battery CHRYSLER VOYAGER 2001 Service Manual

REMOVAL
(1) Remove valve body from transaxle. (Refer to 21
- TRANSMISSION/TRANSAXLE/AUTOMATIC -
31TH/VALVE BODY - REMOVAL)
(2) Remove three (3) torque converter clutch sole-
noid-to-valve body screws (Fig. 223).
(3) Remove torque converter clutch solenoid (Fig.
223). Note orientation of plug and spring.
INSTALLATION
(1) Install plug and spring as shown in (Fig. 223).
(2) Install torque converter clutch solenoid to valve
body (Fig. 223) and torque screws to 5 N´m (45 in.
lbs.).
(3) Install valve body to transaxle. (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC -
31TH/VALVE BODY - INSTALLATION)
THROTTLE VALVE CABLE
REMOVAL
(1) Disconnect battery negative cable.
(2) Disconnect cable core from throttle lever pin
(Fig. 224).
(3) Disconnect cable retainer from throttle body
bracket (Fig. 224).
(4) Disconnect cable from throttle valve lever at
transaxle (Fig. 225).
(5) Disconnect cable retainer at transaxle bracket
(Fig. 225).
INSTALLATION
(1) Install throttle valve cable to bracket at trans-
axle (Fig. 226). Connect cable to transaxle throttle
valve lever.
(2) Route cable through center of intake manifold
(#2 & #3) runners.
Fig. 223 Torque Converter Clutch Solenoid and Regulator/Control Valves
1 - CONVERTER PRESSURE CONTROL VALVE
2 - END COVER
3 - SCREW (3)4 - REGULATOR VALVE THROTTLE PRESSURE PLUG SPRING
5 - REGULATOR VALVE THROTTLE PRESSURE PLUG
6 - SWITCH VALVE
21 - 118 AUTOMATIC - 31THRS
SOLENOID - TCC (Continued)

(3) Connect throttle valve cable retainer to throttle
body bracket (Fig. 227).
(4) Connect cable core clip to throttle lever (Fig.
227).(5) Adjust throttle valve cable. (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC -
31TH/THROTTLE VALVE CABLE - ADJUST-
MENTS)
(6) Connect battery negative cable.
Fig. 224 Throttle Valve Cable at Throttle Body
1 - THROTTLE VALVE CABLE CLIP
2 - THROTTLE BODY LEVER
3 - CABLE RETAINER
Fig. 225 Throttle Valve Cable at Transaxle
1 - LEVER
2 - BRACKET
3 - THROTTLE VALVE CABLE
Fig. 226 Throttle Valve Cable at Transaxle
1 - LEVER
2 - BRACKET
3 - THROTTLE VALVE CABLE
Fig. 227 Throttle Valve Cable at Throttle Body
1 - THROTTLE VALVE CABLE CLIP
2 - THROTTLE BODY LEVER
3 - CABLE RETAINER
RSAUTOMATIC - 31TH21 - 119
THROTTLE VALVE CABLE (Continued)

ADJUSTMENT - TRANSFER SHAFT BEARING
(1) Use Tool L-4434 to remove the retaining nut
and washer. Remove the transfer shaft gear using
Tool L-4407.
(2) Install a 2.29 mm (0.090 inch) and a 1.39 mm
(0.055 inch) gauging shims on the transfer shaft
behind the governor support.
(3) Install transfer shaft gear and bearing assem-
bly and torque the nut to 271 N´m (200 ft. lbs.).
(4) To measure bearing end play:Attach Tool
L-4432 to the transfer gear.
(5) Mount a steel ball with grease into the end of
the transfer shaft.
(6) Push and pull the gear while rotating back and
forth to insure seating of the bearing rollers.
(7) Using a dial indicator, measure transfer shaft
end play.
(8) Refer to the Transfer Bearing Shim Chart for
the required shim combination to obtain the proper
bearing setting.
(9) Use Tool L-4434 to remove the retaining nut
and washer. Remove the transfer shaft gear using
Tool L-4407.
(10) Remove the two gauging shims and install the
correct shim combination. Install the transfer gear
and bearing assembly.
(11) Install the retaining nut and washer and
torque to 271 N´m (200 ft. lbs.). Measure transfer
shaft end play, end play should be 0.05 to 0.25 mm
(0.002 to 0.010 inch).
(12) Measure bearing end play as outlined in Step
(4). End play should be between 0.05 mm and 0.25
mm (0.002 to 0.010 inch).
NOTE: If end play is too high, install a 0.05 mm
(0.002 inch) thinner shim combination. If end play is
too low, install a 0.05 mm (0.002 inch) thicker shim
combination. Repeat until 0.05 to 0.25 mm (0.002 to
0.010 inch) end play is obtained.
End Play
(with 2.29
mm and 1.39
mm gauging
shims
installed)Required Shim
CombinationTotal
Thickness
mm inch mm mm inch
.0 .0 2.29 + 1.39 3.68 .145
.05 .002 2.29 + 1.39 3.68 .145
.10 .004 2.29 + 1.39 3.68 .145
.15 .006 2.29 + 1.39 3.68 .145
.20 .008 2.29 + 1.34 3.63 .143
.25 .010 2.29 + 1.29 3.58 .141
End Play
(with 2.29
mm and 1.39
mm gauging
shims
installed)Required Shim
CombinationTotal
Thickness
mm inch mm mm inch
.30 .012 2.29 + 1.24 3.53 .139
.35 .014 2.29 + 1.19 3.48 .137
.40 .016 2.29 + 1.14 3.43 .135
.45 .018 2.29 + 1.09 3.38 .133
.50 .020 2.29 + 1.04 3.33 .131
.55 .022 2.29 + .99 3.28 .129
.60 .024 1.84 + 1.39 3.23 .127
.65 .026 1.84 + 1.34 3.18 .125
.70 .028 1.84 + 1.29 3.13 .123
.75 .030 1.84 + 1.24 3.08 .121
.80 .032 1.84 + 1.19 3.03 .119
.85 .034 1.84 + 1.14 2.98 .117
.90 .036 1.84 + 1.09 2.93 .115
.95 .038 1.84 + 1.04 2.88 .113
1.00 .040 1.84 + .99 2.83 .111
1.05 .042 1.39 + 1.39 2.78 .109
1.10 .044 1.39 + 1.34 2.73 .107
1.15 .046 1.39 + 1.29 2.68 .105
1.20 .048 1.39 + 1.24 2.63 .103
1.25 .049 1.39 + 1.19 2.58 .101
1.30 .050 1.39 + 1.14 2.53 .099
1.35 .052 1.39 + 1.09 2.48 .097
1.40 .055 1.39 + 1.04 2.43 .095
1.45 .057 1.39 + .99 2.38 .093
1.50 .059 .94 + 1.39 2.33 .091
1.55 .061 .94 + 1.34 2.28 .089
1.60 .063 .94 + 1.29 2.23 .087
VALVE BODY
REMOVAL
(1) Disconnect battery negative cable.
(2) Disconnect throttle valve cable from throttle
valve lever at transaxle.
(3) Disconnect gearshift cable from gearshift lever
at transaxle.
(4) Disconnect torque converter clutch solenoid
connector.
(5) Raise vehicle on hoist.
21 - 142 AUTOMATIC - 31THRS
TRANSFER SYSTEM - TRANSFER SHAFT/GEAR/BEARING (Continued)

(5) Install oil filter and gasket (Fig. 336).
(6) Install oil filter-to-valve body screws (Fig. 337)
to 5 N´m (45 in. lbs.).
(7) Install a bead of Moparž Silicone Rubber Adhe-
sive Sealant to oil pan (Fig. 338) and immediately
install to case.
(8) Install and torque oil pan-to-transaxle bolts
(Fig. 339) to 19 N´m (165 in. lbs.).(9) Lower vehicle.
(10) Connect torque converter clutch solenoid.
(11) Connect gearshift cable to manual valve lever.
(12) Connect throttle valve cable to throttle valve
lever at transaxle.
(13) Connect battery negative cable.
Fig. 335 Parking Rod
1 - VALVE BODY
2 - PARKING ROD
Fig. 336 Oil Filter and Gasket
1 - OIL FILTER
2 - GASKET
3 - VALVE BODY
Fig. 337 Oil Filter Screws
1 - SCREWDRIVER HANDLE
2 - SPECIAL TOOL L-4553
3 - OIL FILTER SCREWS (2)
4 - OIL FILTER
Fig. 338 Transaxle Oil Pan
1 - TRANSAXLE OIL PAN
2 - OIL FILTER
21 - 156 AUTOMATIC - 31THRS
VALVE BODY (Continued)

Converter housing leaks have several potential
sources. Through careful observation, a leak source
can be identified before removing the transmission
for repair.
Pump seal leaks tend to move along the drive hub
and onto the rear of the converter (Fig. 6). Pump
o-ring or pump body leaks follow the same path as a
seal leak. Pump attaching bolt leaks are generally
deposited on the inside of the converter housing and
not on the converter itself. Pump seal or gasket leaks
usually travel down the inside of the converter hous-
ing (Fig. 6).
TORQUE CONVERTER LEAKAGE
Possible sources of torque converter leakage are:
²Torque converter weld leaks at the outside diam-
eter weld (Fig. 7).
²Torque converter hub weld (Fig. 7).
REMOVAL
NOTE: If transaxle assembly is being replaced or
overhauled (clutch and/or seal replacement), it is
necessary to perform the TCM Quick Learn Proce-
dure. (Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)NOTE: If the torque converter assembly is being
replaced, it is necessary to reset the TCC Break-In
Strategy. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
(1) Disconnect battery cables.
(2) Remove battery shield (Fig. 8).
(3) Remove coolant recovery bottle (Fig. 9).
Fig. 6 Converter Housing Leak Paths
1 - PUMP SEAL
2 - PUMP VENT
3 - PUMP BOLT
4 - PUMP GASKET
5 - CONVERTER HOUSING
6 - CONVERTER
7 - REAR MAIN SEAL LEAK
Fig. 7 Converter Leak Points - Typical
1 - OUTSIDE DIAMETER WELD
2 - TORQUE CONVERTER HUB WELD
3 - STARTER RING GEAR
4 - LUG
Fig. 8 Battery Thermal Guard
1 - BATTERY THERMAL GUARD
2 - INTELLIGENT POWER MODULE
3 - FRONT CONTROL MODULE
RSAUTOMATIC - 41TE21 - 165
AUTOMATIC - 41TE (Continued)

(4) Remove fluid level indicator/tube assembly.
Plug opening to prevent debris from entering trans-
axle.
(5) Using a blade or suitable hose cutter, cut trans-
axle oil cooler lines off flush with fittings. Plug lines
and fittings to prevent debris from entering transaxle
or cooler circuit. A service splice kit will be installed
upon reassembly.
(6) Disconnect input and output shaft speed sensor
connectors (Fig. 10).
(7) Disconnect transmission range sensor (TRS)
connector (Fig. 10).
(8) Disconnect solenoid/pressure switch assembly
connector (Fig. 10).
(9) Disconnect gear shift cable from manual valve
lever and upper mount bracket (Fig. 11).
(10) Disconnect crankshaft position sensor (if
equipped).
(11) Reposition leak detection pump harness and
hoses.
(12) Remove wiper module assembly to gain access
to and remove rear mount bracket bolts. (Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - REMOVAL)
(13) Remove rear mount bracket-to-transaxle case
bolts (Fig. 12).
(14) Remove transaxle upper bellhousing-to-block
bolts.
(15) Raise vehicle on hoist.
(16) Remove transaxle oil pan and drain fluid into
suitable container.
(17) Remove front wheel/tire assemblies.
Fig. 9 Coolant Recovery Bottle
1 - UPPER BOLT ATTACHING TO BATTERY TRAY
2 - COOLANT RECOVERY/RESERVE CONTAINER
3 - UPPER BOLT
4 - HOSE
5 - LOWER BOLT (QTY. 2)
6 - LEFT SIDE FRAME RAIL
Fig. 10 Component Connector LocationÐTypical
1 - SOLENOID/PRESSURE SWITCH ASSY. CONNECTOR
2 - INPUT SPEED SENSOR CONNECTOR
3 - OUTPUT SPEED SENSOR CONNECTOR
4 - TRANSMISSION RANGE SENSOR CONNECTOR
Fig. 11 Gearshift Cable at Transaxle - Typical
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
21 - 166 AUTOMATIC - 41TERS
AUTOMATIC - 41TE (Continued)

INSTALLATION
NOTE: If transaxle assembly has been replaced or
overhauled (clutch and/or seal replacement), it is
necessary to perfrom the TCM Quick Learn proce-
dure. (Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
NOTE: If torque converter assembly has been
replaced, it is necessary to reset the TCC Break-In
Strategy. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
(1) Using a transmission jack and a helper, posi-
tion transaxle assembly to engine. Install and torque
bolts to 95 N´m (70 ft. lbs.).
(2) Install upper mount assembly to transaxle and
torque bolts to 54 N´m (40 ft. lbs.) (Fig. 164).
(3) Raise engine/transaxle assembly into position.
Install and torque upper mount-to-bracket thru-bolt
to 75 N´m (55 ft. lbs.) (Fig. 164).
(4) Remove transmission jack and screw jack.
(5) Secure left wheelhouse splash shield.
(6) Install torque converter-to-drive plate bolts and
torque to 88 N´m (65 ft. lbs.)
(7) Install inspection cover.(8) Install lateral bending brace.
(9) Install starter motor.
(10) Install front mount/bracket assembly.
(11) Install rear mount and bracket assembly into
position (Fig. 165).
(12) Install and torque rear mount bolts to 54 N´m
(40 ft. lbs.) (Fig. 166).
(13) Lower vehicle.
(14) Install and torque rear mount bracket-to-tran-
saxle vertical bolts (Fig. 165) to 102 N´m (75 ft. lbs.).
(15) Raise vehicle.
(16) Install rear mount bracket-to-transaxle hori-
zontal bolt (Fig. 165) and torque to 102 N´m (75 ft.
lbs.).
(17) Install rear mount thru-bolt and torque to 54
N´m (40 ft. lbs.) (Fig. 166).
(18) Install rear mount heat shield (Fig. 167).
(19) AWD models: Install power transfer unit.
(Refer to 21 - TRANSMISSION/TRANSAXLE/
POWER TRANSFER UNIT - INSTALLATION)
(20) Install cradle plate.
(21) Install exhaust pipe to manifold (Fig. 168).
(22) Install left and right halfshaft assemblies.
(Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - INSTALLATION)
(23) Install front wheel/tire assemblies.
(24) Lower vehicle.
(25) Install transaxle upper bellhousing-to-block
bolts and torque to 95 N´m (70 ft. lbs.).
(26) Install wiper module assembly. (Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - INSTALLATION)
(27) Connect crank position sensor (if equipped).
(28) Connect gearshift cable to upper mount
bracket and transaxle manual valve lever (Fig. 169).
(29) Connect solenoid/pressure switch assembly
(Fig. 170).
(30) Connect transmission range sensor connector
(Fig. 170).
(31) Connect input and output speed sensor con-
nectors (Fig. 170).
(32) Remove plugs and install transaxle oil cooler
line service splice kit. Refer to instructions included
with kit.
(33) Remove plug and Install fluid level indicator/
tube assembly.
(34) Install coolant recovery bottle (Fig. 171).
(35) Install battery shield.
(36) Connect battery cables.
(37) Fill transaxle with suitable amount of ATF+4
(Automatic Transmission FluidÐType 9602). (Refer
to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC
- 41TE/FLUID - STANDARD PROCEDURE)
Fig. 164 Left Mount to Bracket and Transaxle
1 - BOLT - BRACKET TO FRAME RAIL 68 N´m (50 ft. lbs.)
2 - BOLT - MOUNT TO RAIL THRU 75 N´m (55 ft. lbs.)
3 - BOLT - LEFT MOUNT TO TRANSAXLE 54 N´m (40 ft. lbs.)
4 - TRANSAXLE
5 - MOUNT - LEFT
6 - BRACKET - LEFT MOUNT
RSAUTOMATIC - 41TE21 - 209
AUTOMATIC - 41TE (Continued)

Fig. 168 Catalytic Converter to Exhaust Manifold
1 - FLAG NUT
2 - GASKET
3 - BOLT
4 - CATALYTIC CONVERTER
Fig. 169 Gearshift Cable at Transaxle - Typical
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
Fig. 170 Component Connector Location - Typical
1 - SOLENOID/PRESSURE SWITCH ASSY. CONNECTOR
2 - INPUT SPEED SENSOR CONNECTOR
3 - OUTPUT SPEED SENSOR CONNECTOR
4 - TRANSMISSION RANGE SENSOR CONNECTOR
Fig. 171 Coolant Recovery Bottle
1 - UPPER BOLT ATTACHING TO BATTERY TRAY
2 - COOLANT RECOVERY/RESERVE CONTAINER
3 - UPPER BOLT
4 - HOSE
5 - LOWER BOLT (QTY. 2)
6 - LEFT SIDE FRAME RAIL
RSAUTOMATIC - 41TE21 - 211
AUTOMATIC - 41TE (Continued)

(5) Pour four quarts of Moparž ATF+4 (Automatic
Transmission Fluid) Type 9602 through the dipstick
opening.
(6) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(7) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the lowest mark on the dip-
stick (Fig. 217).
(8) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.). Refer
to Fluid Level and Condition Check for the proper
fluid fill procedure.
(9) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
DIPSTICK TUBE FLUID SUCTION METHOD
(ALTERNATIVE)
(1) When performing the fluid suction method,
make sure the transaxle is at full operating temper-
ature.
(2) To perform the dipstick tube fluid suction
method, use a suitable fluid suction device (VaculaŸ
or equivalent).
(3) Insert the fluid suction line into the dipstick
tube.
NOTE: Verify that the suction line is inserted to the
lowest point of the transaxle oil pan. This will
ensure complete evacuation of the fluid in the pan.
(4) Follow the manufacturers recommended proce-
dure and evacuate the fluid from the transaxle.
(5) Remove the suction line from the dipstick tube.
(6) Pour four quarts of Moparž ATF+4 (Automatic
Transmission Fluid) Type 9602 through the dipstick
opening.(7) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the lowest mark on the dip-
stick (Fig. 217).
(9) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.).
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 41TE/FLUID - STANDARD PROCEDURE)
(10) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
GEAR SHIFT CABLE
REMOVAL
(1) Disconnect battery cables.
(2) Remove battery shield.
(3) Remove battery.
(4) Remove speed control servo and position out of
way.
(5) Disconnect gear shift cable at manual valve
lever (Fig. 218).
(6) Disconnect gear shift cable from upper mount
bracket (Fig. 218).
Fig. 217 Transaxle Fluid Level Indicator
1 - TRANSAXLE DIPSTICK
Fig. 218 Gearshift Cable at Transaxle - Typical
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
21 - 248 AUTOMATIC - 41TERS
FLUID (Continued)

INSTALLATION
(1) Fish gear shift cable dash panel opening into
engine compartment and secure grommet (Fig. 223).
(2) Install gear shift cable through column bracket
(Fig. 224) until audible ªclickº is heard.
(3) Connect gear shift cable to gear shift lever (Fig.
224).(4) Install knee bolster (Fig. 225).
(5) Install instrument panel lower silencer (Fig.
226).
(6) Install gear shift cable to transaxle upper
mount bracket (Fig. 227). An audible ªclickº should
be heard.
(7) Connect gear shift cable end to transaxle man-
ual valve lever (Fig. 227).
(8) Adjust gearshift cable. (Refer to 21 - TRANS-
MISSION/TRANSAXLE/AUTOMATIC - 41TE/GEAR
SHIFT CABLE - ADJUSTMENTS)
(9) Install speed control servo into position.
(10) Install battery.
(11) Install battery shield.
(12) Connect battery cables.
Fig. 223 Gearshift Cable/Grommet at Dash Panel
1 - CABLE GROMMET
2 - DASH PANEL
Fig. 224 Gearshift Cable at Column
1 - GEAR SHIFT CABLE
Fig. 225 Knee Bolster
1 - KNEE BOLSTER
Fig. 226 Instrument Panel Lower Silencer
1 - INSTRUMENT PANEL LOWER SILENCER
21 - 250 AUTOMATIC - 41TERS
GEAR SHIFT CABLE (Continued)