AUX CHRYSLER VOYAGER 1996 Service Manual

the end of the threads turn back 1/8 turn and, pull
the stem (Fig. 30) from the radiator tank.
INSTALLATION
(1) Push the draincock assembly body into the
tank opening until it snaps into place.
(2) Tighten the draincock stem by turning clock-
wise until it stops.
FAN MODULE
REMOVAL
There are no repairs to be made to the fan or
shroud assembly. If the fan is warped, cracked, or
otherwise damaged, it must be replaced as a assem-
bly (Fig. 31).
(1) Raise the vehicle on hoist.
(2) Remove the radiator outlet hose from hose
retaining clip and remove clip from shroud.
(3) Remove lower auxiliary transmission cooler
lines from retaining clips on the fan module shroud,
if equipped.
(4) Lower the vehicle. Remove the air intake res-
onator from the throttle body and air cleaner assem-
bly.
(5) Disconnect the fans electrical connector
located on the left side of the fan module.
(6) Remove the Coolant Recovery System (CRS)
attaching screw from the upper crossmember.
(7) Remove upper grill to crossmember valence
panel.
(8) Disconnect the upper radiator mounts from the
crossmember. Remove the upper crossmember. Refer
to Group 23 Body for procedure.
(9) Remove the air cleaner assembly.
(10) Remove fan module retaining fasteners (Fig.
31).
(11) Remove upper auxiliary transmission cooler
lines from retaining clips on the fan module shroud,
if equipped.(12) Disconnect and plug the transmission line
from the radiator fitting on the lower left side.
(13) Raise vehicle on the hoist and remove the fil-
ter/drier, fan module and radiator mounting bolts
located on the lower right of the module.
(14) Lower the vehicle on hoist and remove the
upper fan module to radiator retaining clips.
(15) Remove the fan module from the vehicle.
INSTALLATION
(1) Install fan module assembly into attaching
clips on the radiator.
(2) Install the upper fan module to radiator
retaining clips.
(3) Raise vehicle on the hoist and install the fil-
ter/drier, fan module and radiator mounting fasten-
ers located on the lower right of the module.
(4) Lower the vehicle. Connect the transmission
line to the radiator fitting on the lower left side.
(5) Install the upper auxiliary transmission cooler
lines to the retaining clips on the fan module shroud,
if equipped.
(6) Install fan module retaining fasteners (Fig.
31). Tighten to 12 N´m (105 in. lbs.).
(7) Install the air cleaner assembly.
(8) Install the crossmember. Refer to Group 23
Body for procedure. Connect the upper radiator
mounts to the crossmember. Tighten fasteners to 12
N´m (105 in. lbs.).
(9) Install the Coolant Recovery System (CRS)
attaching screw to the upper crossmember. Tighten
to 2 N´m (18 in. lbs.).
(10) Install upper grill to crossmember valence
panel.
(11) Connect the fans to the connector located on
the left side of the fan module.
(12) Install the air intake resonator to the throttle
body and air cleaner assembly.
Fig. 30 Draincock Disassembled
Fig. 31 Fan Module
7 - 22 COOLING SYSTEMNS
REMOVAL AND INSTALLATION (Continued)

(13) Raise the vehicle. Install the lower auxiliary
transmission cooler lines to the retaining clips on the
fan module shroud, if equipped.
(14) Install outlet hose retainer clip to the shroud.
Install the radiator outlet hose to the retaining clip.
(15) Lower the vehicle.
ENGINE BLOCK HEATER
REMOVAL
(1) Drain coolant from radiator and cylinder block.
Refer to Cooling System Drain, Clean, Flush and
Refill of this section for procedure.
(2) Remove power cord plug from heater.
(3) Loosen screw in center of heater. Remove
heater assembly.
INSTALLATION
(1) Thoroughly clean core hole and heater seat.
(2) Insert heater assembly with element loop posi-
tionedupward.
(3) With heater seated, tighten center screw
securely to assure a positive seal.
(4) Fill cooling system with coolant to the proper
level, vent air, and inspect for leaks. Pressurize sys-
tem with Radiator Pressure Tool before looking for
leaks.
(5) Install power cord plug to heater.
ACCESSORY DRIVE BELTSÐ2.4L
REMOVAL/INSTALLATION-ADJUST
GENERATOR AND AIR CONDITIONING
(1) Loosen lower generator pivot bolt and upper
locking nut, then loosen adjusting bolt (Fig. 32) to
remove belt tension.
CAUTION: Belt damage may occur if the following
procedure is not performed.
(2) Tighten lock nut to 21 N´m (180 in. lbs.) and
torque generator pivot bolt to 54 N´m (40 ft. lbs.). To
assure proper alignment of generator assembly.
Adjust belt tension by tightening the adjusting bolt
until proper belt tension is obtained. Refer to tension
specification in Belt Tension Chart.
(3) Torque lock nut to 54 N´m (40 ft. lbs.).
POWER STEERING PUMP
(1) From on top of the vehicle loosen locking nuts
D and F (Fig. 33).
(2) From under the vehicle loosen the pivot bolt E.
Loosen adjusting bolt G until belt can be removed.
(3) After installing a new belt, adjust belt tension
by tightening the adjusting bolt until the proper ten-sion obtained. Refer to tension specification in Belt
Tension Chart.
(4) Tighten locking nuts D and F to 54 N´m (40 ft.
lbs.).
(5) Tighten pivot bolt E to 54 N´m (40 ft. lbs.)
Fig. 32 Air Conditioning Compressor/Generator
BeltsÐ2.4L
Fig. 33 Power Steering Pump Adjustment
NSCOOLING SYSTEM 7 - 23
REMOVAL AND INSTALLATION (Continued)

REVERSE SHIFT LEVER
REMOVAL
(1) Remove reverse shift lever E-clip.
(2) Remove the flat and wave washers.
(3) Remove the reverse shift lever from the mount-
ing stud.
INSTALLATION
(1) Position the reverse shift lever onto the mount-
ing stud.
(2) Install the washers onto the mounting stud.
(3) Install the E-clip.
CLEANING AND INSPECTION
TRANSAXLE
Clean the gears, bearings, shafts, synchronizers,
thrust washers, oil feeder, shift mechanism, gear
case, and bellhousing with solvent. Dry all parts
except the bearings with compressed air. Allow thebearings to either air dry or wipe them dry with
clean shop towels.
Inspect the gears, bearings, shafts and thrust
washers. Replace the bearings and cups if the rollers
are worn, chipped, cracked, flat spotted, or brin-
nelled, or if the bearing cage is damaged or distorted.
Replace the thrust washers if cracked, chipped, or
worn. Replace the gears if the teeth are chipped,
cracked, or worn thin. Inspect the synchronizers.
Replace the sleeve if worn or damaged in any way.
Replace the stop rings if the friction material is
burned, flaking off, or worn. Check the condition of
the synchro struts and springs. Replace these parts if
worn, cracked, or distorted.
SYNCHRONIZER
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.
INSPECT
Proper inspection of components involve:
²Teeth, for wear, scuffed, nicked, burred, or bro-
ken teeth
²Struts, for wear or distortion
²Springs, for distortion, cracks, or wear
If any of these conditions exist in these compo-
nents, replace as necessary.
ADJUSTMENTS
GEARSHIFT CROSSOVER CABLE
Before replacing the gearshift cables for a hard-
shifting complaint, disconnect both cables at the
transaxle. Then, from the driver's seat, manually
operate the gearshift lever through all gear ranges. If
the gearshift lever moves smoothly, the cable(s)
should NOT be replaced. If the gear lever binds
replace the cable that is causing the binding condi-
tion. If the problem still exists, check the crossover
cable adjustment (Fig. 210).
(1) Working over the left front fender, remove the
auxiliary vent from the selector shaft housing (Fig.
211).
(2) Locate the gearshift lock pin that has been
included in the new vehicle packet located in the
glove box.
(3) Place transaxle gearshift in the neutral posi-
tion.
(4) Insert lock pin (so long end is down) into same
threaded hole (Fig. 212). A hole in the selector shaft
will align with the lock pin, allowing the lock pin to
Fig. 208 Slide Hammer 3752
Fig. 209 Shift Rail Bushing Removal
21 - 52 A±598 MANUAL TRANSAXLENS/GS
DISASSEMBLY AND ASSEMBLY (Continued)

be screwed into the housing. This operation locks the
selector shaft in the 3-4 neutral position.
(5) Remove gearshift knob (Fig. 213).
(6) Remove gearshift boot (Fig. 214).
(7) Remove gearshift console screws and remove
the console (Fig. 215).
(8) Loosen crossover cable adjustment screw.
(9) Verify gearshift mechanism is in the neutral
position.CAUTION: Be sure crossover bellcrank does NOT
move when tightening adjusting screw.
Fig. 210 Gearshift Mechanism
Fig. 211 Auxiliary Vent Removal
Fig. 212 Lock Pin Installation
NS/GSA±598 MANUAL TRANSAXLE 21 - 53
ADJUSTMENTS (Continued)

(10) Tighten crossover cable adjuster to 8 N´m (70
in. lbs.) (Fig. 216).CAUTION: Proper torque to the crossover cable
adjusting screw is very important.
(11) Remove lock pin from gearshift housing. Rein-
stall auxiliary vent in gear shift housing (Fig. 217).
Tighten auxiliary vent to 8 N´m (70 in. lbs.).
(12) Check for shift into first and reverse.
(13) Gearshift mechanism and cables are now
functioning properly.
(14) Install gearshift console.
(15) Install gearshift boot.
(16) Install gearshift knob.
(17) Stow gearshift lock pin in glove packet.
Fig. 213 Gearshift Knob
Fig. 214 Gearshift Boot
Fig. 215 Gearshift Console
Fig. 216 Crossover Cable Adjustment
Fig. 217 Auxiliary Vent Installation
21 - 54 A±598 MANUAL TRANSAXLENS/GS
ADJUSTMENTS (Continued)

GEARSHIFT CROSSOVER CABLE
Before replacing the gearshift cables for a hard-
shifting complaint, disconnect both cables at the
transaxle. Then, from the driver's seat, manually
operate the gearshift lever through all gear ranges. If
the gearshift lever moves smoothly, the cable(s)
should NOT be replaced. If the gear lever binds
replace the cable that is causing the binding condi-
tion. If the problem still exists, check the crossover
cable adjustment (Fig. 218).
(1) Working over the left front fender, remove the
auxiliary vent from the selector shaft housing (Fig.
219).
(2) Locate the gearshift lock pin that has been
included in the new vehicle packet located in the
glove box.
(3) Place transaxle gearshift in the neutral posi-
tion.
(4) Insert lock pin (so long end is down) into same
threaded hole (Fig. 220). A hole in the selector shaft
will align with the lock pin, allowing the lock pin to
be screwed into the housing. This operation locks the
selector shaft in the 3-4 neutral position.
(5) Remove gearshift knob (Fig. 221).
(6) Remove gearshift boot (Fig. 222).
(7) Remove gearshift console screws and remove
the console (Fig. 223).(8) Loosen crossover cable adjustment screw.
(9) Verify gearshift mechanism is in the neutral
position.
CAUTION: Be sure crossover bellcrank does NOT
move when tightening adjusting screw.
Fig. 218 Gearshift Mechanism
Fig. 219 Auxiliary Vent Removal
NS/GSA±598 MANUAL TRANSAXLE 21 - 55
ADJUSTMENTS (Continued)

(10) Tighten crossover cable adjuster to 8 N´m (70
in. lbs.) (Fig. 224).
CAUTION: Proper torque to the crossover cable
adjusting screw is very important.
(11) Remove lock pin from gearshift housing. Rein-
stall auxiliary vent in gear shift housing (Fig. 225).
Tighten auxiliary vent to 8 N´m (70 in. lbs.).
(12) Check for shift into first and reverse.
(13) Gearshift mechanism and cables are now
functioning properly.
(14) Install gearshift console.
(15) Install gearshift boot.
(16) Install gearshift knob.(17) Stow gearshift lock pin in glove packet.
BEARING ADJUSTMENT PROCEDURE
The A-598 (T-750) transaxle has two bearing
adjustment procedures that must be performed if the
transaxle case or related components have been
replaced. If the intermediate shaft, and/or bearing
cups and cones have been replaced, you must per-
form the intermediate shaft preload shim adjust-
ment. If the differential case, cups or cones have
Fig. 220 Lock Pin Installation
Fig. 221 Gearshift Knob
Fig. 222 Gearshift Boot
Fig. 223 Gearshift Console
21 - 56 A±598 MANUAL TRANSAXLENS/GS
ADJUSTMENTS (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)

GENERAL INFORMATION
INTRODUCTION
Both the heater and the heater/air conditioning
systems share many of the same components. This
group will deal with both systems together when
component function is common, and separately when
they are not.
For proper operation of the instrument panel con-
trols, refer to the Owner's Manual provided with the
vehicle.
All vehicles are equipped with a common A/C-
heater unit housing assembly. When the vehicle has
only a heater system, the evaporator and recirculat-
ing air door are omitted.
An optional zone control HVAC unit is available.
This unit has dual blend-air doors that can be regu-
lated independently of each other. The temperature
setting can be different from driver's side to passen-
ger side. There is also a rear (aux.) heating and A/C
system available when the vehicle is equipped with
zone control.
SAFETY PRECAUTIONS AND WARNINGS
WARNING: WEAR EYE PROTECTION WHEN SER-
VICING THE AIR CONDITIONING REFRIGERANT
SYSTEM. SERIOUS EYE INJURY CAN RESULT
FROM EYE CONTACT WITH REFRIGERANT. IF EYE
CONTACT IS MADE, SEEK MEDICAL ATTENTION
IMMEDIATELY.
DO NOT EXPOSE REFRIGERANT TO OPEN
FLAME. POISONOUS GAS IS CREATED WHEN
REFRIGERANT IS BURNED. AN ELECTRONIC TYPE
LEAK DETECTOR IS RECOMMENDED.
LARGE AMOUNTS OF REFRIGERANT RELEASED
IN A CLOSED WORK AREA WILL DISPLACE THE
OXYGEN AND CAUSE SUFFOCATION.
THE EVAPORATION RATE OF REFRIGERANT AT
AVERAGE TEMPERATURE AND ALTITUDE IS
EXTREMELY HIGH. AS A RESULT, ANYTHING THAT
COMES IN CONTACT WITH THE REFRIGERANT
WILL FREEZE. ALWAYS PROTECT SKIN OR DELI-
CATE OBJECTS FROM DIRECT CONTACT WITH
REFRIGERANT. R-134a SERVICE EQUIPMENT OR
VEHICLE A/C SYSTEM SHOULD NOT BE PRES-
SURE TESTED OR LEAK TESTED WITH COM-
PRESSED AIR.
SOME MIXTURES OF AIR and R-134a HAVE BEEN
SHOWN TO BE COMBUSTIBLE AT ELEVATED
PRESSURES. THESE MIXTURES ARE POTENTIALLY
DANGEROUS AND MAY RESULT IN FIRE OR
EXPLOSION CAUSING INJURY OR PROPERTY
DAMAGE.
ANTIFREEZE IS AN ETHYLENE GLYCOL BASE
COOLANT AND IS HARMFUL IF SWALLOWED ORINHALED. SEEK MEDICAL ATTENTION IMMEDI-
ATELY IF SWALLOWED OR INHALED. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN AND PETS.
DO NOT OPEN A COOLING SYSTEM WHEN THE
ENGINE IS AT RUNNING TEMPERATURE. PER-
SONAL INJURY CAN RESULT.
CAUTION: The engine cooling system is designed
to develop internal pressure of 97 to 123 kPa (14 to
18 psi). Allow the vehicle to cool a minimum of 15
minutes before opening the cooling system. Refer
to Group 7, Cooling System.
DESCRIPTION AND OPERATION
AIR DISTRIBUTION DUCTS
The air distribution ducts for the A/C, Heater,
Defroster, and Second Seating Air Distribution are
not serviceable in vehicle. The procedures for service
of these ducts are covered in Group 8E, Instrument
Panel and Gauges.
The only ducts that are serviceable in the vehicle
are the side window demister ducts and the ducts
that feed the front door outlets for the first rear pas-
senger(s) seating. To service the door ducts refer to
Group 23, Body.
A/C PRESSURE TRANSDUCER
The A/C Pressure Transducer (Fig. 1) monitors the
refrigerant gas pressure on the high side of the sys-
tem. The transducer is located on the liquid line. The
pressure transducer turns off the voltage to the com-
pressor clutch coil when refrigerant gas pressure
drops to levels that could damage the compressor.
The transducer also is used to adjust condenser fan
speeds and will turn off compressor at high refriger-
ant pressures. The pressure transducer is a sealed
factory calibrated unit. It must be replaced if defec-
tive. O-ring replacement is required whenever the
pressure transducer is serviced. Be sure to use the
O-ring specified for the transducer.
A/C SERVICE PORTS
The A/C service port valve cores are located within
the A/C lines (Fig. 2). The High Side (Discharge)
valve service port is located on the liquid line near
the right frame rail. The Low Side (Suction) valve
service port is located on the suction line near the
compressor.
24 - 2 HEATING AND AIR CONDITIONINGNS

REAR HEATING AND AIR CONDITIONING SYSTEM
INDEX
page page
GENERAL INFORMATION
INTRODUCTION......................... 41
DESCRIPTION AND OPERATION
REAR BLOWER RESISTOR BLOCK.......... 41
REAR HEATER AND A/C LINES............. 41
SYSTEM OPERATION.................... 41
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES............... 43
REMOVAL AND INSTALLATION
AIR DISTRIBUTION DUCT-A/C.............. 43
AIR DISTRIBUTION DUCT-HEATER.......... 43
EVAPORATOR AND EXPANSION VALVE...... 44MODE DOOR ACTUATOR................. 49
MODE DOOR........................... 49
REAR AIR CONDITIONING LINES........... 45
REAR HEATER A/C AIR OUTLETS........... 45
REAR HEATER A/C BLOWER MOTOR........ 46
REAR HEATER A/C UNIT.................. 46
REAR HEATER CORE.................... 48
REAR HEATER LINES.................... 49
REAR HEATER-A/C AUXILIARY CONDENSER . . 45
REAR HEATER-A/C CONTROL ILLUMINATION
BULB............................... 46
GENERAL INFORMATION
INTRODUCTION
For proper operation of the rear heating A/C sys-
tem, refer to Owner's Manual supplied with the vehi-
cle.
DESCRIPTION AND OPERATION
REAR BLOWER RESISTOR BLOCK
The rear blower motor resistor is not serviceable
separately. The resistor is integral to the blower
motor. If resistor is faulty, it is necessary to replace
the complete blower motor.
REAR HEATER AND A/C LINES
The rear heater and A/C lines are all serviced as
individual pieces. When disconnecting any line orblock ensure that the area around it is clean of any
contaminations that can get in to the system (Fig. 1),
(Fig. 2), (Fig. 4), (Fig. 3) and (Fig. 5).
SYSTEM OPERATION
The auxiliary rear heating-air/conditioning unit is
located in the right rear quarter panel. The rear
heater A/C control operates in conjunction with the
front heater A/C control. A four position two speed
blower (override) switch is located on the front
Heater A/C control panel (Fig. 6). The operator can
use the rear heater A/C blower switch to operate the
blower, regardless of the rear control setting. In the
OFF position, the rear control will not function. In
the ON (RR) position, the rear control will function
normally providing three speeds (Fig. 7). The mode
setting is controlled by the front A/C control panel.
Fig. 1 Rear Heater and A/C Lines
NSHEATING AND AIR CONDITIONING 24 - 41