brakes CHRYSLER VOYAGER 2004 Service Manual

SPEED CONTROL
TABLE OF CONTENTS
page page
SPEED CONTROL
DESCRIPTION..........................1
OPERATION
OPERATION..........................1
OPERATION - INTERACTIVE SPEED
CONTROL (4 Speed EATX Only)...........2
DIAGNOSIS AND TESTING - ROAD TEST.....3
SPECIFICATIONS - TORQUE...............3
CABLE
DESCRIPTION..........................4
OPERATION............................4
REMOVAL.............................4
INSTALLATION..........................4
SERVO
DESCRIPTION..........................4OPERATION............................4
REMOVAL.............................5
INSTALLATION..........................5
SWITCH
DESCRIPTION..........................6
OPERATION............................6
REMOVAL.............................6
INSTALLATION..........................6
VACUUM RESERVOIR
DESCRIPTION..........................6
OPERATION............................6
REMOVAL.............................6
INSTALLATION..........................6
SPEED CONTROL
DESCRIPTION
The speed control system is electronically con-
trolled and vacuum operated. The electronic control
is integrated into the Powertrain Control Module.
The controls are located on the steering wheel. The
ON/OFF, and SET buttons are located on the left side
of the airbag module. The RESUME/ACCEL, CAN-
CEL and COAST buttons are located on the right
side of the airbag module (Fig. 1).The system is designed to operate at speeds above
30 mph (48 km/h).
WARNING: THE USE OF SPEED CONTROL IS NOT
RECOMMENDED WHEN DRIVING CONDITIONS DO
NOT PERMIT MAINTAINING A CONSTANT SPEED,
SUCH AS IN HEAVY TRAFFIC OR ON ROADS THAT
ARE WINDING, ICY, SNOW COVERED, OR SLIP-
PERY.
OPERATION
OPERATION
When speed control is activated by depressing the
ON switch, the PCM allows a set speed to be stored
in RAM for speed control. To store a set speed,
depress and release the SET switch while the vehicle
is moving at a speed between 30 and 85 mph. In
order for the speed control to engage, the brakes can-
not be applied, nor can the gear selector be indicat-
ing the transmission is in Park or Neutral (ATX) or
1st/2nd gear (MTX). The speed control can be disen-
gaged manually by:
²Stepping on the brake pedal
²Depressing the OFF switch
²Depressing the CANCEL switch.
²Depressing the clutch pedal
²Operating in 1st or 2nd gear (autostick, if
equipped)
Fig. 1 SPEED CONTROL SWITCHES - Typical
RSSPEED CONTROL8P-1

AUTOMATIC SPEED CONTROL OVERSPEED
REDUCTION
DESCRIPTION
Transmission control software includes an auto-
matic speed control overspeed reduction feature. This
maintains vehicle speed at the selected set point
when descending a grade.
OPERATION
The TCM (on SBEC vehicles) (PCM on NGC vehi-
cles) first senses that the speed control is set. If the
set speed is exceeded by more than 4 mph (6.5
km/hr) and the throttle is closed, the TCM (on SBEC
vehicles) (PCM on NGC vehicles) causes the trans-
axle to downshift to THIRD gear. After downshifting,
the automatic speed control resumes normal opera-
tion. To ensure that an upshift is appropriate after
the set speed is reached, the TCM (on SBEC vehi-
cles) (PCM on NGC vehicles) waits until the speed
control system opens the throttle at least 6 degrees
before upshifting to OVERDRIVE again.
If the driver applies the brakes, canceling auto-
matic speed control operation with the transaxle still
in THIRD gear, the TCM (on SBEC vehicles) (PCM
on NGC vehicles) maintains this gear until the driver
opens the throttle at least 6 degrees to avoid an inap-
propriate upshift. The upshift is also delayed for 2.5
seconds after reaching the 6 degrees throttle opening
in anticipation that the driver might open the throt-
tle enough to require THIRD gear. This will avoid
unnecessary and disturbing transmission cycling. If
the automatic speed control RESUME feature is used
after braking, the upshift is delayed until the set
speed is achieved to reduce cycling and provide bet-
ter response.
DIAGNOSIS AND TESTING - ROAD TEST
Perform a vehicle road test to verify reports of
speed control system malfunction. The road test
should include attention to the speedometer. Speed-
ometer operation should be smooth and without flut-
ter at all speeds.
Flutter in the speedometer indicates a problem
which might cause surging in the speed control sys-
tem. The cause of any speedometer problems should
be corrected before proceeding. Refer to the Instru-
ment Cluster for speedometer diagnosis.
If a road test verifies an inoperative system, and
the speedometer operates properly, check for:
²A Diagnostic Trouble Code (DTC). If a DTC
exists, conduct tests per the Powertrain Diagnostic
Procedures manual.
²A misadjusted brake (stop) lamp switch. This
could also cause an intermittent problem.
²Loose or corroded electrical connections at the
servo. Corrosion should be removed from electrical
terminals and a light coating of Mopar Multipurpose
Grease, or equivalent, applied.
²Leaking vacuum reservoir.
²Loose or leaking vacuum hoses or connections.
²Defective one-way vacuum check valve.
²Secure attachment at both ends of the speed
control servo cable.
²Smooth operation of throttle linkage and throttle
body air valve.
²Conduct electrical test at PCM.
²Failed speed control servo. Do the servo vacuum
test.
CAUTION: When test probing for voltage or conti-
nuity at electrical connectors, care must be taken
not to damage connector, terminals or seals. If
these components are damaged, intermittent or
complete system failure may occur.
SPECIFICATIONS - TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Servo Mounting Bracket
Nuts14 10.3 123.9
Servo Mounting Bracket
Bolts14 10.3 123.9
Servo Mounting Nuts 6.7 60
RSSPEED CONTROL8P-3
SPEED CONTROL (Continued)

WIRING
TABLE OF CONTENTS
page page
WIRING DIAGRAM INFORMATION....... 8W-01-1
COMPONENT INDEX.................. 8W-02-1
POWER DISTRIBUTION............... 8W-10-1
GROUND DISTRIBUTION.............. 8W-15-1
BUS COMMUNICATIONS.............. 8W-18-1
CHARGING SYSTEM.................. 8W-20-1
STARTING SYSTEM.................. 8W-21-1
FUEL/IGNITION SYSTEM.............. 8W-30-1
TRANSMISSION CONTROL SYSTEM..... 8W-31-1
VEHICLE SPEED CONTROL............ 8W-33-1
ANTILOCK BRAKES................... 8W-35-1
VEHICLE THEFT SECURITY SYSTEM..... 8W-39-1
INSTRUMENT CLUSTER............... 8W-40-1
HORN/CIGAR LIGHTER/POWER OUTLET . . 8W-41-1
AIR CONDITIONING-HEATER........... 8W-42-1
AIRBAG SYSTEM.................... 8W-43-1
INTERIOR LIGHTING.................. 8W-44-1
BODY CONTROL MODULE............. 8W-45-1
MESSAGE CENTER................... 8W-46-1AUDIO SYSTEM..................... 8W-47-1
REAR WINDOW DEFOGGER............ 8W-48-1
OVERHEAD CONSOLE................. 8W-49-1
FRONT LIGHTING.................... 8W-50-1
REAR LIGHTING..................... 8W-51-1
TURN SIGNALS...................... 8W-52-1
WIPERS............................ 8W-53-1
TRAILER TOW....................... 8W-54-1
POWER WINDOWS................... 8W-60-1
POWER DOOR LOCKS................ 8W-61-1
POWER MIRRORS................... 8W-62-1
POWER SEATS...................... 8W-63-1
POWER SUNROOF................... 8W-64-1
SPLICE INFORMATION................ 8W-70-1
CONNECTOR PIN-OUTS............... 8W-80-1
CONNECTOR/GROUND/SPLICE
LOCATION........................ 8W-91-1
POWER DISTRIBUTION SYSTEM........ 8W-97-1 RSWIRING
8W-1

8W-35 ANTILOCK BRAKES
Component Page
Body Control Module................. 8W-35-2
Brake Lamp Switch.................. 8W-35-3
Controller Antilock Brake.......... 8W-35-2, 3, 4
Engine Control Module................ 8W-35-3
Front Control Module................. 8W-35-3
Fuse 9............................ 8W-35-2
Fuse 21............................ 8W-35-2
Fuse 26............................ 8W-35-3
G100.............................. 8W-35-2Component Page
G200.............................. 8W-35-2
G300.............................. 8W-35-3
Integrated Power Module............ 8W-35-2, 3
Left Front Wheel Speed Sensor......... 8W-35-4
Left Rear Wheel Speed Sensor.......... 8W-35-4
Powertrain Control Module............ 8W-35-3
Right Front Wheel Speed Sensor........ 8W-35-4
Right Rear Wheel Speed Sensor......... 8W-35-4
Traction Control Switch............... 8W-35-2
RS8W-35 ANTILOCK BRAKES8W-35-1

BRAKE FLUID LEVEL SWITCH-2WAY
CAV CIRCUIT FUNCTION
1 B20 20DG/OR BRAKE FLUID LEVEL SWITCH SENSE
2 Z420 20BK/OR GROUND
BRAKE LAMP SWITCH - BLACK 6 WAY
CAV CIRCUIT FUNCTION
1 A103 18GY/RD FUSED B(+)
2 L50 18WT/TN (DIESEL) PRIMARY BRAKE SWITCH SIGNAL
2 L50 18WT/TN (GAS) BRAKE LAMP SWITCH OUTPUT
3 V30 20VT/WT (GAS) S/C BRAKE SWITCH OUTPUT
4 V32 20VT/YL (GAS) SPEED CONTROL ON/OFF SWITCH SENSE
5 Z429 20BK/OR GROUND
6 B29 20DG/WT SECONDARY BRAKE SWITCH SIGNAL
BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K32 18DB/YL BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID
CONTROL
2 F2 18PK/YL FCM OUTPUT (UNLOCK-RUN-START)
C100 - BLACK (BODY SIDE)
CAV CIRCUIT
1 D21 20WT/DG
2 D123 20WT/BR
3 D15 20DG/YL (DIESEL)
3 D20 20WT/LG (GAS)
4 T141 20YL/OR (GAS MTX EXPORT)
5 Z111 20BK/WT
6 N1 16DB/OR (DIESEL)
6 G31 18VT/LG (EXCEPT EXPORT)
7 N2 18DB/YL (DIESEL)
7 D15 20DG/YL (GAS EATX)
8 K22 20OR/DB (DIESEL)
8 V32 20VT/YL (GAS)
9 B29 20DG/WT
10 V37 20VT
11 V30 20VT/WT (GAS)
12 K900 20DB/DG
13 B1 18DG/OR (ANTILOCK BRAKES)
14 B2 18DG/LB (ANTILOCK BRAKES)
RS8W-80 CONNECTOR PIN-OUTS8W-80-19

C100 - BLACK (POWERTRAIN SIDE)
CAV CIRCUIT
1 D21 20WT/DG (2.4L)
1 D21 20WT/BR (3.3L/3.8L)
2 D123 20WT/BR (2.4L EATX)
2 D123 20WT/OR (3.3L/3.8L)
3 D20 20WT/LG (GAS)
4 T141 18YL (GAS MTX EXPORT)
5 Z111 20BK/WT (3.3L/3.8L EXCEPT
EXPORT/2.4L)
5 Z111 18BK/WT (3.3L/3.8L EXPORT/
DIESEL)
6 G31 18VT/LB (2.4L)
6 N1 18DB/OR (DIESEL)
7 N2 18DB/YL (DIESEL)
7 D15 18DG/YL (GAS EATX)
8 K22 20OR/DB (DIESEL)
8 V32 18VT/YL (GAS)
9 B29 20DG/WT (DIESEL)
9 B29 18DG/WT (GAS)
10 V37 20VT/TN (DIESEL)
10 V37 18VT (GAS)
11 V30 20VT/WT (GAS)
12 K900 20DB/DG
13 B1 18DG/OR (ANTILOCK BRAKES)
14 B2 18DG/LB (ANTILOCK BRAKES)
C101 (DIESEL) - LT. GRAY (BODY SIDE)
CAV CIRCUIT
1 L50 18WT/TN
2-
3 F853 20LG/PK
4 K119 20DB/LG (MTX)
5 B4 18DG/GY (ANTILOCK BRAKES)
6 B3 18DG/YL (ANTILOCK BRAKES)
7 F500 18DG/PK
8 K4 20BK/LB
9 F852 20VT/PK
10 K151 20WT
8W - 80 - 20 8W-80 CONNECTOR PIN-OUTSRS

C101 (DIESEL) - LT. GRAY (POWERTRAIN SIDE)
CAV CIRCUIT
1 L50 20WT/TN
2-
3 F853 20LG/PK
4 K119 20DB/LG (MTX)
5 B4 18DG/GY (ANTILOCK BRAKES)
6 B3 18DG/YL (ANTILOCK BRAKES)
7 F500 18DG/PK
8 K4 20BK/LB
9 F852 20VT/PK
10 K151 20WT
C101 (GAS) - LT. GRAY (BODY SIDE)
CAV CIRCUIT
1 L50 18WT/TN
2 B4 18DG/GY
3 B3 18DG/YL
4 F500 18DG/PK
C101 (GAS) - LT. GRAY (POWERTRAIN SIDE)
CAV CIRCUIT
1 L50 18WT/TN
2 B4 18DG/GY
3 B3 18DG/YL
4 F500 18DG/PK
C102 (GAS) - BLACK (FUEL RAIL SIDE)
CAV CIRCUIT
1 K11 16BR/YL (2.4L)
1 K342 16BR/WT (3.3L/3.8L)
2 K12 16BR/DB (2.4L)
2 K1 18VT/BR (3.3L/3.8L)
3 K13 16BR/LB (2.4L)
3 K11 16BR/YL (3.3L/3.8L)
4 K14 16BR/TN (2.4L)
4 K12 16BR/DB (3.3L/3.8L)
5 K342 16BR/WT (2.4L)
5 K13 16BR/LB (3.3L/3.8L)
6 K900 18DB/DG (2.4L)
6 K14 16BR/TN (3.3L/3.8L)
7 K2 18VT/OR (2.4L)
7 K900 18DB/DG (3.3L/3.8L)
8 K1 18VT/BR (2.4L)
8 K38 16BR/OR (3.3L/3.8L)
9 K58 16BR/VT (3.3L/3.8L)
10 F855 18PK/YL
RS8W-80 CONNECTOR PIN-OUTS8W-80-21

STANDARD PROCEDURE - FLUID AND FILTER
SERVICE
NOTE: Refer to the maintenance schedules in
LUBRICATION and MAINTENANCE, or the vehicle
owner's manual, for the recommended maintenance
(fluid/filter change) intervals for this transaxle.
NOTE: Only fluids of the type labeled MoparTATF+4
(Automatic Transmission Fluid) should be used. A
filter change should be made at the time of the
transmission oil change. The magnet (on the inside
of the oil pan) should also be cleaned with a clean,
dry cloth.
NOTE: If the transaxle is disassembled for any rea-
son, the fluid and filter should be changed.
FLUID/FILTER SERVICE (RECOMMENDED)
(1) Raise vehicle on a hoist. Refer to LUBRICA-
TION and MAINTENANCE for proper procedures.
Place a drain container with a large opening, under
transaxle oil pan.
(2) Loosen pan bolts and tap the pan at one corner
to break it loose allowing fluid to drain, then remove
the oil pan.
(3) Install a new filter and o-ring on bottom of the
valve body (Fig. 211).
(4) Clean the oil pan and magnet. Reinstall pan
using new Mopar Silicone Adhesive sealant. Tighten
oil pan bolts to 19 N´m (165 in. lbs.).(5) Pour four quarts of MopartATF+4 (Automatic
Transmission Fluid) 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. 212).
(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.
Fig. 211 Filter and O-Ring
1 - OIL FILTER
2 - O-RING
Fig. 212 Fluid Level Indicator
1 - FLUID LEVEL INDICATOR
RS41TE AUTOMATIC TRANSAXLE21 - 203
FLUID (Continued)

(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)

STANDARD PROCEDURE - FLUID AND FILTER
SERVICE
NOTE: Refer to the maintenance schedules in
LUBRICATION and MAINTENANCE, or the vehicle
owner's manual, for the recommended maintenance
(fluid/filter change) intervals for this transaxle.
NOTE: Only fluids of the type labeled MoparTATF+4
should be used. A filter change should be made at
the time of the transmission oil change. The magnet
(on the inside of the oil pan) should also be cleaned
with a clean, dry cloth.
NOTE: If the transaxle is disassembled for any rea-
son, the fluid and filter should be changed.
FLUID/FILTER SERVICE (RECOMMENDED)
(1) Raise vehicle on a hoist. Refer to LUBRICA-
TION and MAINTENANCE for proper procedures.
Place a drain container with a large opening, under
transaxle oil pan. (2) Remove both engine mount-to-engine cross-
member cradle nuts. Using suitable screw jack and
wood block, raise engine and transmission slightly to
facilitate transaxle oil pan removal and installation. (3) Loosen pan bolts and tap the pan at one corner
to break it loose allowing fluid to drain, then remove
the oil pan. (4) Install a new filter and o-ring on bottom of the
valve body (Fig. 189). (5) Clean the oil pan and magnet. Reinstall pan
using new Mopar Silicone Adhesive sealant. Tighten
oil pan bolts to 19 N´m (165 in. lbs.). (6) Pour four quarts of Mopar tATF+4 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. 190).
(9) 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. (10) 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.
Fig. 189 Filter and O-Ring
1 - OIL FILTER
2 - O-RING
Fig. 190 Fluid Level Indicator
1 - FLUID LEVEL INDICATOR
21s - 104 40TE AUTOMATIC TRANSAXLERS
FLUID (Continued)