passenger Door Arm/Disarm Switch.......8W-45-8
Passenger Door Lock Switch...........8W-45-6, 8
Passenger Power Mirror...............8W-45-10
Passenger Power Window Switch.........8W-45-6
Power Distribution Center...........8W-45-2, 3, 4
Power Folding Mirror Switch...........8W-45-10
Power Mirror Fold Relay...............8W-45-10
Power Mirror Switch...................8W-45-5
Power Mirror Unfold Relay.............8W-45-10
Powertrain Control Module..............8W-45-9
PS01...............................8W-45-3
PS02...............................8W-45-3
PTC 3 (JB)..........................8W-45-7
Radio.............................8W-45-4, 5
Rear Blower Front Control Switch........8W-45-5
Rear Blower Rear Control Switch.........8W-45-6
Rear Washer Motor....................8W-45-4
Rear Wiper Motor.....................8W-45-4
Remote Keyless Entry Module...........8W-45-6
Right Mid Reading Lamp...............8W-45-8
Right Rear Door Ajar Switch.............8W-45-8
Right Rear Reading Lamp...............8W-45-8
Right Visor/Vanity Mirror Lamps.........8W-45-8
Seat Belt Switch......................8W-45-7
Traction Control Switch.................8W-45-5
Universal Garage Door Opener...........8W-45-6
Wiper Module........................8W-45-3
Wiper On Relay.......................8W-45-4
NS/GS8W - 45 BODY CONTROL MODULE 8W - 45 - 1

8W-50 FRONT LIGHTING
Component Page
Body Control Module.....8W-50-2, 9, 10, 11, 12, 13
BS15.............................8W-50-3, 6
BS16...............................8W-50-8
Combination Flasher/DRL
Module...................8W-50-2, 11, 12, 13
Courtesy Lamp Relay...............8W-50-9, 10
Dome Lamp Switch.................8W-50-9, 10
Fog Lamp Indicator.................8W-50-9, 10
Fog Lamp Relay....................8W-50-3, 5
Front Reading Lamps/Switch.........8W-50-9, 10
Fuse 1 (JB)......................8W-50-11, 12
Fuse 3 (JB)......................8W-50-11, 12
Fuse 4 (JB)..........................8W-50-7
Fuse 4 (PDC)...................8W-50-2, 3, 5, 6
Fuse 5 (JB)......................8W-50-11, 12
Fuse 5 (PDC)...................8W-50-2, 3, 4, 6
Fuse 6 (PDC)...................8W-50-2, 3, 5, 6
Fuse 7 (PDC)...................8W-50-2, 3, 4, 6
Fuse 10 (PDC)....................8W-50-11, 12
Fuse 12 (JB)........................8W-50-13
Fuse 22 (PDC)..................8W-50-7, 11, 12
G200..........................8W-50-2, 8, 13
G300..............8W-50-5, 6, 8, 9, 10, 11, 12, 13
G301......................8W-50-4, 6, 8, 11, 12
Headlamp Dimmer Switch..........8W-50-2, 5, 13
Headlamp Switch...............8W-50-7, 8, 9, 10Component Page
High Beam Relay..............8W-50-2, 3, 4, 5, 6
Ignition Switch......................8W-50-13
Illumination Lamp..................8W-50-9, 10
Junction Block......8W-50-2, 5, 7, 9, 10, 11, 12, 13
Left Fog Lamp....................8W-50-5, 6, 7
Left Front Park/Turn Signal Lamp. . . .8W-50-11, 12
Left Headlamp......................8W-50-3, 6
Left Headlamp Leveling Motor...........8W-50-8
Left High Headlamp.................8W-50-3, 5
Left Low Headlamp....................8W-50-5
Low Beam Relay..............8W-50-2, 3, 4, 5, 6
Message Center....................8W-50-3, 13
Park Brake Switch...................8W-50-13
Park Lamp Relay................8W-50-7, 11, 12
Power Distribution
Center.............8W-50-2, 3, 4, 5, 6, 7, 11, 12
Radio..............................8W-50-10
Rear Fog Lamp Indicator..............8W-50-10
Right Fog Lamp...................8W-50-5, 6, 7
Right Front Park/Turn Signal Lamp . . .8W-50-11, 12
Right Headlamp..................8W-50-3, 6, 8
Right Headlamp Leveling Motor..........8W-50-8
Right High Headlamp................8W-50-3, 4
Right Low Headlamp.................8W-50-3, 4
Right Rear Lamp Assembly.............8W-50-11
NS/GS8W - 50 FRONT LIGHTING 8W - 50 - 1

G300
6
4 ACC 0 OFF
3 LOCK 2 RUN 1 START
4
2
03
GY/BK20 G9
GY/BK20 G9MESSAGE
CENTER
9
BK20Z1PARK
BRAKE
SWITCH
14
G200
IGNITION
SWITCH
2C1
1C1 C3
89C3
10DRIVERLAMP WARNING RED BRAKE
1
COMBINATION
FLASHER/
DRL
MODULE
11
10A
FUSE
122BODY
CONTROL
MODULE
33C3
9
SWITCH) FUNCTION
MULTI-
(PART OF
SWITCH
DIMMER
HEADLAMPL93
22
PK
RUN A22
612
HIGH/LOW
BEAM
RELAY
CONTROL FUSED
IGNITION
(RUN)
GROUND
2C2
Z1
14
BK
G9
20
GY/BK
BLOCK JUNCTION
(8W-15-7)(8W-46-3)
(8W-15-4)(8W-10-14) (8W-12-12)
(8W-45-3)(8W-50-2)
(8W-10-14)
(8W-12-2)
(8W-12-17)
NS/GS8W-50 FRONT LIGHTING
DRL8W - 50 - 13
GS005013J988W-3

8W-80 CONNECTOR PIN-OUTS
Component Page
A/C Heater Control - C1................8W-80-5
A/C Heater Control - C2................8W-80-5
A/C Compressor Clutch.................8W-80-5
A/C Pressure Transducer (Gas)...........8W-80-6
A/C Pressure Transducer (Diesel).........8W-80-6
A/C Zone Door Actuator.................8W-80-6
Accelerator Pedal Position Sensor (Diesel) . .8W-80-6
Airbag Control Module - C1.............8W-80-6
Airbag Control Module - C2.............8W-80-7
All Wheel Drive Solenoid - C1............8W-80-7
All Wheel Drive Solenoid - C2............8W-80-7
Ambient Air Temperature Sensor.........8W-80-7
Ash Receiver Lamp (LHD)...............8W-80-8
Ash Receiver Lamp (RHD)..............8W-80-8
Automatic Day/Night Mirror.............8W-80-8
B09 HS5D...........................8W-80-9
B09S02.............................8W-80-9
B13AW4............................8W-80-9
B17 LJ01............................8W-80-9
B23P18............................8W-80-10
B23P34............................8W-80-11
B33 E120...........................8W-80-12
B33E36............................8W-80-12
B56 HS5P..........................8W-80-12
B56S02............................8W-80-12
B70E43............................8W-80-13
B75C20............................8W-80-13
B98T08............................8W-80-14
B99T05............................8W-80-14
Back-Up Switch......................8W-80-14
Blend Door Actuator..................8W-80-14
Body Control Module - C1..............8W-80-15
Body Control Module - C2..............8W-80-16
Brake Pressure Switch................8W-80-16
C19EC1 ...........................8W-80-17
Camshaft Position Sensor..............8W-80-17
Center Dome Lamp...................8W-80-17
Center High Mounted Stop Lamp........8W-80-17
Clockspring - C1.....................8W-80-18
Clockspring - C2.....................8W-80-18
Clutch Interlock Switch................8W-80-18
Clutch Interlock Switch Jumper.........8W-80-18
Clutch Switch.......................8W-80-18
Controller Anti-Lock Brake.............8W-80-19
Crank Case Heater...................8W-80-19
Crankshaft Position Sensor.............8W-80-19
D01D B02..........................8W-80-20
D01P B03..........................8W-80-20
D02B01 ...........................8W-80-20
D02 B120 (LHD).....................8W-80-21
D02 B120 (RHD).....................8W-80-21
Data Link Connector..................8W-80-22Component Page
Downstream Heated Oxygen Sensor......8W-80-22
Driver Door Arm/Disarm Switch.........8W-80-22
Driver Door Courtesy Lamp............8W-80-22
Driver Door Lock Motor................8W-80-23
Driver Door Lock Switch...............8W-80-23
Driver Heated Seat Back...............8W-80-23
Driver Heated Seat Cushion............8W-80-23
Driver Heated Seat Module.............8W-80-23
Driver Heated Seat Switch.............8W-80-24
Driver Power Mirror - C1..............8W-80-24
Driver Power Mirror - C2..............8W-80-24
Driver Power Seat Switch..............8W-80-25
Driver Power Window Switch...........8W-80-25
Driver Seat Front Vertical Motor.........8W-80-25
Driver Seat Horizontal Motor...........8W-80-25
Driver Seat Rear Vertical Motor.........8W-80-26
Driver Seat Recliner Motor.............8W-80-26
Driver Window Motor.................8W-80-26
E40RF3 ...........................8W-80-26
E69F09............................8W-80-27
E78F02............................8W-80-27
E95 B107...........................8W-80-27
E96 B108...........................8W-80-28
E97 B106...........................8W-80-28
EGR Solenoid (2.4L MTX/3.3L/3.8L)......8W-80-28
EGR Solenoid (Diesel).................8W-80-28
Electric Wiper De-Icer - C1.............8W-80-29
Electric Wiper De-Icer - C2.............8W-80-29
Engine Coolant Temperature Sensor
(Diesel)..........................8W-80-29
Engine Coolant Temperature Sensor
(Gas)............................8W-80-29
Engine Oil Pressure Switch.............8W-80-29
Engine Speed Sensor (Diesel)...........8W-80-30
Evap Leak Detection Pump
(Except Built-Up-Export).............8W-80-30
Evap/Purge Solenoid..................8W-80-30
Evaporator Temperature Sensor.........8W-80-30
Flexible Fuel Sensor..................8W-80-30
Front Blower Motor...................8W-80-31
Front Blower Motor Resistor Block.......8W-80-31
Front Cigar Lighter/Power Outlet........8W-80-31
Front Reading Lamps/Switch...........8W-80-32
Front Reading Lamps/Switch
(Overhead Console).................8W-80-32
Front Washer Motor..................8W-80-32
Fuel Heater.........................8W-80-32
Fuel Injector No. 1 (2.0L/2.4L)...........8W-80-33
Fuel Injector No. 1 (3.3L/3.8L)...........8W-80-33
Fuel Injector No. 2 (2.0L/2.4L)...........8W-80-33
Fuel Injector No. 2 (3.3L/3.8L)...........8W-80-33
Fuel Injector No. 3 (2.0L/2.4L)...........8W-80-33
NS/GS8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 1

Component/
GroundColor Location Fig.
Camshaft
Position Sensor
3.3L, 3.8LBK RT Side of
Engine9
Center Dome
LampBK At Lamp N/S
CHMSL RD Rear of CHMSL 21
Cigar Lighter BK Rear of Lighter 9
Clockspring C1 YL Rear of
Clockspring11
Clockspring C2 NAT Rear of
Clockspring11
Clutch Interlock
SwitchBK Top of Clutch
Pedal13
Controller
Anti-Lock BrakeBK RT Side of
Engine
CompartmentN/S
Crankcase Vent
HeaterAt Heater N/S
Crankshaft
Position SensorBK Rear of Engine 5, 6, 7,
9
D01 BK On Kick Panel 18
D02 BK On Kick Panel 18
Data Link
ConnectorBK LT of Steering
Column12
Downstream
Heated Oxygen
SensorBK Front Center of
Floor Pan16
Driver Airbag YL Rear of Airbag 11
E36 BK LT Frame Rail 2
E40 BK At Radiator Fan
ModuleN/S
E43 LT/GY LT Frame Rail 2
E69 BK LT Side of
Intake6, 7
E78 BK Near Throttle
Body9
EC1 Above RT
Vanity Mirror17
EGR Solenoid BK LT Rear of
Engine6, 9
Electric Wiper
De-Icer C1BK At Left Base of
Windshield11
Electric Wiper
De-Icer C2BK At Right Base
of Windshield11Component/
GroundColor Location Fig.
Engine Coolant
Temp Sensor
2.4LBK On Cylinder
BlockN/S
Engine Coolant
Temp Sensor
2.5BK On Cylinder
Head8
Engine Coolant
Temp Sensor
3.3L, 3.8LBK On Cylinder
BlockN/S
Engine Oil
Pressure SwitchGN On Cylinder
Block5, 6, 7,
8, 9
Engine Starter
MotorRear of Starter 5, 6, 7,
8, 9
EVAP/Purge
SolenoidBK RT Motor
Mount3
Evaporator
Temperature
SensorBK RT Side of
HVACN/S
F02 BK Near Throttle
Body9
F09 BK LT Side of
Intake6, 7
Front Blower
MotorBK At Motor 10
Front Blower
Motor Resistor
BlockBK RT Side Cowl 4
Front Cigar
LighterBK Rear of Lighter 9
Front Reading
Lamps/SwitchRD At Lamp 15
Front Washer
MotorBK Bottom of
Reservior4
Fuel Injection
PumpBK Near Pump 8
Fuel Injector #1 BK At Injector N/S
Fuel Injector #2 BK At Injector N/S
Fuel Injector #3 BK At Injector N/S
Fuel Injector #4 BK At Injector N/S
Fuel Injector #5 BK At injector N/S
Fuel Injector #6 BK At Injector N/S
Fuel Injectors
(2.0L)BK At Injectors 5
Fuel Pump
HeaterBK At Heater N/S
Fuel Pump
ModuleLT/GY Side of Fuel
Tank20
8W - 90 - 2 8W - 90 CONNECTOR/GROUND LOCATIONSNS/GS
DESCRIPTION AND OPERATION (Continued)

Component/
GroundColor Location Fig.
Message Center BL Rear of
Message
Center11
Mode Door
ActuatorBK LT Side of
HVAC15
Multi Function
SwitchBK Rear of Switch 11
Name Brand
Speaker RelayLT/GY LT of Steering
Column11
Needle
Movement
SensorBK Back of
Generator8
Output Shaft
Speed SensorGY Front of
Transmission7, 9
Overhead
ConsoleRD Front of
Console15
P18 GY RT of Steering
Column12
P25 BK RT of I.P
Center Stack10
P30 BK RT Side of
HVAC10
P34 GY RT of Steering
Column12
P50 NAT Right Side of
HVAC Unit
Taped to
Harness10
Park Brake
SwitchBK Top of Park
Brake13
Park/Neutral
Positon SwitchBK Front of
TransmissionN/S
Passenger
AirbagYL Rear of Airbag 11
PDC C1 NAT Bottom of PDC 2
PDC C2 OR Bottom of PDC 2
PDC C3 DK/
GNBottom of PDC 2
PDC C4 BK Bottom of PDC 2
PDC C5 LT/GY Bottom of PDC 2
PDC C6 LT/GN Bottom of PDC 3
PDC C7 LT/GY Bottom of PDC 3
PDC C8 BL Bottom of PDC 3
Power Folding
Mirror SwitchBK At Switch N/SComponent/
GroundColor Location Fig.
Power Mirror
SwitchBK Rear of Switch 11
Power Steering
Pressure SwitchBK RT Side of
Engine
CompartmentN/S
Powertrain
Control Module
C1BK LT Fender Side
Shield3
Powertrain
Control Module
C2BK LT Fender Side
Shield3
Radiator Fan
No.1BK At Motor N/S
Radiator Fan
No.2BK At Motor N/S
Radiator Fan
Solid State
RelayBK LT Front Frame
Rail3
Radio C1 GY Rear of Radio 11
Radio C2 BK Rear of Radio 11
Radio C3 BK Rear of Radio 11
Radio Choke LT/GY Rear of Radio N/S
Rear A/C-
Heater UnitLT/GN RT Quarter
Panel22
Rear Blower
Front Control
SwitchBK Rear of Switch 11
Rear Blower
Rear Control
SwitchBK At Switch N/S
Rear Cigar
Lighter/Power
OutletBK LT Quarter
Panel21
Rear Dome
LampBK At Lamp N/S
Rear Washer
MotorBK Bottom of
Reservior4
Rear Window
DefoggerBK On Liftgate 21
Rear Wiper
MotorBK At Motor 21
Recirculation
Door ActuatorNAT RT Side of
HVAC15
Remote Keyless
Entry ModuleRD Top Left of I.P. 11
RF3 BK At Radiator Fan N/S
NS/GS8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 5
DESCRIPTION AND OPERATION (Continued)

ENGINE ASSEMBLY
REMOVAL
(1) Disconnect the battery.
(2) Remove the air cleaner assembly and inlet
hose.
(3) Remove both hoses at intercooler and engine.
(4) Disconnect EGR vacuum hose.
(5) Disconnect brake booster vacuum hose.
(6) Disconnect oil pressure switch connector (Fig.
19).
(7) Disconnect Wiring harness bracket at transaxle
shift tower.
(8) Disconnect transaxle wiring at speed sensor,
crank sensor, and backup light switch.
(9) Remove both transmission shift cables at trans-
mission.
(10) Remove negative battery cable at cylinder
block (Fig. 19).
(11) Remove oil separator.
(12) Remove connectors at coolant temperature
sensor and A/C compressor.
(13) Disconnect fuel injection pump wiring connec-
tors (Fig. 19).
(14) Disconnect glow plug connectors.
(15) Disconnect electrical connector at number 1
fuel injector.
(16) Raise vehicle on hoist.
(17) Remove right side splash shield (Fig. 20).
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED. USE
CARE TO PREVENT SCALDING BY HOT COOLANT.CAREFULLY RELEASE THE PRESSURE BEFORE
REMOVING THE RADIATOR DRAIN COCK AND CAP.
(18) Drain the cooling system (refer to Group 7,
Cooling).
(19) Lower vehicle.
(20) Remove Coolant pressure bottle and discon-
nect low coolant level sensor.
(21) Disconnect both heater hoses.
(22) Remove the lower radiator hose.
(23) Remove the upper radiator hose.
(24) Remove fuel line at injector pump and cap.
(25) Remove power steering reservoir and reposi-
tion.
(26) Remove upper radiator crossmember.
(27) Disconnect cooling fan module connector.
Fig. 18 Shift Cables at Rear MountFig. 19 Component Locations
Fig. 20 Right Side Splash Shield
NS/GSENGINE 9 - 53
REMOVAL AND INSTALLATION (Continued)

AIR CONDITIONING (A/C) CONTROLSÐPCM
INPUTS
The A/C control system information applies to fac-
tory installed air conditioning units.
A/C REQUEST SIGNAL:When either the A/C or
Defrost mode has been selected and the A/C low and
high±pressure switches are closed, an input signal is
sent to the powertrain control module (PCM). The
PCM uses this input to cycle the A/C compressor
through the A/C relay.
If the A/C low or high±pressure switch opens, the
PCM will not receive an A/C request signal. The
PCM will then remove the ground from the A/C relay.
This will deactivate the A/C compressor clutch. Also,
if the engine coolant reaches a temperature outside
normal of its normal range, or it overheats, the PCM
will deactivate the A/C clutch.
BRAKE SWITCHÐPCM INPUT
When the brake light switch is activated, the PCM
receives an input indicating that the brakes are
being applied. After receiving this input, the PCM is
used to control the speed control system. There is a
Primary and a Secondary brake switch. The Second-
ary brake switch is closed until the brake pedal is
pressed.
DATA LINK CONNECTORÐPCM INPUT AND
OUTPUT
The 16±way data link connector (diagnostic scan
tool connector) links the Diagnostic Readout Box(DRB) scan tool with the PCM. The data link connec-
tor is located under the instrument panel near the
bottom of steering column (Fig. 7).
VEHICLE SPEED SENSORÐPCM INPUT
The vehicle speed sensor (Fig. 8) is located in the
extension housing of the transmission. The sensor
input is used by the PCM to determine vehicle speed
and distance traveled.
Fig. 6 Speed Sensor Operation
Fig. 7 Data Link Connector Location
Fig. 8 Vehicle Speed SensorÐTypical
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 47
DESCRIPTION AND OPERATION (Continued)

VEHICLE LEADS TO THE SIDE
POWER STEERING FLUID LEAK
CONDITION POSSIBLE CAUSES CORRECTION
STEERING WHEEL DOES NOT
WANT RETURN TO CENTER
POSITION.1. Radial tire lead. 1.Rotate tires as recommended in
the Tire And Wheel Group of this
service manual.
2. Front suspension misaligned. 2. Align the front suspension as
required. Refer to the Wheel
Alignment Procedure in the
Suspension Group of this service
manual for the required wheel
alignment procedure.
3. Wheel braking. 3. Check for dragging brakes. Refer
to the procedures in the Brake
Group of this service manual.
4. Unbalanced steering gear valve.
(If this is the cause, the steering
efforts will be very light in direction
of lead and heavier in the opposite
direction.4. Replace steering gear.
STEERING WHEEL HAS FORE
AND AFT LOOSENESS.1. Steering wheel to steering column
shaft retaining nut not properly
tightened and torqued.1. Tighten the retaining nut to its
specified torque specification.
2. Steering column lower bearing
spring retainer slipped on steering
column shaft.2. Replace steering column.
3. Loose steering column to
instrument panel mounting nuts.3. Verify that the 4 mounting nuts for
the steering column are tightened to
the specified torque.
4. Binding intermediate steering
shaft coupler.4. Disconnect intermediate steering
coupler and see if looseness no
longer exists. If yes replace
intermendiate steering coupler.
CONDITION POSSIBLE CAUSES CORRECTION
LOW FLUID LEVEL WITH: NO
VISIBLE SIGNS OF A LEAK ON
THE STEERING GEAR, POWER
STEERING PUMP, FLOOR OR
ANYWHERE ELSE.1. Overfilled power steering pump
fluid reservoir.1. Adjust the power steering fluid fill
to the correct level.
LOW FLUID LEVEL WITH:
VISIBLE LEAK ON STEERING
GEAR, POWER STEERING
PUMP, FLOOR OR ANYWHERE
ELSE.2. Power steering hose connections
at the power steering pump or
steering gear.2. Check for loose fittings and if
found, tighten the fitting to its
specified torque. If fittings are tight
examine the fittings for damaged or
missing O-ring seals and replace as
required.
3. Power steering pump or power
steering gear leaking.3. Identify the location of the leak
and repair or replace the component
as required. Refer to Power Steering
Pump and/or Power Steering Gear in
this group of the service manual for
required procedures.
NSSTEERING 19 - 7
DIAGNOSIS AND TESTING (Continued)

(13) Remove the pan and clean all sealant from
the pan and transaxle mating surfaces. Clean the
magnet and the inside of the pan.
(14) Separate the filter from the valve body to
allow additional fluid to drain from the transaxle.
Inspect the filter O-ring for any damage and replace
as necessary.
(15) After the transaxle has stopped draining,
reinstall the filter and O-ring.
(16) 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.).
(17) Lower the vehicle and add 4 Quarts of Mopar
ATF Plus 3 Type 7176 transaxle fluid.
(18) 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.
(19) 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.
(20) Recheck the fluid level after the transaxle is
at normal operating temperature. The level should be
in the HOT range.
FLUID DRAIN AND REFILL
(1) Raise vehicle on a hoist (See Group 0, Lubrica-
tion). Place a drain container with a large opening,
under transaxle oil pan.
(2) Loosen pan bolts and tap the pan at one corner
to break it loose allowing fluid to drain, then remove
the oil pan.
(3) Install a new filter and gasket on bottom of the
valve body and tighten retaining screws to 5 N´m (40
inch-pounds).
(4) Clean the oil pan and magnet. Reinstall pan
using new sealant. Tighten oil pan bolts to 19 N´m
(165 in. lbs.).
(5) Pour four quarts of Mopar ATF PLUS 3 (Auto-
matic Transmission Fluid) Type 7176 through the
dipstick opening.
(6) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(7) Add sufficient fluid to bring level to 1/8 inch
below the ADD mark.
(8) Recheck fluid level after transaxle is at normal
operating temperature. The level should be in the
HOT region.
ALUMINUM THREAD REPAIR
Damaged or worn threads in the aluminum transaxle
case and valve body can be repaired by the use of Heli-
Coils, or equivalent. This repair consists of drilling out
the worn-out damaged threads. Then tapping the hole
with a Heli-Coil tap, or equivalent, and installing a
Heli-Coil insert, or equivalent, into the hole. This
brings the hole back to its original thread size.
Heli-Coil, or equivalent, tools and inserts are readily
available from most automotive parts suppliers.
FLUSHING COOLERS AND TUBES
When a transaxle failure has contaminated the
fluid, the oil cooler(s) must be flushed. The cooler
bypass valve in the transaxle must be replaced also.
The torque converter must also be replaced with an
exchange unit. This will ensure that metal particles
or sludged oil are not later transferred back into the
reconditioned (or replaced) transaxle.
The recommended procedure for flushing the cool-
ers and tubes is to use Tool 6906A Cooler Flusher.
WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.1±1968. WEAR STANDARD INDUSTRIAL RUB-
BER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
COOLER FLUSH USING TOOL 6906A
(1) Remove cover plate filler plug on Tool 6906A.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Flushing solvents are petroleum based solutions gen-
erally used to clean automatic transmission compo-
nents.DO NOTuse solvents containing acids, water,
gasoline, or any other corrosive liquids.
(2) Reinstall filler plug on Tool 6906A.
(3) Verify pump power switch is turned OFF. Con-
nect red alligator clip to positive (+) battery post.
Connect black (-) alligator clip to a good ground.
(4) Disconnect the cooler lines at the transmission.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
21 - 18 TRANSAXLE AND POWER TRANSFER UNITNS
SERVICE PROCEDURES (Continued)