ECU CHRYSLER VOYAGER 2001 Service Manual

(13) Using a crowfoot wrench, remove the power
steering fluid pressure and return lines (Fig. 6) from
the power steering gear.(14) Remove the 3 bolts and nuts (Fig. 7) mount-
ing the steering gear to the front suspension cradle.
NOTE: The next step must be done to allow the
removal of the steering gear from the front suspen-
sion cradle. The steering gear can not be removed
from the vehicle with the intermediate coupler
attached to the steering gear.
(15) Lower steering gear from suspension cradle
enough to allow access to the intermediate coupler
roll pin (Fig. 8). Install Remover/Installer Special
Tool 6831A through the center of the roll pin, secur-
ing with the knurled nut (Fig. 8). Hold threaded rod
stationary while turning nut, this will pull the roll
pin out of the intermediate coupler.
(16) Separate the coupler from the shaft of the
steering gear.
Fig. 3 Removing/Installing Tie Rod End Attaching Nut
1 - TIE ROD END
2 - STEERING KNUCKLE
3 - WRENCH
4 - SOCKET
5 - TIE ROD END STUD
Fig. 4 TIE ROD REMOVAL WITH TOOL C-3894-A
1 - OUTER TIE ROD
2 - SPECIAL TOOL C-3894-A
3 - STEERING KNUCKLE
Fig. 5 CRADLE CROSSMEMBER REINFORCEMENT
ATTACHMENT
1 - STEERING GEAR
2 - RIGHT LOWER CONTROL ARM
3 - LEFT LOWER CONTROL ARM
4 - CRADLE CROSSMEMBER REINFORCEMENT
5 - REAR CRADLE CROSSMEMBER ISOLATOR BUSHING
6 - STABILIZER BAR
7 - CRADLE CROSSMEMBER
RSGEAR19-19
GEAR (Continued)

(17) Remove the steering gear assembly from the
vehicle.
INSTALLATION - GEAR
(1) Install the steering gear up in the front sus-
pension cradle, leaving room to install intermediate
coupler.
(2) Start the roll pin into the intermediate coupler
before installing coupler on steering gear shaft. Start
roll pin into coupler, using a hammer and tapping itinto the coupler. Then install the intermediate cou-
pler on the shaft of the steering gear.
(3) Install Remover/Installer Special Tool 6831A
through the center of the roll pin, securing it with
the knurled nut (Fig. 9). Hold threaded rod station-
ary while turning nut, this will pull the roll pin into
the intermediate coupler.
Fig. 6 Power Steering Fluid Pressure And Return
Hoses At Steering Gear
1 - CROWFOOT
2 - POWER STEERING FLUID PRESSURE LINE
3 - FRONT SUSPENSION CRADLE
4 - STEERING GEAR
5 - POWER STEERING FLUID RETURN LINE
Fig. 7 Steering Gear Mounting To Suspension Cradle
1 - STEERING GEAR
2 - MOUNTING BOLTS
3 - MOUNTING BOLT
4 - FRONT SUSPENSION CRADLE
Fig. 8 Removing Roll Pin From Intermediate Coupler
1 - INTERMEDIATE COUPLER
2 - KNURLED NUT
3 - SUSPENSION CRADLE
4 - REMOVER SPECIAL TOOL 6831A
5 - STEERING GEAR
6 - NUT
7 - ROLL PIN
8 - THREADED ROD
Fig. 9 Installing Roll Pin In Intermediate Coupler
1 - INTERMEDIATE COUPLER
2 - SUSPENSION CRADLE
3 - KNURLED NUT
4 - ROLL PIN
5 - STEERING GEAR
19 - 20 GEARRS
GEAR (Continued)

SERVICE WARNINGS AND CAUTIONS
WARNING: POWER STEERING FLUID, ENGINE
PARTS AND EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH THE ENGINE OFF TO PREVENT PERSONAL
INJURY FROM MOVING PARTS.
CAUTION: When the system is open, cap all open
ends of the hoses, power steering pump fittings or
power steering gear ports to prevent entry of for-
eign material into the components.
STANDARD PROCEDURE - POWER STEERING
PUMP INITIAL OPERATION
CAUTION: The fluid level should be checked with
engine off to prevent injury from moving compo-
nents. Use only MoparTPower Steering Fluid (MS-
5931) or approved equivalent. Do not overfill.
Read the fluid level through the side of the power
steering fluid reservoir. The fluid level should indi-
cateªFILL RANGEºwhen the fluid is at a temper-
ature of approximately 21ÉC to 27ÉC (70ÉF to 80ÉF).
(1) Wipe the filler cap and area clean, then remove
the cap.
(2) Fill the fluid reservoir to the proper level and
let the fluid settle for at least two (2) minutes.
(3) Start the engine and let run for a few seconds,
then turn the engine off.
(4) Add fluid if necessary. Repeat the above steps
until the fluid level remains constant after running
the engine.
(5) Raise the front wheels off the ground.
(6) Start the engine.
(7) Slowly turn the steering wheel right and left,
lightly contacting the wheel stops.
(8) Add fluid if necessary.
(9) Lower the vehicle, then turn the steering wheel
slowly from lock-to-lock.
(10) Stop the engine. Check the fluid level and
refill as required.
(11) If the fluid is extremely foamy, allow the vehi-
cle to stabilize a few minutes, then repeat the above
procedure.
REMOVAL - PUMP (2.4L ENGINE)
(1) Remove the (-) negative battery cable from the
battery and isolate cable.
(2) Remove the cap from the power steering fluid
reservoir.
(3) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(4) Raise the vehicle on jack stands or centered on
a frame contact type hoist. See Hoisting in Lubrica-
tion and Maintenance.
(5) Disconnect the oxygen sensor wiring harness
from the vehicle wiring harness at the rear engine
mount bracket.
NOTE: The exhaust system needs to be removed
from the engine to allow for an area to remove the
power steering pump from the vehicle.
(6) Remove the four bolts and flag nuts securing
the catalytic converter from the exhaust manifold
(Fig. 3).
(7) Disconnect all the exhaust system isolators/
hangers from the brackets on the exhaust system (2
at the mufflers and 1 at the resonator) (Fig. 4).
(8) Remove the exhaust system by moving it as far
rearward, then lowering the front below the cross-
member and out of the vehicle.
(9) Remove the power steering fluid supply hose
from the fitting on the power steering pump. Drain
off excess power steering fluid from hose.
Fig. 3 Catalytic Converter to Exhaust Manifold
1 - CATALYTIC CONVERTER
2 - BOLT
3 - GASKET
4 - FLAG NUT
RSPUMP19-25
PUMP (Continued)

(11) Remove the bolts attaching the cradle cross-
member reinforcement to the front suspension cradle
crossmember (Fig. 4). Remove the 2 bolts fastening
the reinforcement and rear of cradle crossmember to
the body of the vehicle. Remove the reinforcement.
(12) If the vehicle is equipped with All-Wheel-
Drive, remove the power transfer unit (Refer to 21 -
TRANSMISSION/TRANSAXLE/POWER TRANSFER
UNIT - REMOVAL).
(13) Remove the power steering fluid pressure and
return hoses from the power steering gear (Fig. 5).
(14) Remove the routing clamp bolt securing the
power steering fluid hoses to the rear of the cradle
crossmember (Fig. 6). Allow the hoses to hang down
out of the way.
(15) Remove the heat shield from the steering gear
(Fig. 5).
Fig. 2 Removing/Installing Tie Rod End Attaching
Nut
1 - TIE ROD END
2 - STEERING KNUCKLE
3 - WRENCH
4 - SOCKET
5 - TIE ROD END STUD
Fig. 3 TIE ROD REMOVAL WITH TOOL C-3894-A
1 - OUTER TIE ROD
2 - SPECIAL TOOL C-3894-A
3 - STEERING KNUCKLE
Fig. 4 CRADLE CROSSMEMBER REINFORCEMENT
ATTACHMENT
1 - STEERING GEAR
2 - RIGHT LOWER CONTROL ARM
3 - LEFT LOWER CONTROL ARM
4 - CRADLE CROSSMEMBER REINFORCEMENT
5 - REAR CRADLE CROSSMEMBER ISOLATOR BUSHING
6 - STABILIZER BAR
7 - CRADLE CROSSMEMBER
19a - 2 GEARRG
GEAR (Continued)

(16) Remove the 3 bolts and nuts mounting the
steering gear to the front suspension cradle.
NOTE: The next step must be done to allow the
removal of the steering gear from the front suspen-
sion cradle. The steering gear cannot be removed
from the vehicle with the intermediate coupler
attached to the steering gear.
(17) Lower steering gear from suspension cradle
enough to allow access to the intermediate coupler
roll pin (Fig. 7). Install Remover/Installer, Special
Tool 6831A, through the center of the roll pin, secur-
ing with the knurled nut (Fig. 7). Hold threaded rod
stationary while turning nut, this will pull the roll
pin out of the intermediate coupler.
(18) Separate the coupler from the steering gear
shaft.
(19) Remove the power steering gear from the
vehicle.
Fig. 5 RHD GEAR HEAT SHIELD AND HOSE
FITTINGS
1 - HEAT SHIELD
2 - CRADLE CROSSMEMBER
3 - RETURN HOSE FITTING
4 - PRESSURE HOSE FITTING
5 - POWER STEERING GEAR
Fig. 6 RHD POWER STEERING GEAR - 2.5L DIESEL
SHOWN
1 - RETURN HOSE
2 - PRESSURE HOSE
3 - CRADLE CROSSMEMBER
4 - POWER STEERING GEAR
5 - RETURN HOSE FITTING
6 - PRESSURE HOSE FITTING
7 - HOSE ROUTING CLAMP
Fig. 7 Removing Roll Pin From Intermediate Coupler
1 - INTERMEDIATE COUPLER
2 - KNURLED NUT
3 - SUSPENSION CRADLE
4 - REMOVER SPECIAL TOOL 6831A
5 - STEERING GEAR
6 - NUT
7 - ROLL PIN
8 - THREADED ROD
RGGEAR19a-3
GEAR (Continued)

INSTALLATION - RHD GEAR
(1) Install the steering gear up in the front sus-
pension cradle crossmember, leaving room to install
intermediate coupler.
(2) Start the roll pin into the intermediate coupler
before installing coupler on steering gear shaft. Start
roll pin into coupler, using a hammer and tapping it
into the coupler. Then install the intermediate cou-
pler on the shaft of the steering gear.
(3) Install Remover/Installer Special Tool 6831A
through the center of the roll pin, securing it with
the knurled nut (Fig. 8). Hold threaded rod station-
ary while turning nut. This will pull the roll pin into
the intermediate coupler.
(4) Install power steering gear on the front suspen-
sion cradle. Install the 3 steering gear mounting
bolts and nuts. Tighten the 3 steering gear to sus-
pension cradle mounting bolts to a torque of 183 N´m
(135 ft. lbs.).
CAUTION: Proper torque on the steering gear to
suspension cradle mounting bolts is very impor-
tant.
(5) Install the heat shield on the steering gear
(Fig. 5).
(6) Attach the power steering fluid pressure and
return hoses to the proper fittings on the steering
gear (Fig. 5). Do not fully tighten the fittings at this
time.
(7) Install the routing clamp with the bolt securing
the power steering fluid hoses to the rear of the cra-
dle crossmember (Fig. 6).(8) Using a crowfoot wrench on a torque wrench,
tighten the power steering fluid hose tube nuts at the
gear to a torque of 31 N´m (275 in. lbs.).
(9) Install tie rod end into steering knuckle. Start
tie rod end to steering knuckle attaching nut onto
stud of tie rod end. While holding stud of tie rod end
stationary using a socket (Fig. 2), tighten tie rod end
to steering knuckle attaching nut. Then using a
crowfoot and socket (Fig. 9), tighten the tie rod end
attaching nut to a torque of 75 N´m (55 ft. lbs.).
(10) If the vehicle is equipped with All-Wheel-
Drive, install the power transfer unit (Refer to 21 -
TRANSMISSION/TRANSAXLE/POWER TRANSFER
UNIT - INSTALLATION).
CAUTION: Proper torque on the cradle reinforce-
ment to suspension cradle mounting bolts is very
important.
(11) Install the reinforcement on the front suspen-
sion cradle crossmember and install the bolts attach-
ing the reinforcement to the cradle crossmember
(Fig. 4). Tighten the M-14 size bolts to a torque of
163 N´m (120 ft. lbs.). Tighten the M-12 size bolts to
a torque of 108 N´m (80 ft. lbs.).
(12) Install the lower control arm rear bushing
retainer bolts through reinforcement on each side of
each lower control arm rear bushing. Tighten bolts to
a torque of 61 N´m (45 ft. lbs.).
(13) Install the two bolts and bushings attaching
the reinforcement and rear of cradle crossmember to
body of vehicle (Fig. 4). Tighten bolts to a torque of
163 N´m (120 ft. lbs.).
Fig. 8 Installing Roll Pin In Intermediate Coupler
1 - INTERMEDIATE COUPLER
2 - SUSPENSION CRADLE
3 - KNURLED NUT
4 - ROLL PIN
5 - STEERING GEAR
Fig. 9 Torquing Tie Rod End Attaching Nut
1 - STEERING KNUCKLE
2 - TIE ROD END
3 - CROWFOOT
4 - SOCKET
5 - TORQUE WRENCH
19a - 4 GEARRG
GEAR (Continued)

(3) Assemble Tool L-4440 to overrunning clutch as
shown in (Fig. 61).
(4) Orient springs as shown on left side of (Fig.
62).(5) Install overrunning clutch/tool assembly to
transaxle and remove Tool L-4440.
(6) Install #10 thrust washer to rear of rear plan-
etary gear assembly. Use petrolatum to retain and
secure during installation.
(7) Install rear planetary gear assembly (Fig. 63).
(8) Install #9 thrust washer (Fig. 64). Use petrola-
tum to secure.
Fig. 61 Install Overrunning Clutch Rollers and
Springs
1 - TOOL L-4440
2 - ROLLER (8)
3 - OVERRUNNING CLUTCH CAM ASSEMBLY
4 - SPRING (8)
Fig. 62 Proper Spring/Roller Orientation
1 - TOOL L-4440
2 - SPRING
3 - ROLLER
4 - CONTACT AREA
Fig. 63 Rear Planetary Gear Assembly
1 - REAR PLANETARY GEAR ASSEMBLY
Fig. 64 No. 9 Thrust Washer
1 - #9 THRUST WASHER
2 - OUTPUT SHAFT
3 - REAR PLANETARY GEAR ASSEMBLY
RSAUTOMATIC - 31TH21-51
AUTOMATIC - 31TH (Continued)

INSTALLATION
(1) Fish gear shift cable dash panel opening into
engine compartment and secure grommet (Fig. 175).
Fig. 172 PRNDL Cable
1 - PRNDL CABLE
2 - GEAR SHIFT LEVER
Fig. 173 Gearshift Cable at Column
1 - GEAR SHIFT CABLE
Fig. 174 Gearshift Cable/Grommet at Dash Panel
1 - CABLE GROMMET
2 - DASH PANEL
Fig. 175 Gearshift Cable/Grommet at Dash Panel
1 - CABLE GROMMET
2 - DASH PANEL
RSAUTOMATIC - 31TH21 - 101
GEAR SHIFT CABLE (Continued)

TORQUE CONVERTER CLUTCH (TCC)
In a standard torque converter, the impeller and
turbine are rotating at about the same speed and the
stator is freewheeling, providing no torque multipli-
cation. By applying the turbine's piston to the front
cover's friction material, a total converter engage-
ment can be obtained. The result of this engagement
is a direct 1:1 mechanical link between the engine
and the transmission.
The engagement and disengagement of the TCC
are automatic and controlled by the Powertrain Con-
trol Module (PCM). The engagement cannot be acti-
vated in the lower gears because it eliminates the
torque multiplication effect of the torque converter
necessary for acceleration. Inputs that determine
clutch engagement are: coolant temperature, vehicle
speed and throttle position. The torque converter
clutch is engaged by the clutch solenoid on the valve
body. The clutch will engage at approximately 56
km/h (35 mph) with light throttle, after the shift to
third gear.
REMOVAL
(1) Remove transmission and torque converter
from vehicle. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 31TH - REMOVAL)
(2) Place a suitable drain pan under the converter
housing end of the transmission.
CAUTION: Verify that transmission is secure on the
lifting device or work surface, the center of gravity
of the transmission will shift when the torque con-
verter is removed creating an unstable condition.
The torque converter is a heavy unit. Use caution
when separating the torque converter from the
transmission.
(3) Pull the torque converter forward until the cen-
ter hub clears the oil pump seal.
(4) Separate the torque converter from the trans-
mission.
INSTALLATION
Check converter hub and drive notches for sharp
edges, burrs, scratches, or nicks. Polish the hub and
notches with 320/400 grit paper or crocus cloth if nec-
essary. The hub must be smooth to avoid damaging
the pump seal at installation.(1) Lubricate converter hub and oil pump seal lip
with transmission fluid.
(2) Place torque converter in position on transmis-
sion.
CAUTION: Do not damage oil pump seal or bushing
while inserting torque converter into the front of the
transmission.
(3) Align torque converter to oil pump seal open-
ing.
(4) Insert torque converter hub into oil pump.
(5) While pushing torque converter inward, rotate
converter until converter is fully seated in the oil
pump gears.
(6) Check converter seating with a scale and
straightedge (Fig. 237). Surface of converter lugs
should be 1/2 in. to rear of straightedge when con-
verter is fully seated.
(7) If necessary, temporarily secure converter with
C-clamp attached to the converter housing.
(8) Install the transmission in the vehicle. (Refer
to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC
- 31TH - INSTALLATION)
(9) Fill the transmission with the recommended
fluid.
Fig. 237 Checking Torque Converter Seating
1 - SCALE
2 - STRAIGHTEDGE
RSAUTOMATIC - 31TH21 - 125
TORQUE CONVERTER (Continued)

HYDRAULIC CONTROL PRESSURE
ADJUSTMENTS
LINE PRESSURE
An incorrect throttle pressure setting will cause
incorrect line pressure readings even though line
pressure adjustment is correct. Always inspect and
correct throttle pressure adjustment before adjusting
the line pressure.
The approximate adjustment for line pressure is
1-5/16 inches, measured from valve body to inner
edge of adjusting nut. However, due to manufactur-
ing tolerances, the adjustment can be varied to
obtain specified line pressure.
The adjusting screw may be turned with an Allen
wrench. One complete turn of adjusting screw
changes closed throttle line pressure approximately
1-2/3 psi. Turning adjusting screw counterclockwise
increases pressure, and clockwise decreases pressure.
THROTTLE PRESSURE
Throttle pressures cannot be tested accurately;
therefore, the adjustment should be measured if a
malfunction is evident.
(1) Insert gauge pin of Tool C-3763 between the
throttle lever cam and kickdown valve.
(2) By pushing in on tool, compress kickdown
valve against its spring so throttle valve is com-
pletely bottomed inside the valve body.
(3) While compressing spring, turn throttle lever
stop screw with adapter C-4553. Turn until head of
screw touches throttle lever tang, with throttle lever
cam touching tool and throttle valve bottomed. Be
sure adjustment is made with spring fully com-
pressed and valve bottomed in the valve body.
VEHICLE SPEED SENSOR/
PINION GEAR
REMOVAL
(1) Remove harness connector from sensor (Fig.
340) . Be sure weather seal stays on harness connec-
tor.
(2) Remove bolt securing the sensor in the exten-
sion housing (Fig. 340) .
(3) Carefully pull sensor and pinion gear assembly
out of extension housing.
(4) Remove pinion gear from sensor (Fig. 340) .
(5) Inspect pinion gear for damage (missing teeth,
etc.) and replace as necessary.
NOTE: When removing vehicle speed sensor for
any reason, a new o-ring MUST be used.
INSTALLATION
(1) Install vehicle speed sensor and pinion gear to
extension housing with new o-ring (Fig. 340).
(2) Install bolt and torque to 7 N´m (60 in. lbs.).
(3) Connect connector.
(4) Lower vehicle.
Fig. 339 Transaxle Oil Pan Bolts
1 - TRANSAXLE OIL PAN
2 - OIL PAN BOLTS
Fig. 340 Vehicle Speed Sensor Removal/Installation
1 - CONNECTOR
2 - SPEEDO PINION
3 - O-RING
4 - SENSOR
RSAUTOMATIC - 31TH21 - 157
VALVE BODY (Continued)