display CHRYSLER VOYAGER 2001 Service Manual

TEST ACTION APPLICABILITY
2 Turn the ignition off.
NOTE: Visually inspect the related wiring harness and CCD/PCI Bus
(whichever applicable) circuits. Look for any chafed, pierced, pinched, or
partially broken wires.
NOTE: Visually inspect the related wiring harness connectors. Look for
broken, bent, pushed out, or corroded terminals.
Note: Refer to any Technical Service Bulletins (TSB) that may apply.
Were any problems found?All
Ye s®Repair as necessary.
Perform SKIS VERIFICATION TEST.
No®Go To 3
3NOTE: Before proceeding it will be necessary to obtain the SKIM PIN
number.
Turn the ignition on.
With the DRB III, display and erase all PCM and SKIM DTC's.
Perform 5 ignition key cycles, leaving the ignition key on for a minimum of 90 seconds
per cycle.
With the DRB III, read the SKIM DTC's.
Does the code appear?All
Ye s®Replace and program the Powertrain Control Module in accor-
dance with the Service Information.
Perform SKIS VERIFICATION TEST.
No®Test Complete.
4 Turn the ignition off.
Note: Visually inspect the related wiring harness. Look for any chafed,
pierced, pinched, or partially broken wires.
NOTE: Visually inspect the related wiring harness connectors. Look for
broken, bent, pushed out, or corroded terminals.
Note: Refer to any Technical Service Bulletins (TSB) that may apply.
Were any problems found?All
Ye s®Repair wiring harness/connectors as necessary.
No®Test Complete.
269
VEHICLE THEFT/SECURITY
PCM STATUS FAILURE ÐContinued

Symptom:
ROLLING CODE FAILURE
When Monitored and Set Condition:
ROLLING CODE FAILURE
When Monitored: At ignition on, after ignition on during any rolling code handshake that
occurs with the PCM due to a SKIM or PCM reset.
Set Condition: When a PCM STATUS message with a Valid Key status is not received by
the SKIM within 3.5 seconds of transmitting the last Valid Key Code message to the PCM.
POSSIBLE CAUSES
VERIFYING PCM VIN
INTERMITTENT WIRING HARNESS PROBLEM
PCM
TEST ACTION APPLICABILITY
1 With the DRB III, erase the SKIM DTC's.
Turn the ignition off.
Wait 10 seconds.
Turn the ignition on and wait 2 minutes.
With the DRB III, read the SKIM DTC's.
Does the DRB III display the DTC that was previously erased?All
Ye s®Go To 2
No®Go To 4
2NOTE: Ensure that a VIN has been programmed into the PCM. If a VIN is not
displayed, attempt to program the PCM with the correct vehicle VIN before
continuing.
Turn the ignition on.
With the DRB III, select Engine system from the main menu.
Display and record the Vehicle Identification Number.
Does the VIN recorded from the PCM match the VIN of the vehicle?All
Ye s®Go To 3
No®Replace and program the Powertrain Control Module in accor-
dance with the Service Information.
270
VEHICLE THEFT/SECURITY

TEST ACTION APPLICABILITY
3 Turn the ignition off.
Replace and program the Sentry Key Immobilizer Module in accordance with the
Service Information.
Turn the ignition on.
With the DRB III, display and clear all PCM and SKIM DTC's.
Perform 5 ignition key cycles leaving the ignition key on for 90 seconds per cycle.
With the DRB III, check for SKIM DTC's.
Does the DRB III display the same DTC?All
Ye s®Replace and program the Powertrain Control Module in accor-
dance with the Service Information.
Perform SKIS VERIFICATION TEST.
No®Test Complete.
4 Turn the ignition off.
Note: Visually inspect the related wiring harness. Look for any chafed,
pierced, pinched, or partially broken wires.
NOTE: Visually inspect the related wiring harness connectors. Look for
broken, bent, pushed out, or corroded terminals.
Note: Refer to any Technical Service Bulletins (TSB) that may apply.
Were any problems found?All
Ye s®Repair wiring harness/connectors as necessary.
Perform SKIS VERIFICATION TEST.
No®Test Complete.
271
VEHICLE THEFT/SECURITY
ROLLING CODE FAILURE ÐContinued

TEST ACTION APPLICABILITY
1 With the DRB III, read and record the SKIM DTCs.
With the DRB III, erase the SKIM DTCs.
NOTE: Perform the following test several times to ensure the DTC is
current.
Turn the ignition off.
Wait 10 seconds.
Turn the ignition on.
With the DRB III, read the SKIM DTCs.
Does the DRB display the DTC that was previously erased?All
Ye s®Go To 2
No®Go To 7
2 Are there multiple vehicle ignition keys available? All
Ye s®Go To 3
No®Go To 4
3NOTE: Perform the following steps using one of the vehicle ignition keys.
When finished, repeat the procedure using each of the other vehicle keys
one at a time.
With the DRB III, erase the SKIM DTC's.
Turn the ignition off.
Wait 10 seconds.
Turn the ignition on.
With the DRB III, read the SKIM DTC's.
Is the DTC present for all ignition keys?All
Ye s®Replace the Sentry Key Immobilizer Module in accordance with
the Service Information.
Perform SKIS VERIFICATION TEST.
No®Test Complete.
4 With the DRB III, attempt to reprogram the ignition keys to the SKIM.
With the DRB III, erase the SKIM DTC's.
Wait 10 seconds.
Turn the ignition on.
With the DRB III, read the SKIM DTC's.
Does the DTC reset?All
Ye s®Go To 5
No®Test Complete.
5 Replace the ignition key with a new key.
With the DRB III, program the new ignition key to the SKIM.
With the DRB III, erase the SKIM DTC's
Turn the ignition off.
Wait 10 seconds.
Turn the ignition on.
With the DRB III, read the SKIM DTC's.
Does the DTC reset?All
Ye s®Go To 6
No®Test Complete.
273
VEHICLE THEFT/SECURITY
TRANSPONDER COMMUNICATION FAILURE ÐContinued

VERIFICATION TESTS
31TH TRANSMISSION VERIFICATION TEST - VER 1. APPLICABILITY
1. Connect the DRBIIItto the Data Link Connector (DLC).
2. Reconnect any disconnected components.
3. With the DRBIIIt, erase the PCM DTC's.
4. Check the transmission fluid and adjust if necessary. Refer to the Service information for the
Fluid Fill procedure.
5. Road test the vehicle. With the DRBIIIt, monitor the engine RPM. Make 15 to 20 1-2, 2-3
upshifts. Perform these shifts from a standing start to 45 MPH with a constant throttle opening
of 20 to 25 degrees.
6. Below 25 MPH, make 5 to 8 wide open throttle kickdowns to 1st gear. Allow at least 5 seconds
each in 2nd and 3rd gear between each kickdown.
7. For a specific DTC, drive the vehicle to the Symptom's When Monitored/When Set conditions
to verify the DTC repair.
8. Check for Diagnostic Trouble Codes (DTC's) during the road test. If a DTC sets during the
road test , return to the Symptom list and follow the path.
Were any Trouble Codes set during the road test?All
Ye s®Refer to the Symptom List for appropriate diagnostic tests.
No®Repair is complete.
41TE TRANSMISSION VERIFICATION TEST - VER 1. APPLICABILITY
1. Connect the DRBIIItto the Data Link Connector (DLC).
2. Reconnect any disconnected components.
3. With the DRBIIIt, erase all Transmission DTC's, also erase the PCM DTC's.
4. With the DRBIIIt, display transmission temperature. Start and run the engine until the
transmission temperature is HOT (above 110 deg. F).
5. Check the transmission fluid and adjust if necessary. Refer to the Service information for the
Fluid Fill procedure.
6. NOTE: If the Transmission Control Module or torque converter has been replaced
or if the transmission has been repaired or replaced it is necessary to perform the
DRBIIItQuick Learn Procedure and reset the(Pinion Factor(
7. Road test the vehicle. With the DRBIIIt, monitor the engine RPM. Make 15 to 20 1-2, 2-3,
3-4 upshifts. Perform these shifts from a standing start to 45 MPH with a constant throttle
opening of 20 to 25 degrees.
8. Below 25 MPH, make 5 to 8 wide open throttle kickdowns to 1st gear. Allow at least 5 seconds
each in 2nd and 3rd gear between each kickdown.
9. For a specific DTC, drive the vehicle to the Symptom's When Monitored/When Set conditions
to verify the DTC repair.
10. Check for Diagnostic Trouble Codes (DTC's) during the road test. If a DTC sets during the
road test , return to the Symptom list and follow the path.
11. NOTE: Erase P0700 DTC in the PCM to turn the MIL light off after making
transmission repairs. This will turn the MIL off.
Were any Trouble Codes set during the road test?All
Ye s®Refer to the Symptom List for appropriate diagnostic tests.
No®Repair is complete.
275
VERIFICATION TESTS

BODY VERIFICATION TEST - VER 1 APPLICABILITY
1. Disconnect all jumper wires and reconnect all previously disconnected components and
connectors.
2. With the DRBIIIt, record and erase all DTCs from ALL modules. Cycle the ignition on then
off
3. If the Sentry Key Immobilizer Module (SKIM) or the Powertrain Control Module (PCM) was
replaced, proceed to number 7. If the SKIM or PCM was not replaced, continue to the next
number.
4. If the Body Control Module was replaced, turn the ignition on for 15 seconds (to allow the
new BCM to learn VIN) or engine may not start (if VTSS equipped). If the vehicle is equipped
with VTSS, use the DRBIIItand enable VTSS.
5. Program all other options as needed.
6. If any repairs were made to the HVAC System, disconnect the battery or, using the DRBIIIt,
recalibrate the HVAC doors. Proceed to number 14.
7. Obtain the Vehicle's unique PIN assigned to it's original SKIM from either the vehicle's
invoice or from Chrysler's Customer Assistance Center (1-800-992-1997).
8. NOTE: Once Secured Access Mode is active, the SKIM will remain in that mode for 60
seconds.
9. With the DRBIIIt, select THEFT ALARM, SKIM, MISCELLANEOUS and select SKIM
REPLACED. Enter the 4 digit PIN to put the SKIM in Secured Access Mode.
10. The DRBIIItwill prompt for the following steps. (1) Program the country code into the
SKIM's memory. (2) Program the vehicle's VIN into the SKIM memory. (3) Transfer the
vehicle's Secret Key data from the PCM.
11. Using the DRBIIIt, program all customer keys into the SKIM memory. This requires that
the SKIM be in Secured Access Mode, using the 4 digit PIN.
12. Note: If the PCM is replaced, the VIN and the unique Secret Key data must be transferred
from the SKIM to the PCM. This procedure requires the SKIM to be placed in Secured Access
Mode using the 4-digit PIN.
13. Note: If 3 attempts are made to enter Secured Access Mode using an incorrect PIN, Secured
Access Mode will be locked out for 1 hour which causes the DRBIIItto display9Bus +\- Signals
Open9. To exit this mode, turn ignition to Run for 1 hour.
14. Ensure that all accessories are turned off and the battery is fully charged.
15. Start and run the engine for 2 minutes. Operate all functions of the system that caused the
original concern.
16. Turn the ignition off and wait 5 seconds. Turn the ignition on and using the DRBIIIt, read
DTCs from ALL modules.
Are any DTC's present or is the original condition still present?All
Ye s®Repair is not complete, refer to the appropriate symptom.
No®Repair is complete.
276
VERIFICATION TESTS
VERIFICATION TESTS ÐContinued

POWERTRAIN VERIFICATION TEST VER-1 APPLICABILITY
1. NOTE: If the PCM has been replaced and the correct VIN and mileage have not
been programmed, a DTC will be set in the ABS Module, Airbag Module and the
SKIM.
2. NOTE: If the vehicle is equipped with a Sentry Key Immobilizer System, Secret
Key data must be updated. Refer to the Service Information for the PCM, SKIM and
the Transponder (ignition key) for programming information.
3. Inspect the vehicle to ensure that all components related to the repair are connected
properly.
4. Inspect the engine oil for fuel contamination. Replace the oil and filter as necessary.
5. Attempt to start the engine.
6. If the No Start condition is still present, refer to the symptom list and perform the diagnostic
testing as necessary. refer to and Technical Service Bulletins that may apply.
7. Run the engine for one warm-up cycle to verify operation.
8. With the DRBIIIt, confirm that no DTCs or Secondary Indicators are present and that all
components are functioning properly.
9. If a DTC is present, refer to the appropriate category and select the corresponding symptom.
Are any DTCs present?All
Ye s®Repair is not complete, refer to appropriate symptom.
No®Repair is complete.
SKIS VERIFICATION APPLICABILITY
1. Reconnect all previously disconnected components and connectors.
2. Obtain the vehicle's unique Personal Identification Number (PIN) assigned to it's original
SKIM. This number can be obtained from the vehicle's invoice or Chrysler's Customer Center
(1-800-992-1997).
3. NOTE: When entering the PIN, care should be taken because the SKIM will only
allow 3 consecutive attempts to enter the correct PIN. If 3 consecutive incorrect
PIN's are entered the SKIM will Lock Out the DRB III for 1 hour.
4. To exit Lock Out mode, the ignition key must remain in the Run position continually for 1
hour. Turn off all accessories and connect a battery charger if necessary.
5. With the DRB III, select Theft Alarm, SKIM and Miscellaneous. Then select desired
procedure and follow the steps that will be displayed.
6. If the SKIM has been replaced, ensure all of the vehicle ignition keys are programmed to the
new SKIM.
7. NOTE: Prior to returning vehicle to the costumer, perform a module scan to be
sure that all DTC's are erased. Erase any DTC's that are found.
8. With the DRB III erase all DTC's. Perform 5 ignition key cycles leaving the key on for at least
90 seconds per cycle.
9. With the DRB III, read the SKIM DTC's.
Are there any SKIM DTC's?All
Ye s®Repair is not complete, refer to appropriate symptom.
No®Repair is complete.
281
VERIFICATION TESTS
VERIFICATION TESTS ÐContinued

TABLE OF CONTENTS
1.0 INTRODUCTION.........................................................1
1.1SYSTEM COVERAGE...............................................1
1.2SIX -STEP TROUBLESHOOTING PROCEDURE..........................1
2.0 IDENTIFICATION OF SYSTEM.............................................1
3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION......................1
3.1GENERAL DESCRIPTION............................................1
3.2FUNCTIONAL OPERATION...........................................1
3.2.1AUTOSTICK FEATURE.......................................1
3.2.2TRANSMISSION OPERATION AND SHIFT SCHEDULING AT
VARIOUS OIL TEMPERATURES................................2
3.3DIAGNOSTIC TROUBLE CODES......................................3
3.3.1HARD CODE................................................3
3.3.2ONE TRIP FAILURES.........................................3
3.3.3INTERMITTENT CODE........................................3
3.3.4STARTS SINCE SET COUNTER................................3
3.3.5TROUBLE CODE ERASURE...................................4
3.3.6LIST OF DIAGNOSTIC TROUBLE CODES........................4
3.3.7DTC DESCRIPTIONS.........................................5
3.3.8QUICK LEARN.............................................16
3.3.9CLUTCH VOLUMES.........................................17
3.3.10ELECTRONIC PINION FACTOR...............................17
3.4USING THE DRBIIIT................................................18
3.5DRBIIITERROR MESSAGES........................................18
3.5.1DRBIIITDOES NOT POWER UP (BLANK SCREEN)...............18
3.5.2DISPLAY IS NOT VISIBLE....................................18
3.6TRANSMISSION SIMULATOR (MILLER TOOL # 8333) AND
FWD ADAPTER (MILLER TOOL #8333-1)..............................18
4.0 DISCLAIMERS, SAFETY, AND WARNINGS.................................18
4.1DISCLAIMERS.....................................................18
4.2.1TECHNICIAN SAFETY INFORMATION..........................19
4.2.2VEHICLE PREPARATION FOR TESTING........................19
4.2.3SERVICING SUB-ASSEMBLIES...............................19
4.2.4DRBIIITSAFETY INSTRUCTIONS.............................19
4.3WARNINGS.......................................................20
4.3.1VEHICLE DAMAGE WARNINGS...............................20
4.3.2ROAD TEST COMPLAINT VEHICLE............................20
4.3.3ELECTRONIC PINION FACTOR WARNINGS.....................20
4.3.4BULLETINS AND RECALLS...................................20
5.0 REQUIRED TOOLS AND EQUIPMENT.....................................20
6.0 GLOSSARY OF TERMS..................................................21
6.1ACRONYMS......................................................21
6.2DEFINITIONS.....................................................21
7.0 DIAGNOSTIC INFORMATION AND PROCEDURES...........................23
i

1.0 INTRODUCTION
The procedures contained in this manual include
all of the specifications, instructions, and graphics
needed to diagnose 41TE/AE Electronic Automatic
Transaxle (EATX) problems. The diagnostics in this
manual are based on the failure condition or symp-
tom being present at the time of diagnosis.
When repairs are required, refer to the appropri-
ate volume of the service manual for the proper
removal and repair procedure.
Diagnostic procedures change every year. New
diagnostic systems may be added and/or carryover
systems may be enhanced. READ THIS MANUAL
BEFORE TRYING TO DIAGNOSE A VEHICLE
TROUBLE CODE. It is recommended that you
review the entire manual to become familiar with
all new and changed diagnostic procedures.
This book reflects many suggested changes from
readers of past issues. After using this book, if you
have any comments or recommendations, please fill
out the form at the back of the book and mail it back
to us.
1.1 SYSTEM COVERAGE
This diagnostic procedures manual covers all
2001 RG equipped with a 41TE/AE transaxle.
1.2 SIX -STEP TROUBLESHOOTING
PROCEDURE
Diagnosis of the 41TE/AE electronic transaxle is
done in six basic steps:
verification of complaint
verification of any related symptoms
symptom analysis
problem isolation
repair of isolated problem
verification of proper operation
2.0 IDENTIFICATION OF
SYSTEM
RG series vehicles equipped with a 4 speed trans-
mission.
3.0 SYSTEM DESCRIPTION AND
FUNCTIONAL OPERATION
3.1 GENERAL DESCRIPTION
The 41TE/AE electronic transaxle is a conven-
tional transaxle in that it uses hydraulically ap-
plied clutches to shift a planetary gear train. How-
ever, the electronic control system replaces many of
the mechanical and hydraulic components used in
conventional transmission valve bodies.
3.2 FUNCTIONAL OPERATION
The 41TE/AE electronic transaxle has a fully
adaptive control system. The system performs it's
functions based on continuous real-time sensor
feedback information. The control system automat-
ically adapts to changes in engine performance and
friction element variations to provide consistent
shift quality. The control system ensures that clutch
operation during upshifting and downshifting is
more responsive without increased harshness.
The Transmission Control Module (TCM) contin-
uously checks for electrical problems, mechanical
problems, and some hydraulic problems. When a
problem is sensed, the TCM stores a diagnostic
trouble code. Some of these codes cause the tran-
saxle to go into limp-in or default mode.
While in this mode, electrical power is taken
away from the transaxle via the TCM, de-
energizing the transmission control relay, and tak-
ing power from the solenoid pack. When this hap-
pens, the only transaxle mechanical functions are:
Park and Neutral
Reverse
Second Gear
No upshifts or downshifts are possible. The posi-
tion of the manual valve alone allows the three
ranges that are available. Although vehicle perfor-
mance is seriously degraded while in this mode, it
allows the owner to drive the vehicle in for service.
Once the DRBIIItis in the EATX portion of the
diagnostic program, it constantly monitors the
TCM to see if the system is in limp-in mode. If the
transaxle is in limp-in mode, the DRBIIIž will flash
the red LED.
3.2.1 AUTOSTICK FEATURE
This feature allows the driver to manually shift
the transaxle when the shift lever is pulled back
into the AutoStick position. When in AutoStick
mode, the instrument cluster displays the current
gear.
1
GENERAL INFORMATION

> Trailer towing in OD gear position (use 3 position
(or A/S 3rd) if frequent shifting occurs)
> Cooling system failure causing engine to operate
over 110C (230ÉF)
> Engine coolant temperature stays low too long -
If engine coolant temperature drops below 65C
(150ÉF), the transmission will disengage EMCC.
Extended operation with the EMCC disengaged
will cause the transmission to overheat.
> A brake switch issue will cause the EMCC to
disengage. Extended operation with the EMCC
disengaged will cause the transmission to over-
heat.
> Transmission fluid overfilled
> Transmission cooler or cooler lines restricted
> Transmission Temperature Sensor circuit
3.3 DIAGNOSTIC TROUBLE CODES
Diagnostic trouble codes (DTC's) are codes stored
by the Transmission Control Module (TCM) that
help us diagnose Transmission problems. They are
viewed using the DRBIIItscan tool.
Always begin by performing a visual inspection of
the wiring, connectors, cooler lines and the trans-
mission. Any obvious wiring problems or leaks
should be repaired prior to performing any diagnos-
tic test procedures. Some engine driveability prob-
lems can be misinterpreted as a transmission prob-
lem. Ensure that the engine is running properly
and that no PCM DTC's are present that could
cause a transmission complaint.
If there is a communication bus problem, trouble
codes will not be accessible until the problem is
fixed. The DRBIIItwill display an appropriate
message. The following is a possible list of causes
for a bus problem:
± open or short to ground/battery in PCI bus
circuit (pin 43).
± internal failure of any module or component on
the bus
Each diagnostic trouble code is diagnosed by
following a specific testing sequence. The diagnostic
test procedures contain step-by-step instructions
for determining the cause of a transmission diag-
nostic trouble code. Possible sources of the code are
checked and eliminated one by one. It is not neces-
sary to perform all of the tests in this book to
diagnose an individual code. These tests are based
on the problem being present at the time that the
test is run.All testing should be done with a
fully charged battery.
If the TCM records a DTC that will adversely
affect vehicle emissions, it will request (via the
communication bus) that the PCM illuminate the
Malfunction Indicator Lamp (MIL). Although theseDTC's will be stored in the TCM immediately as a 1
trip failure, it may take up to five minutes of
accumulated trouble confirmation set the DTC and
illuminate the MIL. Three consecutive successful
OBDII (EURO STAGE III OBD) trips or clearing
the DTC's with a diagnostic tool (DRBIIItor equiv-
alent) is required to extinguish the MIL. When the
TCM requests that the PCM illuminate the MIL,
the PCM sets a DTC P0700(89) to alert the techni-
cian that there are DTC's in the TCM. This must
also be erased in the PCM in order to extinguish the
MIL.
3.3.1 HARD CODE
Any Diagnostic Trouble Code (DTC) that is set
whenever the system or component is monitored is
a HARD code. This means that the problem is there
every time the TCM checks that system or compo-
nent. Some codes will set immediately at start up
and others will require a road test under specific
conditions. It must be determined if a code is
repeatable (Hard) or intermittent before attempt-
ing diagnosis.
3.3.2 ONE TRIP FAILURES
A One Trip Failure, when read from the TCM, is
a hard OBDII (EURO STAGE III OBD) code that
has not matured for the full 5 minutes. This applies
to codes that will only set after 5 minutes of
substituted gear operation.
3.3.3 INTERMITTENT CODE
A diagnostic trouble code that is not there every
time the TCM checks the circuit or function is an a
intermittent code. Some intermittent codes, such as
codes P1792(12), P1767(14), P1768(15), P0725(18),
P1716(19), P1781(21), P1782(22), P1724(24),
P0705(28), P0120(29), P0750(41), P0755(42),
P0760(43), P0765(44), P1793(48), P0715(56),
P0720(57), P1794(58), P1796(70), P1799(74),
P1739(76), P1717(77), and P0600(78) are caused by
wiring or connector problems. However intermit-
tent codes 50 - 54 are usually caused by intermit-
tent hydraulic seal leakage in the clutch and/or
accumulator circuits. Problems that come and go
like this are the most difficult to diagnose, they
must be looked for under the specific conditions
that cause them.
3.3.4 STARTS SINCE SET COUNTER
For the most recent code (Code 1), the Starts
Since Set counter counts the number of times the
vehicle has started since it was last set. The counter
will count up to 255 starts. Note that this code only
applies to the last code set.
When there are no diagnostic trouble codes stored
in memory, the DRBIIItwill display ``NO DTC'S
3
GENERAL INFORMATION