battery CHRYSLER VOYAGER 2003 Service Manual

(11) Remove battery hold down nut, clamp, and
battery (Fig. 168).
(12) Remove battery tray (Fig. 169). Disconnect
battery temperature sensor.(13) Remove coolant recovery bottle from bracket.
(14) Remove coolant recovery bottle mounting
bracket (Fig. 170).
(15) Disconnect crossover cable from transaxle
crossover lever (Fig. 171).
(16) Remove crossover cable retainer clip and dis-
engage cable from mount bracket (Fig. 171).
Fig. 168 Battery and Hold-Down Clamp
1 - BATTERY
2 - HOLD-DOWN CLAMP
Fig. 169 Battery Tray
1 - BATTERY TRAY
Fig. 170 Coolant Recovery Bottle Bracket
1 - COOLANT RECOVERY BOTTLE BRACKET
2 - NUT
3 - MOUNT BRACKET
Fig. 171 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
RST850 MANUAL TRANSAXLE21-83
GEARSHIFT CABLE - SELECTOR (Continued)
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(17) Raise vehicle on hoist.
(18) Remove selector cable from engine compart-
ment, then remove cable from passenger compart-
ment through opening in floor pan.
INSTALLATION
(1) From underneath vehicle, install gearshift
selector cable into passenger compartment through
floor pan hole. Install remainder of cable into posi-
tion in engine compartment.
(2) Lower vehicle.
(3) Install selector cable to mount bracket and
secure with retainer clip (Fig. 172).
(4) Install cable to transaxle selector lever (Fig.
172).
(5)2.4L Gas models goto Step 10. 2.5L TD
models:Install coolant recovery bottle bracket (Fig.
173).(6) Install coolant recovery bottle to bracket.
(7) Connect battery temperature sensor to battery
tray. Install battery tray into position (Fig. 174).
Fig. 172 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
Fig. 173 Coolant Recovery Bottle Bracket
1 - COOLANT RECOVERY BOTTLE BRACKET
2 - NUT
3 - MOUNT BRACKET
Fig. 174 Battery Tray
1 - BATTERY TRAY
21 - 84 T850 MANUAL TRANSAXLERS
GEARSHIFT CABLE - SELECTOR (Continued)
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(8) Install battery, hold-down clamp, and nut (Fig.
175).
(9) Install battery thermal shield (Fig. 176).(10) Install selector cable to gearshift mechanism
(Fig. 177). Install retainer clip (Fig. 178).
Fig. 175 Battery and Hold-Down Clamp
1 - BATTERY
2 - HOLD-DOWN CLAMP
Fig. 176 Battery Thermal Shield
1 - BATTERY THERMAL SHIELD
Fig. 177 Selector Cable at Gearshift Mechanism
1 - GEARSHIFT MECHANISM
2 - SELECTOR CABLE
Fig. 178 Selector Cable Retainer Clip
1 - RETAINER CLIP
RST850 MANUAL TRANSAXLE21-85
GEARSHIFT CABLE - SELECTOR (Continued)
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(15) Install gearshift knob to gearshift lever (Fig.
183). Orient shift pattern1¤4-turn clockwise, push
down and rotate1¤4-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
1¤4-turn clockwise (Fig. 184).
INSTALLATION
(1) Install gearshift knob pattern1¤4-turn clock-
wise, press down, and rotate1¤4-turn counter clock-
wise (Fig. 184).
(2) Secure gearshift boot to base of knob.
GEARSHIFT MECHANISM
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove gearshift knob by pushing down and
rotating
1¤4turn clock-wise (Fig. 185).
Fig. 183 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 184 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 185 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
RST850 MANUAL TRANSAXLE21-87
GEARSHIFT CABLE - SELECTOR (Continued)
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(7) Install cupholder plugs (Fig. 202).
(8) Install gearshift boot to console (Fig. 203).
Secure with three (3) retainer clips.(9) Install gearshift knob to gearshift lever (Fig.
204). Orient shift pattern1¤4-turn clockwise, push
down and rotate1¤4-turn counter-clockwise and
release. Secure boot to knob.
(10) Connect battery negative cable.
Fig. 202 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
Fig. 203 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 204 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
21 - 92 T850 MANUAL TRANSAXLERS
GEARSHIFT MECHANISM (Continued)
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TORQUE CONVERTER LEAKAGE
Possible sources of torque converter leakage are:
²Torque converter weld leaks at the outside diam-
eter weld (Fig. 8).
²Torque converter hub weld (Fig. 8).
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)
(1) Disconnect battery cables.
(2) Remove battery shield (Fig. 9).
(3) Remove coolant recovery bottle (Fig. 10).
(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. 11).
(7) Disconnect transmission range sensor (TRS)
connector (Fig. 11).
(8) Disconnect solenoid/pressure switch assembly
connector (Fig. 11).
Fig. 8 Converter Leak Points - Typical
1 - OUTSIDE DIAMETER WELD
2 - TORQUE CONVERTER HUB WELD
3 - STARTER RING GEAR
4 - LUG
Fig. 9 Battery Thermal Guard
1 - BATTERY THERMOWRAP (IF EQUIPPED)
2 - INTEGRATED POWER MODULE
3 - FRONT CONTROL MODULE
Fig. 10 Coolant Recovery Bottle
1 - UPPER BOLT ATTACHING TO BATTERY TRAY
2 - COOLANT RECOVERY CONTAINER
3 - UPPER BOLT
4 - HOSE
5 - LOWER BOLT (QTY. 2)
6 - LEFT SIDE FRAME RAIL
21 - 124 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
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(20) Connect solenoid/pressure switch assembly
(Fig. 166).
(21) Connect transmission range sensor connector
(Fig. 166).
(22) Connect input and output speed sensor con-
nectors (Fig. 166).
(23) Remove plugs and install transaxle oil cooler
line service splice kit. Refer to instructions included
with kit.
(24) Remove plug and Install fluid level indicator/
tube assembly.(25) Install coolant recovery bottle (Fig. 167).
(26) Install battery shield.
(27) Connect battery cables.
(28) Fill transaxle with suitable amount of ATF+4
(Automatic Transmission FluidÐType 9602). (Refer
to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC
- 41TE/FLUID - STANDARD PROCEDURE)
Fig. 166 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. 167 Coolant Recovery Bottle
1 - UPPER BOLT ATTACHING TO BATTERY TRAY
2 - COOLANT RECOVERY CONTAINER
3 - UPPER BOLT
4 - HOSE
5 - LOWER BOLT (QTY. 2)
6 - LEFT SIDE FRAME RAIL
21 - 168 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
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(6) Pour four quarts of MopartATF+4 (Automatic
Transmission Fluid) 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. 212).
(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. 213).
(6) Disconnect gear shift cable from upper mount
bracket (Fig. 213).(7) Remove instrument panel lower silencer (Fig.
214).
(8) Remove knee bolster (Fig. 215).
(9) Disconnect gear shift cable from gear shift
lever (Fig. 216).
(10) Remove gear shift cable from column bracket
(Fig. 216).
(11) Disengage grommet from dash panel (Fig.
217) and remove gear shift cable from inside vehicle.
Fig. 213 Gearshift Cable at Transaxle - Typical
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
Fig. 214 Instrument Panel Lower Silencer
1 - INSTRUMENT PANEL LOWER SILENCER
Fig. 215 Knee Bolster
1 - KNEE BOLSTER
21 - 204 41TE AUTOMATIC TRANSAXLERS
FLUID (Continued)
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(4) Install knee bolster (Fig. 220).
(5) Install instrument panel lower silencer (Fig.
221).
(6) Install gear shift cable to transaxle upper
mount bracket (Fig. 222). An audible ªclickº should
be heard.
(7) Connect gear shift cable end to transaxle man-
ual valve lever (Fig. 222).
(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.
ADJUSTMENTS
GEARSHIFT CABLE ADJUSTMENT
VERIFICATION
(1) Place gearshift lever in gated park (P).
(2) Attempt to move vehicle by rocking back and
forth on level ground. If vehicle does not move,
attempt to start engine. If engine starts, the park
position is correct.
(3) Set parking brake.
(4) Turn key to on/run and depress brake pedal.
Place gearshift lever in neutral (N).
(5) Attempt to start engine. If engine starts in
both neutral (N) or park (P), gearshift cable is
adjusted properly. No adjustment is required.
(6) If engine does not start in either park (P) or
neutral (N), perform adjustment procedure.
Fig. 220 Knee Bolster
1 - KNEE BOLSTER
Fig. 221 Instrument Panel Lower Silencer
1 - INSTRUMENT PANEL LOWER SILENCER
Fig. 222 Gearshift Cable at Transaxle
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
21 - 206 41TE AUTOMATIC TRANSAXLERS
GEAR SHIFT CABLE (Continued)
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INSTALLATION
(1) Using Tool C-4193, install oil pump seal (Fig.
290).
(2) Install transaxle to vehicle (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC - 41TE
- INSTALLATION).
SHIFT INTERLOCK SOLENOID
DESCRIPTION
The Brake/Transmission Shift Interlock system
consists of an electro-magnetic solenoid mounted to
the steering column (Fig. 291). The solenoid's plunger
consists of an integrated hook, which operates the
shift lever pawl (part of shift lever assembly), and a
plunger return spring (Fig. 292). The solenoid also
has an integrated bracket, which facilitates fastening
to the steering column.
OPERATION
The Brake/Transmission Shift Interlock (BTSI) Sole-
noid prevents the transmission shift lever from being
moved out of PARK (P) unless the brake pedal is
applied. The BTSI solenoid is hardwired to and con-
trolled by the Intelligent Power Module (IPM). Battery
voltage is applied to one side of the solenoid with the
ignition key is in either the OFF, ON/RUN, or START
positions (Fig. 293). The ground side of the solenoid is
controlled by a driver within the IPM. It relies on volt-
age supplied from the stop lamp switch to the stop
lamp sense circuit within the IPM to tell when the
brake pedal is depressed. When the brake pedal is
depressed, the ground circuit opens, de-energizing the
solenoid. When the brake pedal is released, the ground
circuit is closed, energizing the solenoid.
When the ignition key is in either the OFF,
ON/RUN, or START positions, the BTSI solenoid is
energized, and the solenoid plunger hook pulls the
shift lever pawl into position, prohibiting the shift
lever from moving out of PARK (P) (Fig. 294). When
the brake pedal is depressed, the ground circuit
opens, de-energizing the solenoid. This moves the
gearshift lever pawl out of the way (Fig. 295), allow-
ing the shift lever to be moved into any gear position.
Fig. 290 Install Oil Pump Seal
1 - TOOL C-4193
2 - HANDLE TOOL C-4171
Fig. 291 Brake/Transmission Shift Interlock (BTSI)
Solenoid Location
1 - BTSI SOLENOID
Fig. 292 Solenoid Plunger and Return Spring
1 - PLUNGER
2 - RETURN SPRING
3 - BTSI SOLENOID
RS41TE AUTOMATIC TRANSAXLE21 - 233
SEAL - OIL PUMP (Continued)
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