display CHRYSLER VOYAGER 2001 Service Manual

Transmission Effects and possible causes:
Scenario 1)- All PRNDL lights stay illuminated
indefinitely in Park following a Key start.
> Wrong Part Number TCM for application
> TRS connector not plugged in
> C1 through C4 (T1, T3, T41, or T42) circuits are
either open, shorted to ground, or shorted to 12
volts.
> PCI bus failure (Open or shorted resulting in no
communication to BCM or Cluster)
> TRS
> TCM
> BCM
Scenario 2)-9P9is indicated following a key start
but all PRNDL lights illuminate in9N9following a
shift from9R9to9N9. If PRNDL lights illuminate in
9N9and shifter is moved directly into939or9L9
position without pausing in9OD9, then the9OD9
position shift schedule and electronic display will
indicate9OD9until the shifter is shifted into the
9OD9position and held for at least 3 seconds.
> Worn Manual Lever (Rooster Comb). Check for
heavy wearing by TRS switch contacts
> Intermittent C1 through C4 (T1, T3, T41 or T42)
circuits. Check for corrosion, terminal push-outs
or spread terminals at 60-way and/or TRS switch
10-way connector
> TRS
> TCM
> BCM
Scenario 3)- If the invalid code happened while
operating in the939or9L9position, then the939or
9L9shift schedule and electronic display will be
frozen (regardless of whether9OD9,939or9L9is
selected) until the shifter is moved to the9N9
position (all PRNDL lights will illuminate) and
then back to the9OD9position and held there for at
least 3 seconds in order to resume the normal9OD9
shift schedule and electronic display.
> Intermittent C1 through C4 (T1, T3, T41 or T42)
circuits. Check for corrosion, terminal push-outs
or spread terminals at 60-way and/or TRS con-
nector
> TRS
> TCM
> BCM
These same symptoms may occur without the
code P0705(28) getting set. It is possible that the
invalid code that was sensed by the TCM only
occurred once or twice during the given ignition key
start and/or did not last for longer than 0.1 second.Name of code:P0120(29) - Throttle Position Sen-
sor Signal
When monitored:Whenever the engine is run-
ning.
Set condition:This code is set if the throttle angle
goes out of range or if throttle angle changes
abruptly (ie: faster than the throttle body motion
could occur)
Theory of operation:The Transmission Control
Module (TCM) receives the throttle position signal
from the Throttle Position Sensor (TPS) through a
wire spliced into the TPS circuit to the PCM. The
TPS has a 5-volt pull up supplied from the Power-
train Control Module (PCM). The signal is checked
for out-of-range as well as an intermittent (exces-
sive signal changes).
Transmission Effects:Extremely erratic trans-
mission shifting with an intermittent TPS signal
just prior to setting the code. If the intermittent
does not last long enough to set the code, the
customer will say that the transmission violently
hunts between gears. The TCM will use a calcu-
lated throttle angle supplied by the PCM over the
PCI bus. If the PCI bus is unavailable, the TCM will
use a default throttle angle of 24 degrees for the key
start in which the code was set. The TCM will try to
use the TPS signal again on the next key start.
Possible causes:
> Open or shorted TPS signal and/or ground cir-
cuits
> TCM connector problems
> TPS or TPS connector (Check PCM DTC's)
> PCM
> TCM
Name of code:P1787(31) - OD Hydraulic Pressure
Test Failure
P1788(32) - 2-4 Hydraulic Pressure Test Failure
P1789(33) - OD/2-4 Hydraulic Pressure Test Failure
When monitored:In 1st, 2nd, or 3rd gear with
engine speed above 1000 RPM shortly after a shift
and every minute thereafter.
Set condition:Immediately after a shift into 1st,
2nd, or 3rd gear, with engine speed above 1000
RPM, the TCM momentarily turns on element
pressure to the 2-4 and/or OD clutch circuits to
identify that the appropriate pressure switch
closes. If the pressure switch does not close it is
tested again. If the switch does not close the second
time, the appropriate code is set.
Theory of operation:The Transmission Control
Module (TCM) tests the OD and 2-4 pressure
switches when they are off (OD and 2-4 are tested in
1st gear, OD in 2nd gear, and 2-4 in 3rd gear). The
test verifies that the switches are operational. The
TCM verifies that the switch closes when the cor-
9
GENERAL INFORMATION

> Quick Learn should generally not be used as a
repair procedure unless directed by a repair or
diagnostic procedure. If the transmission system
is exhibiting a problem that you think is caused
by an invalid CVI, you should try to relearn the
value by performing the appropriate driving ma-
neuver. In most cases, if a quick learn makes a
vehicle shift better, the vehicle will return with
the same problem.
> Before performing Quick Learn, it is imperative
that the vehicle be shifted into OD with the
engine running and the oil level set to the correct
level. This step will purge air from the clutch
circuits to prevent erroneous clutch volume val-
ues which could cause poor initial shift quality.
> If an unused TCM is installed on a vehicle with a
HOT engine, Quick Learn will cause the TCM to
report a cold calculated oil temperature. This
requires monitoring the calculated oil tempera-
ture using the DRBIIIt. If the temperature is
below 15C (60É F), the transmission must be run
at idle or driven in gear until it goes above 15C
(60ÉF). If the temperature is above 93C (200ÉF),
the transmission must cool to below 93C (200ÉF).
> First gear is engaged in overdrive after Quick
Learn is completed. Place the vehicle in park
after performing Quick Learn.
The Quick Learn function should be performed:
± Upon installation of a new service TCM
± After replacement or rebuild of internal trans-
mission components or the torque converter
± If one or more of the clutch volumes indexes
(CVI's) contain skewed readings because of
abnormal conditions.
To perform the Quick Learn procedure, the fol-
lowing conditions must be met.
± It is imperative that the vehicle be shifted into
OD with the engine running and the oil level
set to the correct level. This step will purge the
air in the clutch circuits to prevent erroneous
clutch volume values, which could cause poor
initial shift quality.
± The brakes must be applied.
± The engine must be idling.
± The throttle angle (TP sensor) must be less
than 3 degrees.
± The shift lever position must stay in neutral
until prompted to shift into OD.
± The shift lever must stay in OD after the9Shift
to Overdrive9prompt until the DRBIIItindi-
cates the procedure is complete.
± The oil temperature must be between 15C
(60ÉF) and 93C (200ÉF).NOTE:The above conditions must be maintained
during the procedure to keep the procedure from
being aborted.
The Quick Learn procedure is performed with the
DRBIIItby selecting9Transmission9system then
9Miscellaneous9functions, then9Quick Learn9. Follow
the procedure instructions displayed on the DRBIIIt.
3.3.9 CLUTCH VOLUMES
The L-R clutch volume is updated when doing a
2-1 or 3-1 coast down shift. The transmission tem-
perature must be between 21-49C (70-120É F). The
clutch volume should be between 35 and 83.
The 2-4 clutch volume is updated when doing a
1-2 shift. The transmission temperature must be
above 43C (110ÉF). The clutch volume should be
between 20 and 77.
The OD clutch volume is updated when doing a
2-3 shift. The transmission temperature must be
above 43C (110ÉF). The clutch volume should be
between 40 and 150.
The UD clutch volume is updated when doing a
4-3 or 4-2 shift. The transmission temperature must
be above 43C (110ÉF). The clutch volume should be
between 24 and 70.
3.3.10 ELECTRONIC PINION FACTOR
The transmission output speed signal supplies
distance pulses to the powertrain control module
(PCM), which are used to calculate speed and
mileage. A pinion factor is stored in the transmis-
sion control module (TCM) in order to provide the
appropriate distance pulses for the vehicle. The
pinion factor is programmed into the TCM at the
assembly plant.
Using the following steps, the pinion factor can be
checked and/or reset using the DRBIIIt:
1. Select Transmission system, then Miscellaneous
functions, then Pinion Factor. The DRBIIItwill
display the current tire size.
2. If the tire size is incorrect, depress the Enter key
and then select the correct size.
3. Depress the Page Back key to exit the reset
procedure.
Notes About Electronic Pinion Factor Features
The nature of the electronic pinion factor requires that
certain features must be taken into consideration.
> If no pinion factor is stored in an installed TCM,
the vehicle speedometer will not operate, engine
speed will be limited to 2300 RPM, and catalyst
damage may occur.
> Selecting a wrong tire size will cause the speed-
ometer to be inaccurate and will also cause any
speed related features to operate improperly.
Note: After replacing the TCM, you must
reprogram pinion factor
17
GENERAL INFORMATION

3.4 USING THE DRBIIIT
Refer to the DRBIIItusers guide for instructions
and assistance with reading trouble codes, erasing
trouble codes, and other DRBIIItfunctions.
3.5 DRBIIITERROR MESSAGES
Under normal operation, the DRBIIItwill dis-
play one of only two error messages:
± User-Requested WARM Boot
± User-Requested COLD Boot
If the DRBIIItshould display any other error
message, record the entire display and call the
S.T.A.R.. Center. This is a sample of such an error
message display:
ver: 2.14
date: 26 Jul93
file: key_itf.cc
date: Jul 26 1993
line: 548
err: 0x1
User-Requested COLD Boot
Press MORE to switch between this
display and the application screen.
Press F4 when done noting information.
3.5.1 DRBIIITDOES NOT POWER UP
(BLANK SCREEN)
If the LED's do not light or no sound is emitted at
start up, check for loose cable connections or a bad
cable. Check the vehicle battery voltage. A mini-
mum of 11 volts is required to adequately power the
DRBIIIt.
If all connections are proper between the DRBIIIt
and the vehicle or other devices, and the vehicle
battery is fully charged, an inoperative DRBIIIt
may be the result of faulty cable or vehicle wiring.
For a blank screen, refer to the appropriate Body
Diagnostic manual.
3.5.2 DISPLAY IS NOT VISIBLE
Low temperatures will affect the visibility of the
display. Adjust the contrast to compensate for this
condition.
3.6 TRANSMISSION SIMULATOR
(MILLER TOOL # 8333) AND FWD
ADAPTER (MILLER TOOL #8333-1)
The transmission simulator, simply put, is an
electronic device that simulates the electronic func-
tions of any EATX controlled transmission (41TE,
42LE, 45RFE, and 545RFE). It's basic function is toaid the technician in determining if an internal
transmission problem exists or if the problem re-
sides in the vehicle wiring or Transmission Control
Module (TCM). It is only useful for electrical prob-
lems. It will not aid in the diagnosis of a failed
mechanical component, but it can tell you that the
TCM and wiring are working properly and that the
problem is internal.
The ignition switch should be in the lock position
before attempting to install the simulator. Follow
all instructions included with the simulator. If the
feedback from the simulator is in doubt, you can
verify it's operation by installing it on a known good
vehicle. A9known good vehicle9would be defined as
a vehicle that does not set any DTC's and drives and
shifts as expected.
One important point to remember is that the
Simulator receives it's power from the Trans Relay
Output circuit. If the transmission system is in
Limp-in (Relay open), the simulator will not oper-
ate. This is not really an indication of a problem,
but an additional symptom. If the simulator does
not power up (9P9led lit), this is an indication that
the problem is still present with the simulator
hooked up. This indicates that the problem is in the
wiring or TCM and not the transmission.
Miller Tool # 8333-1 consists of the adapter cables
and overlay necessary to adapt the simulator to
41TE and 42LE transmissions.
4.0 DISCLAIMERS, SAFETY,
AND WARNINGS
4.1 DISCLAIMERS
All information, illustrations and specifications
contained in this manual are based on the latest
18
GENERAL INFORMATION

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

Symptom:
P1716-BUS COMMUNICATION WITH PCM
When Monitored and Set Condition:
P1716-BUS COMMUNICATION WITH PCM
When Monitored: Continuously with ignition key on.
Set Condition: If no bus messages are received from the Powertrain Control Module for
10 seconds.
POSSIBLE CAUSES
NO COMMUNICATION WITH PCM
OTHER BUS PROBLEMS PRESENT
INTERMITTENT WIRING AND CONNECTORS
TCM - BUS COMMUNICATION
TEST ACTION APPLICABILITY
1 With the DRBIIIt, Check the STARTS SINCE SET counter.
Note: This counter only applies to the last DTC set.
Is the STARTS SINCE SET counter equal to zero?All
Ye s®Go To 2
No®Go To 5
2 Ignition on, engine not running.
With the DRBIIIt, attempt to communicate with the Powertrain Control Module
(PCM).
Can the DRBIIItcommunicate with the PCM?All
Ye s®Go To 3
No®Refer to symptom list for problems related to No Response From
PCM.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
3 With the DRBIIIt, check all of the other modules on the vehicle for evidence of a
vehicle bus problem.
Bus related DTC's in other modules point to an overall vehicle bus problem. Other
symptoms such as a customer complaint of intermittent operation of bus controlled
features also indicate a bus problem.
Does the PRNDL display indicate9No Bus9or is there any evidence of an overall
vehicle bus problem?All
Ye s®Refer to the Communications category for the related symp-
tom(s).
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
No®Go To 4
79
TRANSMISSION

Symptom:
P1717-NO COMMUNICATION WITH THE MIC
When Monitored and Set Condition:
P1717-NO COMMUNICATION WITH THE MIC
When Monitored: Continuously with engine running.
Set Condition: The code sets in approximately 25 seconds if no BUS messages are
received form the MIC.
POSSIBLE CAUSES
OTHER BUS PROBLEMS PRESENT
INTERMITTENT WIRING AND CONNECTORS
MIC - NO COMMUNICATION
TCM - BUS COMMUNICATION
TEST ACTION APPLICABILITY
1 With the DRBIIIt, Check the STARTS SINCE SET counter.
Note: This counter only applies to the last DTC set.
Is the STARTS SINCE SET counter equal to zero?All
Ye s®Go To 2
No®Go To 5
2 With the DRBIIIt, check all of the other modules on the vehicle for evidence of a
vehicle bus problem.
Bus related DTC's in other modules point to an overall vehicle bus problem. Other
symptoms such as a customer complaint of intermittent operation of bus controlled
features also indicate a bus problem.
Does the PRNDL display indicate9No Bus9or is there any evidence of an overall
vehicle bus problem?All
Ye s®Refer to the Communications category for the related symp-
tom(s).
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
No®Go To 3
3 Ignition on, engine not running.
With the DRBIIIt, clear all DTC's.
Start the engine in park.
With the DRBIIIt, read the MIC DTC's.
Can the DRBIIItcommunicate with the MIC?All
Ye s®Go To 4
No®Refer to the communication category and perform symptoms
related for No Response to MIC.
Perform 41TE TRANSMISSION VERIFICATION TEST - VER 1.
81
TRANSMISSION

Symptom:
*BRAKE SHIFT INTERLOCK OUTPUT OPEN
POSSIBLE CAUSES
INTERMITTENT WIRING AND CONNECTORS
BRAKE SHIFT INTERLOCK CONTROL CIRCUIT OPEN
BRAKE SHIFT INTERLOCK FEED CIRCUIT OPEN
BRAKE SHIFT INTERLOCK SOLENOID
FRONT CONTROL MODULE
TEST ACTION APPLICABILITY
1 Ignition on, engine not running.
With the DRBIIIt, record and erase DTC's.
Turn the ignition off to the lock position.
Turn the ignition on.
With the DRBIIIt, read DTCs.
Does the DRBIIItdisplay BRAKE SHIFT INTERLOCK OUTPUT OPEN?All
Ye s®Go To 2
No®Go To 8
2 Turn the ignition off to the lock position.
Disconnect the Brake Shift Interlock harness connector.
Note: Check connectors - Clean/repair as necessary.
Ignition on, engine not running.
Using a 12-volt test light connected to B+, check the Brake Shift Interlock Control
circuit in the Brake Shift Interlock harness connector.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test light illuminate brightly?All
Ye s®Go To 3
No®Go To 6
3 Turn the ignition off to the lock position.
Disconnect the Brake Shift Interlock harness connector.
Note: Check connectors - Clean/repair as necessary.
Ignition on, engine not running.
Using a 12-volt test light connected to ground, check the Brake Shift Interlock Feed
circuit in the Brake Shift Interlock harness connector.
NOTE: The test light must illuminate brightly. Compare the brightness to
that of a direct connection to the battery.
Does the test light illuminate brightly?All
Ye s®Go To 4
No®Go To 5
4 If there are no possible causes remaining, view repair. All
Repair
Replace the Brake Shift Interlock Solenoid in accordance with the
Service Information.
146
TRANSMISSION

Symptom:
*CHECKING PARK/NEUTRAL SWITCH OPERATION
POSSIBLE CAUSES
P/N POSITION SWITCH SENSE CIRCUIT OPEN
P/N POSITION SWITCH SENSE CIRCUIT SHORTED TO GROUND
TRANSMISSION RANGE SENSOR
PCM - P/N POSITION SWITCH
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, read the Park/Neutral Position Switch input state.
While moving the gear selector through all gear positions, Park to 1 and back to Park,
watch the DRBIIItdisplay.
Did the DRBIIItdisplay show P/N and D/R in the correct gear positions?All
Ye s®Test Complete.
No®Go To 2
2 Turn the ignition off.
Disconnect the PCM harness connectors.
Disconnect the Transmission Range Sensor harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resistance of the P/N Position Switch Sense circuit.
Is the resistance below 5.0 ohms?All
Ye s®Go To 3
No®Repair the P/N Position Switch Sense circuit for an open.
3 Turn the ignition off.
Disconnect the PCM harness connectors.
Disconnect the Transmission Range Sensor harness connector.
Note: Check connectors - Clean/repair as necessary.
Measure the resistance between ground and the P/N Position Switch Sense circuit.
Is the resistance above 100k ohms?All
Ye s®Go To 4
No®Repair the P/N Position Switch Sense circuit for a short to ground.
4 Turn the ignition off.
Disconnect the PCM harness connectors.
Move the Gear selector through all gear positions, from Park to 1st and back.
While moving the gear selector through each gear, measure the resistance between
ground and the P/N Position Switch Sense circuit.
Did the resistance change from above 10.0 ohms to below 10.0 ohms?All
Ye s®Go To 5
No®Replace the Transmission Range Sensor.
148
TRANSMISSION

Verification Tests
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. NOTE: Erase DTC P0700 in the PCM to turn the Malfunction Indicator Lamp (MIL)
off after making Transmission repairs.
5. With the DRBIIIt, display Transmission Temperature. Start and run the engine until the
Transmission Temperature is HOT - above 43.33É C or 110É F.
6. Check the Transmission Fluid and adjust if necessary. Refer to the Service information for
the Fluid Fill procedure.
7. 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(
8. NOTE: If the Torque Converter is replaced, or if a TCM is replaced on a vehicle
whose Torque Converter has less than 3750 miles and less than 360 minutes of
PEMCC, then with the DRBIIItrestart the TCC Break-In. This is in order to avoid
possible shudder.
9. 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.
10. 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.
11. For a specific DTC, drive the vehicle to the Symptom's When Monitored/When Set
conditions to verify the DTC repair.
12. NOTE: Use the EATX OBDII Task Manager to run Good Trip time in each gear, this
will confirm the repair and to ensure that the DTC has not re-matured.
13. 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 perform the appropriate Symptom.
Were there any Diagnostic Trouble Codes (DTCs) set during the road test?All
Ye s®Refer to the Symptom List for appropriate Symptom(s).
No®Repair is complete.
157
VERIFICATION TESTS