steering CHRYSLER VOYAGER 1996 Manual PDF

LOCK KEY CYLINDER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove steering column cover retaining screws
(Fig. 3).
(3) Remove screws holding steering column
shrouds (Fig. 5) and remove lower shroud.
(4) Place key cylinder in RUN position. Depress
lock cylinder retaining tab and remove key cylinder
(Fig. 6).
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. 12).
(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.
IGNITION INTERLOCK
Refer to Group 21, Transaxle for Shifter/Ignition
Interlock Service.
LOCK CYLINDER HOUSING
Refer to Steering Column in Group 19, Steering,
for Lock Cylinder Housing Service.
Fig. 12 Socket in Lock Cylinder Housing
8D - 38 IGNITION SYSTEMNS
REMOVAL AND INSTALLATION (Continued)

INSTRUMENT PANEL AND SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION......................... 1
DESCRIPTION AND OPERATION
INSTRUMENT CLUSTER................... 1
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES................ 2
HEADLAMP SWITCH..................... 2
SELF DIAGNOSTIC TEST.................. 2
TRACTION CONTROL SWITCH............. 17
REMOVAL AND INSTALLATION
BODY CONTROL MODULE (BCM).......... 18
CONVENIENCE BIN - CUP HOLDER......... 17
CONVENIENCE BIN LAMP................ 17
CONVENIENCE BIN TRACK............... 18
GLOVE BOX LAMP AND SWITCH.......... 19
GLOVE BOX LOCK STRIKER.............. 20
GLOVE BOX........................... 19
HEADLAMP SWITCH LAMP(S)............ 21
HEADLAMP SWITCH.................... 20
HVAC CONTROL LAMP.................. 21
INSTRUMENT CLUSTER BACK PANEL...... 21
INSTRUMENT CLUSTER BEZEL............ 21
INSTRUMENT CLUSTER ELECTRONIC
ODOMETER AND TRANSMISSION RANGE
INDICATOR.......................... 19
INSTRUMENT CLUSTER LAMPS........... 22
INSTRUMENT CLUSTER LENS - MECHANICAL
TRANSMISSION RANGE INDICATOR
(PRND21)........................... 19
INSTRUMENT CLUSTER LENS............. 22INSTRUMENT CLUSTER PRINTED CIRCUIT
BOARD.............................. 23
INSTRUMENT CLUSTER SUBDIAL.......... 23
INSTRUMENT CLUSTER SUBDIALÐ
MECHANICAL TRANSMISSION RANGE
INDICATOR.......................... 23
INSTRUMENT CLUSTER WITH ELECTRONIC
TRANSMISSION RANGE INDICATOR...... 23
INSTRUMENT CLUSTER WITH MECHANICAL
TRANSMISSION RANGE INDICATOR...... 24
INSTRUMENT PANEL LEFT END COVER..... 27
INSTRUMENT PANEL LOUVERS........... 27
INSTRUMENT PANEL RIGHT END COVER.... 29
INSTRUMENT PANEL TOP COVER.......... 29
INSTRUMENT PANEL.................... 25
JUNCTION BLOCK...................... 30
KNEE BLOCKER REINFORCEMENT......... 30
LOWER CONSOLE...................... 30
LOWER INSTRUMENT PANEL............. 31
LOWER STEERING COLUMN COVER........ 31
MECHANICAL TRANSMISSION RANGE
INDICATOR.......................... 32
MESSAGE CENTER LAMP................ 32
MESSAGE CENTER...................... 32
OUTLET (12 VOLT) BASE................. 32
OVER STEERING COLUMN BEZEL.......... 32
POWER MIRROR SWITCH LAMP.......... 34
POWER MIRROR SWITCH................ 34
RADIO BEZEL AND HVAC CONTROL........ 34
REAR HEATER-A/C SWITCH LAMP......... 35
REAR HEATER-A/C SWITCH............... 35
TRACTION CONTROL SWITCH............. 35
GENERAL INFORMATION
INTRODUCTION
The instrumentation gauges on NS vehicles are
contained in a subdial assemblies within the instru-
ment cluster. The individual gauges are not serviced
separately. If one of the cluster gauges becomes
faulty the entire subdial would require replacement
and all gauges will have to be calibrated. Refer to the
proper Body Diagnostic Procedure Manual for cali-
bration procedures.
DESCRIPTION AND OPERATION
INSTRUMENT CLUSTER
The mechanical instrument cluster with a tachom-
eter is equipped with a electronic vacuum fluorescent
transmission range indicator (PRND3L), odometer,
and trip odometer display.
The mechanical instrument cluster without a
tachometer is equipped with a cable operated trans-
mission range indicator (PRND21).
NSINSTRUMENT PANEL AND SYSTEMS 8E - 1

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)

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)

(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)

(8) Using the indicator adjuster thumbwheel on
the indicator clip below the steering column. Rotate
the indicator thumbwheel to position the indicator
calibration arrow to the center of the N slot on the
instrument cluster mask.
(9) After the indicator has been properly adjusted,
move the shift lever through each gear position to
verify the appropriate gear position has been selected
and the slot is fully covered by the indicator. The left
edge of the indicator will just peek at the left edge of
the P slot in Park.
(10) If the indicator is not covering each of the
selected gear positions when selected, place the shift
lever back into neutral N and readjust the indicator.
Repeat the process until each gear is covered when
selected.
(11) Install the metal knee blocker panel.
(12) Install the lower steering column cover.
INSTRUMENT PANEL
The instrument panel is removed as a unit. The
steering column and wiring harnesses are assembled
into the panel before installation. Service procedures
for interior trim not related to the instrument panel
can be found in Group 23, Body.
REMOVAL
(1) Disconnect the battery, negative cable first.
(2) Remove the lower console.
(3) Remove the screw holding the lower heat duct
to the instrument panel support (Fig. 26).
(4) Disconnect the heat duct from the vehicle.
(5) Remove the bolts holding the lower supports to
the instrument panel frame (Fig. 27).(6) Remove the bolts holding the lower supports to
the floor pan.
(7) Remove the right and left end covers.
(8) Disconnect the wire connectors from the Pas-
senger Airbag Module.
(9) Remove the front door sill trim covers.
(10) Remove the A-pillar trim covers.
(11) Remove the glove box.
(12) Disconnect the antenna lead connector from
behind the glove box.
(13) Remove the lower steering column cover.
(14) Remove the knee blocker panel.
(15) Disconnect the lower two, forty pin wire har-
ness connectors, from the main Junction Block near
left cowl side panel (Fig. 28).
(16) Disconnect the instrument panel wire harness
connector from the bottom of Body Control Module.
(17) Disconnect the two forty pin connectors from
the right of the steering column (Fig. 29).
(18) Remove the clinch bolt holding upper the
steering shaft to the lower steering shaft (Fig. 29).
Fig. 25 Range Indicator Cable
Fig. 26 Heat Duct
Fig. 27 Lower Supports
NSINSTRUMENT PANEL AND SYSTEMS 8E - 25
REMOVAL AND INSTALLATION (Continued)

(19) Separate the upper steering shaft from the
lower steering shaft.
(20) Remove the nuts holding the instrument
panel frame to the die-cast brake pedal support on
each side of the steering column.
(21) With mechanical transmission range indica-
tor:
(a) Remove the indicator cable loop.(b) Remove the clip holding gear shift cable end
to the gear selector adapter.
(c) Pull the cable end from gear selector.
(d) Disconnect the clip for the indicator cable
and guide tube from the shift cable bracket and
move out of the way.
(22) Remove the nut holding gear shift cable
bracket to the instrument panel frame.
(23) Remove the bracket from the instrument
panel.
(24) Remove the screw holding hood release handle
to the instrument panel.
(25) Remove the bolt holding the hood release han-
dle to the instrument panel.
(26) Position the hood release handle out of the
way.
(27) Remove the instrument panel top cover.
(28) Disconnect the wire connector from the HVAC
wire harness behind the glove box area.
(29) Remove the bolts holding the instrument
panel frame to the brackets on cowl side panels (Fig.
30) and (Fig. 31).
(30) Loosen, but do not remove, the pivot bolts
holding the instrument panel to the cowl panels.
(31) Remove the bolts holding the instrument
panel frame to the dash panel below windshield
opening.
(32) Remove the instrument panel from vehicle.
INSTALLATION
For installation, reverse the above procedures.
Fig. 28 Junction Block and Body Control Module
Connectors
Fig. 29 40 Way Connectors Location
Fig. 30 Passenger Side Instrument Panel
8E - 26 INSTRUMENT PANEL AND SYSTEMSNS
REMOVAL AND INSTALLATION (Continued)

INSTRUMENT PANEL LEFT END COVER
REMOVAL
(1) Open driver side front door (Fig. 32).
(2) Remove lower steering column cover as neces-
sary to gain clearance for end cover removal.
(3) Remove attaching screw
(4) Disengage clips holding end cover to instru-
ment panel.(5) Remove instrument panel end cover and foam
pad covering the A/C inlet projection of the end cover
if equipped.
INSTALLATION
For installation, reverse the above procedures.
INSTRUMENT PANEL LOUVERS
CENTER LOUVER HOUSING
REMOVAL
(1) Remove the instrument cluster bezel. Refer to
Instrument Cluster Bezel removal and installation
procedures.
(2) Place cluster bezel on a clean surface face down
with the head lamp switch to the right side (Fig. 33).
(3) Using a flat bladed tool, release the louver
housing locks tabs (Fig. 34).
(4) Release the upper left lock tab first, then the
two lower louver tabs.
(5) Applying pressure on the housing, release the
upper right lock tab and the lower right.
(6) Push out the louver housing from the cluster
bezel.
INSTALLATION
(1) Verify the function of the vanes.
(2) Set louver housing into the cluster bezel.
(3) Using care do not push on the vanes, apply
pressure on outer edge of the housing and push lou-
ver housing into place.
(4) After in place check function of the vanes.
LEFT LOUVER HOUSING
REMOVAL
(1) Remove the instrument cluster bezel. Refer to
Instrument Cluster Bezel Removal and Installation
procedures.
Fig. 31 Driver's Side instrument Panel
Fig. 32 Instrument Panel Left End Cover
Fig. 33 Instrument Cluster Bezel
NSINSTRUMENT PANEL AND SYSTEMS 8E - 27
REMOVAL AND INSTALLATION (Continued)