transmission CHRYSLER VOYAGER 2001 Service Manual

> Transmission Simulator (Miller # 8333)
> Transmission Simulator (Miller # 8333-1)
Adapter harness kit and panel overlay for FWD
vehicles.
> Jumper wires
> Test Light (minimum of 25 ohms of resistance)
> Ohmmeter
> Voltmeter
> Pressure gauge (0-300 PSI)
6.0 GLOSSARY OF TERMS
6.1 ACRONYMS
BCMBody Control Module
CKTCircuit
CVIClutch Volume Index
DLCData Link Connector
DRBIIItDiagnostic Readout Box
DTCDiagnostic Trouble Code
EATXElectronic Automatic Transaxle
EMCCElectronically Modulated Converter
Clutch
FCMFront Control Module (part of the
IPM system)
IODIgnition off-draw
IPMIntelligent Power Module
IRTIntelligent Recovery Timer
ISSInput Speed Sensor
LEDLight Emitting Diode
LRLow/reverse Clutch or Pressure
Switch
LULockupMICMechanical Instrument Cluster
MILMalfunction Indicator Lamp
OBDIIOn Board Diagnostics
ODOverdrive Clutch or Pressure
Switch
OSSOutput Speed Sensor
PCMPowertrain Control Module
PEMCCPartial Electronically Modulated
Converter Clutch
PLUPartial Lockup
REVReverse Clutch
SLPKSolenoid Pack
SSVSolenoid Switch Valve
SWSwitch
TCCTorque Converter Clutch
TCMTransmission Control Module
TPThrottle Position
TRDTorque Reduction
TRSTransmission Range Sensor
UDUnderdrive Clutch
2-42nd and 4th gear Clutch or Pres-
sure Switch
6.2 DEFINITIONS
OBDII (EURO STAGE III OBD) Trip - A vehicle
start and drive cycle such that all once per trip
diagnostic monitors have run.
Key Start - A vehicle start and run cycle of at least
20 seconds.
Warm-up Cycle - A vehicle start and run cycle
such that the engine coolant must rise to at least
71C (160ÉF) and must rise by at least 4.4C (40ÉF)
from initial start up. To count as a warm-up cycle,
no DTC may occur during the cycle.
21
GENERAL INFORMATION

Symptom:
P0120-THROTTLE POSITION SENSOR SIGNAL CIRCUIT
When Monitored and Set Condition:
P0120-THROTTLE POSITION SENSOR SIGNAL CIRCUIT
When Monitored: Whenever the engine is running.
Set Condition: This code is set if the throttle angle goes out of range or if throttle angle
changes abruptly (i.e.: faster than the throttle body motion could occur).
POSSIBLE CAUSES
RELATED PCM DTC'S PRESENT
INTERMITTENT WIRING & CONNECTORS
SENSOR GROUND CIRCUIT OPEN TO TCM
TPS SIGNAL CIRCUIT OPEN TO TCM
TPS VOLTAGE CHANGE NOT SMOOTH
TCM - TPS SIGNAL CIRCUIT
TEST ACTION APPLICABILITY
1NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low locate and repair the leak then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
With the DRBIIIt, read the engine DTC's. Check and repair all engine DTC's prior
to performing Transmission Symptom Diagnostics.
With the DRBIIIt, read Transmission DTC's. Record all DTC's and 1 Trip Failures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Using the wiring diagram/schematic as a guide, inspect the wiring and connectors.
Repair as necessary.
Perform the Shift Lever Position Test. If the test does not pass, refer to Symptom test
for P0705 Check Shifter Signal.
For Gear Ratio DTC's, check and record all CVI's.
Most DTC's set on start up but some must be set by driving the vehicle such that all
diagnostic monitors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB's related to the symptom.
Perform this procedure prior to Symptom diagnosis.All
Continue
Go To 2
2 With the DRBIIIt, check Powertrain Control Module DTC's.
Are any of the following P-codes P0122, P0123, P0121 stored in the PCM?All
Ye s®Refer to the Driveability category for the related symptom(s).
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
No®Go To 3
24
TRANSMISSION

TEST ACTION APPLICABILITY
3 Start the engine. Allow the engine to idle.
With the DRBIIIt, Check the Throttle Position Sensor Voltage under Transmission
Sensors.
Is the Throttle Position Sensor voltage below 0.3 or above 1.0 volts?All
Ye s®Go To 4
No®Go To 7
4 Turn the ignition off.
Disconnect the TPS harness connector.
Disconnect the TCM harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resistance of the Sensor Ground circuit between the TPS harness
connector and the Transmission Control Module harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 5
No®Repair the Sensor Ground circuit for an open.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
5 Turn the ignition off.
Disconnect the Throttle Position Sensor harness connector.
Disconnect the Transmission Control Module harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resistance of the TPS Signal Circuit from the TCM harness connector to
the TPS harness connector.
Is the resistance below 5.0 ohms?All
Ye s®Go To 6
No®Repair the TPS signal circuit for an open.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
6 If there are no possible causes remaining, view repair. All
Repair
Replace the TCM. WITH THE DRBIIItPERFORM QUICK
LEARN AND REPROGRAM PINION FACTOR.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
7 The conditions necessary to set this DTC are not present at this time. Using the
schematics as a guide, inspect the wiring and connectors specific to this circuit.
Wiggle the wires while checking for shorts and open circuits.
Pay particular attention to the the point where the TPS signal and sensor ground
circuits splice off from the engine circuits.
Were any problems found?All
Ye s®Repair wiring and/or connector as necessary.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
No®Go To 8
8 Turn the ignition on.
With the DRBIIIt, read TPS VOLTS.
While monitoring the DRBIIIt, slowly open and close the Throttle.
Is the voltage change smooth?All
Ye s®Test Complete.
No®Replace the Throttle Position Sensor.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
25
TRANSMISSION
P0120-THROTTLE POSITION SENSOR SIGNAL CIRCUIT ÐContinued

Symptom:
P0600-SERIAL COMMUNICATION LINK MALFUNCTION
When Monitored and Set Condition:
P0600-SERIAL COMMUNICATION LINK MALFUNCTION
When Monitored: Continuously with engine running.
Set Condition: The DTC sets in approximately 20 seconds if no BUS messages are
received by the TCM.
POSSIBLE CAUSES
NO COMMUNICATION WITH MIC
NO COMMUNICATION WITH PCM
INTERMITTENT WIRING AND CONNECTORS
TCM - INTERNAL ERROR
TEST ACTION APPLICABILITY
1 With the DRBIIIt, erase TCM DTC's.
Note: Erase P0700 DTC in the PCM to turn the MIL light off after making
transmission repairs.
Start the engine in park.
Did the DTC reset after the engine was started?All
Ye s®Go To 2
No®Go To 5
2 Ignition on, engine not running.
With the DRBIIIt, attempt communication with the MIC
Can you communicate with the MIC?All
Ye s®Go To 3
No®Refer to the Communication category for the related symptom(s).
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
3 Ignition on, engine not running.
With the DRBIIIt, select the following screens in order:9BODY99MIC99MONITOR
DISPLAY99PCI BUS ENGINE INFO9.
Does the DRBIIIt, read9NO RESPONSE9from any of the listed PCM monitors?All
Ye s®Refer to Communication Category for the related symptom(s).
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
No®Go To 4
4 If there are no possible causes remaining, view repair. All
Repair
Replace the TCM. WITH THE DRBIIItPERFORM QUICK
LEARN AND REPROGRAM PINION FACTOR.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
26
TRANSMISSION

TEST ACTION APPLICABILITY
5 The conditions necessary to set this DTC are not present at this time.
Using the schematics as a guide, inspect the wiring and connectors specific to this
circuit.
Wiggle the wiring while checking for shorts and open circuits.
Were there any problems found?All
Ye s®Repair as necessary.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
No®Test Complete.
27
TRANSMISSION
P0600-SERIAL COMMUNICATION LINK MALFUNCTION ÐContinued

Symptom:
P0604-INTERNAL TCM
POSSIBLE CAUSES
TCM - INTERNAL ERROR
TEST ACTION APPLICABILITY
1 If there are no possible causes remaining, view repair. All
Repair
Replace the TCM. WITH THE DRBIIItPERFORM QUICK
LEARN AND REPROGRAM PINION FACTOR.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
28
TRANSMISSION

Symptom:
P0605-INTERNAL TCM
POSSIBLE CAUSES
TCM - INTERNAL ERROR
TEST ACTION APPLICABILITY
1 If there are no possible causes remaining, view repair. All
Repair
Replace the TCM. WITH THE DRBIIItPERFORM QUICK
LEARN AND REPROGRAM PINION FACTOR.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
29
TRANSMISSION

Symptom:
P0700-INTERNAL TCM
POSSIBLE CAUSES
TCM - INTERNAL ERROR
TEST ACTION APPLICABILITY
1NOTE: Make sure this DTC is set in the TCM before making repair.
NOTE: The PCM also sets a P0700 but it only indicates that a DTC is set in
the TCM and turns the MIL on.
If there are no possible causes remaining, view repair.All
Repair
Replace the TCM. WITH THE DRBIIItPERFORM QUICK
LEARN AND REPROGRAM PINION FACTOR.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
30
TRANSMISSION

Symptom:
P0705-CHECK SHIFTER SIGNAL
When Monitored and Set Condition:
P0705-CHECK SHIFTER SIGNAL
When Monitored: Continuously with the ignition key on.
Set Condition: 3 occurrences in one key start of an invalid PRNDL code which lasts for
more than 0.1 second.
POSSIBLE CAUSES
CONDITION P0705 PRESENT
INTERMITTENT WIRING AND CONNECTORS
TRS T1 SENSE CIRCUIT OPEN
TRS T3 SENSE CIRCUIT OPEN
TRS T41 SENSE CIRCUIT OPEN
TRS T42 SENSE CIRCUIT OPEN
TRS T1 SENSE CIRCUIT SHORTED TO GROUND
TRS T3 SENSE CIRCUIT SHORTED TO GROUND
TRS T41 SENSE CIRCUIT SHORTED TO GROUND
TRS T42 SENSE CIRCUIT SHORTED TO GROUND
TRS T1 SENSE CIRCUIT SHORTED TO VOLTAGE
TRS T3 SENSE CIRCUIT SHORTED TO VOLTAGE
TRS T41 SENSE CIRCUIT SHORTED TO VOLTAGE
TRS T42 SENSE CIRCUIT SHORTED TO VOLTAGE
TRANSMISSION RANGE SENSOR
TCM - TRS T1 SENSE CIRCUIT
TCM - TRS T3 SENSE CIRCUIT
TCM - TRS T41 SENSE CIRCUIT
TCM - TRS T42 SENSE CIRCUIT
31
TRANSMISSION

TEST ACTION APPLICABILITY
1NOTE: Low fluid level can be the cause of many Transmission problems. If
the fluid level is low locate and repair the leak then check and adjust the
fluid level per the Service Information.
NOTE: Always perform diagnostics with a fully charged battery to avoid
false symptoms.
With the DRBIIIt, read the engine DTC's. Check and repair all engine DTC's prior
to performing Transmission Symptom Diagnostics.
With the DRBIIIt, read Transmission DTC's. Record all DTC's and 1 Trip Failures.
NOTE: Diagnose 1 Trip Failures as a fully matured DTC.
Using the wiring diagram/schematic as a guide, inspect the wiring and connectors.
Repair as necessary.
Perform the Shift Lever Position Test. If the test does not pass, refer to Symptom test
for P0705 Check Shifter Signal.
For Gear Ratio DTC's, check and record all CVI's.
Most DTC's set on start up but some must be set by driving the vehicle such that all
diagnostic monitors have run.
NOTE: Verify flash level of Transmission Control Module. Some problems
are corrected by software upgrades to the Transmission Control Module.
NOTE: Check for applicable TSB's related to the symptom.
Perform this procedure prior to Symptom diagnosis.All
Continue
Go To 2
2 Using the DRBIIIt, perform the Shift Lever Position Test.
Select the test outcome from the following:All
Test passes
Go To 3
Test fails with DTC
Go To 4
Test fails without DTC
Adjust the shift linkage per the Service Information.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
3 The conditions necessary to set this DTC are not present at this time.
Using the schematics as a guide, inspect the wiring and connectors specific to this
circuit.
Wiggle the wiring while checking for shorts and open circuits.
Were there any problems found?All
Ye s®Repair as necessary.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
No®Test Complete.
32
TRANSMISSION
P0705-CHECK SHIFTER SIGNAL ÐContinued