boot CHRYSLER VOYAGER 2001 Repair Manual

ADJUSTMENT
(1) Disconnect battery negative cable.
(2) Remove gearshift knob by pushing down and
rotating ò-turn clock-wise (Fig. 163).(3) Remove gearshift boot from center console by
disengaging at three (3) retaining clips (Fig. 164).
(4) Apply park brake to allow park brake handle to
clear center console upon removal.
(5) Remove two (2) cupholder bottom plugs (Fig.
165).
Fig. 162 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 163 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 164 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 165 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
21a - 60 T850 MANUAL TRANSAXLERG
GEARSHIFT CABLE - CROSSOVER (Continued)

(6) Remove four (4) center console-to-gearshift
mechanism screws. Remove console assembly (Fig.
166).
(7) Loosen crossover cable adjustment screw (Fig.
167).
(8) Rock gearshift lever back and forth between
1±2 and 5±R planes. Release lever, allowing shifterspring to return lever to the neutral position in the
3±4 plane. Place gearshift lever in the 3rd gear posi-
tion.
(9) Torque crossover lever adjustment screw to 8
N´m (70 in. lbs.).No load should be applied to
the shifter lever in any direction (hands off)
while tightening screw.
(10) Verify gearshift lever travel through all gear
ranges with engine off (not running).
(11) Install center console assembly (Fig. 166).
Install and torque center console-to-gearshift mecha-
nism screws to 5 N´m (45 in. lbs.).
(12) Install cupholder plugs (Fig. 165).
(13) Install gearshift boot to console (Fig. 164).
Secure boot to console with three (3) retainer clips.
(14) Install gearshift knob to gearshift lever (Fig.
163). Orient shift pattern on knob ò-turn clockwise,
push down and rotate ò-turn counter-clockwise and
release. Secure boot to knob.
(15) Connect battery negative cable.
GEARSHIFT CABLE -
SELECTOR
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove gearshift knob by pushing down and
rotating ò-turn clock-wise (Fig. 168).
(3) Remove gearshift boot from center console by
disengaging at three (3) retaining clips (Fig. 169).
Fig. 166 Center Console Removal/Installation (LHD
Shown Ð RHD Typical)
1 - CENTER CONSOLE
2 - SCREW (4)
3 - GEARSHIFT MECHANISM
Fig. 167 Crossover Cable Adjustment Screw
1 - CROSSOVER CABLE
2 - ADJUSTMENT SCREW
Fig. 168 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
RGT850 MANUAL TRANSAXLE21a-61
GEARSHIFT CABLE - CROSSOVER (Continued)

(4) Apply park brake to allow park brake handle to
clear center console upon removal.
(5) Remove two (2) cupholder bottom plugs (Fig.
170).(6) Remove four (4) center console-to-gearshift
mechanism screws. Remove console assembly (Fig.
171).
(7) Remove center console support bracket (Fig.
172).
Fig. 169 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 170 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
Fig. 171 Center Console Removal/Installation (LHD
Shown Ð RHD Typical)
1 - CENTER CONSOLE
2 - SCREW (4)
3 - GEARSHIFT MECHANISM
Fig. 172 Center Console Support Bracket
1 - BRACKET
2 - SCREW
3 - GEARSHIFT MECHANISM
21a - 62 T850 MANUAL TRANSAXLERG
GEARSHIFT CABLE - SELECTOR (Continued)

(13) Install cupholder plugs (Fig. 189).
(14) Install gearshift boot to console (Fig. 190).
Secure with three (3) retainer clips.
(15) Install gearshift knob to gearshift lever (Fig.
191). Orient shift pattern ò-turn clockwise, push
down and rotate ò-turn counter-clockwise and
release. Secure boot to knob.
(16) Connect battery negative cable.
GEARSHIFT KNOB
REMOVAL
(1) Separate gearshift boot from base of knob.
(2) Remove gearshift knob by pushing down and
rotating ò-turn clockwise (Fig. 192).
INSTALLATION
(1) Install gearshift knob pattern ò-turn clock-
wise, press down, and rotate ò-turn counter clock-
wise (Fig. 192).
(2) Secure gearshift boot to base of knob.
Fig. 189 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
Fig. 190 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 191 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 192 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
RGT850 MANUAL TRANSAXLE21a-67
GEARSHIFT CABLE - SELECTOR (Continued)

GEARSHIFT MECHANISM
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove gearshift knob by pushing down and
rotating ò turn clock-wise (Fig. 193).
(3) Remove gearshift boot from center console by
disengaging at three (3) retaining clips (Fig. 194).(4) Apply park brake to allow park brake handle to
clear center console upon removal.
(5) Remove two (2) cupholder bottom plugs (Fig.
195).
(6) Remove four (4) center console-to-gearshift
mechanism screws. Remove console assembly (Fig.
196).
Fig. 193 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 194 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 195 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
Fig. 196 Center Console Removal/Installation (LHD
Shown Ð RHD Typical)
1 - CENTER CONSOLE
2 - SCREW (4)
3 - GEARSHIFT MECHANISM
21a - 68 T850 MANUAL TRANSAXLERG

(6) Install center console assembly (Fig. 209).
Install and torque center console-to-gearshift mecha-
nism screws to 5 N´m (45 in. lbs.).
(7) Install cupholder plugs (Fig. 210).(8) Install gearshift boot to console (Fig. 211).
Secure with three (3) retainer clips.
(9) Install gearshift knob to gearshift lever (Fig.
212). Orient shift pattern ò-turn clockwise, push
down and rotate ò-turn counter-clockwise and
release. Secure boot to knob.
(10) Connect battery negative cable.
Fig. 209 Center Console Removal/Installation (LHD
Shown Ð RHD Typical)
1 - CENTER CONSOLE
2 - SCREW (4)
3 - GEARSHIFT MECHANISM
Fig. 210 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
Fig. 211 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 212 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
21a - 72 T850 MANUAL TRANSAXLERG
GEARSHIFT MECHANISM (Continued)

(3) Remove the silencer boot fasteners located
around the base of the lower steering shaft from the
dash panel so that it may be pushed aside.
(4) Remove the brake lamp switch from its mount-
ing bracket. (Refer to 8 - ELECTRICAL/LAMPS/
LIGHTING - EXTERIOR/BRAKE LAMP SWITCH -
REMOVAL).
(5) Disconnect the power brake booster input rod
(push rod) from the pin on the brake pedal arm.
(Refer to 5 - BRAKES - ABS/HYDRAULIC/ME-
CHANICAL/POWER BRAKE BOOSTER - REMOV-
AL).
(6) Remove the three screws that secure the heater
core shield to the left end of the HVAC distribution
housing (Fig. 17).
(7) Pull the heater core shield rearward far enough
to disengage the two location tabs that position the
front of the shield to the receptacles in the two lower
finger formations of the evaporator housing near the
dash panel.
(8) Remove the heater core shield from the distri-
bution housing.
(9) Take the proper precautions to protect the car-
peting below the heater core from spilled engine cool-
ant and have absorbent toweling readily available to
mop up any spills.
(10) Remove the screw that secures the heater core
tube sealing plate to the heater core supply and
return ports (Fig. 18).
(11) Push both heater core tubes simultaneously
toward the dash panel far enough to disengage their
fittings from the heater core supply and return ports.(12) Install plugs in, or tape over the opened
heater core tube fittings and both heater core ports.
(13) Use absorbent toweling to mop up any engine
coolant spills from the preceding operation.
(14) Remove the two screws that secure the heater
core mounting plate to the distribution housing.
(15) While pulling the accelerator pedal upward
(Fig. 19) and pushing the brake pedal downward
(Fig. 20) far enough for clearance, pull the heater
core out of the distribution housing.
Fig. 17 Heater Core Shield
1 - HEATER/ AIR CONDITIONER HOUSING
2 - HEATER CORE SHIELD
3 - DISTRIBUTION HOUSING
4 - SCREWS (3)
5 - LOCATION TABS (2)
Fig. 18 Heater Core
1 - SEALING PLATE
2 - SCREW
3 - SCREWS (2)
4 - HEATER CORE
5 - HEATER CORE TUBES
Fig. 19 Accelerator Pedal
1 - SLIDE HEATER CORE PAST ACCELERATOR PEDAL
24 - 78 PLUMBING - FRONTRS
HEATER CORE (Continued)

INSTALLATION - HEATER CORE
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING FRONT - WARNING - HEATER PLUMB-
ING).
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) While pushing the brake pedal downward (Fig.
20) and pulling the accelerator pedal upward (Fig.
19) far enough for clearance, slide the heater core
into the distribution housing.
(2) Install and tighten the two screws that secure
the heater core mounting plate to the distribution
housing (Fig. 18). Tighten the screws to 2 N´m (17 in.
lbs.).
(3) Remove the plugs or tape from the heater core
tube fittings and both heater core ports.
(4) Position both heater core tubes and the sealing
plate simultaneously to the heater core supply and
return ports.
(5) The heater core tubes each have a slot that
must be indexed to a location tab within each of the
heater core ports. Adjust the position of the tubes as
required so that the sealing plate fits flush against
the heater core supply and return ports, which indi-
cates that the tubes are properly indexed.
(6) Install and tighten the screw that secures the
heater core tube sealing plate to the heater core sup-
ply and return ports. Tighten the screw to 3 N´m (27
in. lbs.).
(7) Position the heater core shield onto the distri-
bution housing. Be certain that the two location tabs
on the front of the shield are engaged in the recepta-
cles in the two lower finger formations of the evapo-
rator housing near the dash panel (Fig. 17).
(8) Install and tighten the three screws that secure
the heater core shield to the left end of the HVAC
distribution housing. Tighten the screws to 2 N´m (17
in. lbs.).(9) Reconnect the power brake booster input rod
(push rod) to the pin on the brake pedal arm. (Refer
to 5 - BRAKES - ABS/HYDRAULIC/MECHANICAL/
POWER BRAKE BOOSTER - INSTALLATION).
(10) Reinstall the brake lamp switch into its
mounting bracket. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - INSTALLATION).
(11) Reinstall the silencer boot around the base of
the lower steering shaft on the dash panel.
(12) Reconnect the battery negative cable.
(13) Refill the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
(14) Operate sustem for two thermostat cycles to
assure elimination of air in the system.
HEATER HOSE
REMOVAL
There are several heater core plumbing configura-
tions used on this model, depending upon the engine
size and other optional equipment. One plumbing
configuration is used for all 2.4L engines (Fig. 21),
while the 3.3L and 3.8L engines have unique heater
return plumbing on the engine for models with or
without an optional engine oil cooler (Fig. 24) or (Fig.
25). There are also unique plumbing configurations
at the heater core for models with or without the
optional rear heater and air conditioner (Fig. 22) or
(Fig. 23). All models use a combination of formed
steel tubing and rubber hoses. In most cases, the
rubber hose is secured to the steel tubing with a
spring tension clamp.
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING FRONT - WARNING - HEATER PLUMB-
ING).
(1) Drain the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(2) Using spring tension clamp pliers, compress
and slide the clamps that secure each end of the
heater hose to the tube or nipple toward the center of
the hose to be removed. Release the clamp when it is
off of the tube or nipple.
24 - 80 PLUMBING - FRONTRS
HEATER CORE (Continued)

SYMPTOM DIAGNOSTIC TEST
POOR FUEL ECONOMY CHECKING PCM POWER AND GND CKT
CHECKING THE FUEL PRESSURE
CHECKING ECT SENSOR
CHECKING THROTTLE POSITION SENSOR
CHECKING MAP SENSOR
CHECKING IDLE AIR CONTROL MOTOR OPERATION
CHECKING IAT SENSOR
3.4 USING THE DRBIIIT
Refer to the DRBIIItuser 's guide for instructions
and assistance with reading DTC's, erasing DTC's,
and other DRBIIItfunctions.
3.5 DRBIIITERROR MESSAGES AND
BLANK SCREEN
Under normal operation, the DRBIIItwill dis-
play one of only two error messages:
± User-Requested WARM Boot or User-
Requested COLD Boot
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
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 (data link
connector cavity 16). A minimum of 11 volts is
required to adequately power the DRBIIIt.
If all connections are proper between the
DRBIIItand the vehicle or other devices, and the
vehicle battery is fully charged, and inoperative
DRBIIItmay be the result of faulty cable or vehicle
wiring.
3.5.2 DISPLAY IS NOT VISIBLE
Low temperatures will affect the visibility of the
display. Adjust the contrast to compensate for this
condition
4.0 DISCLAIMERS, SAFETY,
WARNINGS
4.1 DISCLAIMERS
All information, illustrations, and specifications
contained in this manual are based on the latest
information available at the time of publication.
The right is reserved to make changes at any time
without notice.
4.2 SAFETY
4.2.1 TECHNICIAN SAFETY INFORMATION
WARNING: ENGINES PRODUCE CARBON
MONOXIDE THAT IS ODORLESS, CAUSES
SLOWER REACTION TIME, AND CAN LEAD
TO SERIOUS INJURY. WHEN THE ENGINE IS
OPERATING, KEEP SERVICE AREAS WELL
VENTILATED OR ATTACH THE VEHICLE
EXHAUST SYSTEM TO THE SHOP EXHAUST
REMOVAL SYSTEM.
Set the parking brake and block the wheels before
testing or repairing the vehicle. It is especially
10
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