fluids CHRYSLER VOYAGER 2004 Service Manual

LUBRICATION & MAINTENANCE
TABLE OF CONTENTS
page page
INTERNATIONAL SYMBOLS
DESCRIPTION..........................1
FLUID TYPES
DESCRIPTION
DESCRIPTION - ENGINE OIL AND
LUBRICANTS.........................1
DESCRIPTION - ENGINE COOLANT........3
DESCRIPTION - FLEXIBLE FUEL ENGINE
OIL .................................3
DESCRIPTION - AUTOMATIC/MANUAL
TRANSAXLE FLUID.....................4
DESCRIPTION - FUEL REQUIREMENTS.....4
DESCRIPTION - FUEL REQUIREMENTS -
DIESEL ENGINE.......................6
DESCRIPTION - ENGINE OIL - DIESEL
ENGINES............................6
DESCRIPTION - AWD REAR DRIVELINE
MODULE FLUIDS......................6
DESCRIPTION - AWD POWER TRANSFER
UNIT FLUID...........................6FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES.......6
FLUID FILL/CHECK LOCATIONS
DESCRIPTION..........................7
LUBRICATION POINTS
DESCRIPTION..........................7
MAINTENANCE SCHEDULES
DESCRIPTION
DESCRIPTION........................7
DESCRIPTION - EXPORT...............15
DESCRIPTION ± DIESEL ENGINES ±
EXPORT............................24
HOISTING
STANDARD PROCEDURE - HOISTING.......27
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING . 27
TOWING
STANDARD PROCEDURE - TOWING........29
INTERNATIONAL SYMBOLS
DESCRIPTION
DaimlerChrysler Corporation uses international
symbols to identify engine compartment lubricant
and fluid inspection and fill locations (Fig. 1).
FLUID TYPES
DESCRIPTION
DESCRIPTION - ENGINE OIL AND LUBRICANTS
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
When service is required, DaimlerChrysler Corpo-
ration recommends that only Mopartbrand parts,
lubricants and chemicals be used. Mopartprovides
the best engineered products for servicing
DaimlerChrysler Corporation vehicles.
Only lubricants bearing designations defined by
the following organization should be used.
Fig. 1 INTERNATIONAL SYMBOLS
RSLUBRICATION & MAINTENANCE0-1

FUEL REQUIREMENTS
The vehicle will operate on both unleaded gasoline
with an octane rating of 87, or E-85 fuel, or any mix-
ture of these two.
For best results, a refueling pattern that alternates
between E-85 and unleaded gasoline should be
avoided. When you do switch fuels, it is recom-
mended that
²you do not switch when the fuel gauge indicates
less than 1/4 full
²you do not add less than 5 gallons when refuel-
ing
²you operate the vehicle immediately after refuel-
ing for a period of at least 5 minutes
Observing these precautions will avoid possible
hard starting and/or significant deterioration in
driveability during warm up.
FFV STARTING
The characteristics of E-85 fuel make it unsuitable
for use when ambient temperatures fall below 0ÉF. In
the range of 0ÉF to 32ÉF, you may experience an
increase in the time it takes for your engine to start,
and a deterioration in driveability (sags and/or hesi-
tations) until the engine is fully warmed up.
Engine Operating on E-85 Fuel
If vehicle operates on E-85 fuel either full or part-
time, use only MopartFlexible Fuel 5W-30 engine oil
or an equivalent that meets DaimlerChrysler Stan-
dard MS-9214. Equivalent commercial Flexible Fuel
engine oils may be labeled as Multi-Fuel, Variable
Fuel, Flexible Fuel, etc. These engine oils may be
satisfactory if they meet the DaimlerChrysler Stan-
dard.
SAE 5W-30 engine oil is preferred for use in Flex-
ible Fuel engines.
CAUTION: If Flexible Fuel engine oil is not used
when using E-85 fuel, engine wear or damage may
result.
CRUISING RANGE
Because E-85 fuel contains less energy per gallon
than gasoline, you will experience an increase in fuel
consumption. You can expect your MPG and your
driving range to decrease by about 30% compared to
gasoline operation.
DESCRIPTION - AUTOMATIC/MANUAL
TRANSAXLE FLUID
NOTE: Refer to the maintenance schedules for the
recommended maintenance (fluid/filter change)
intervals for these transaxles.NOTE: All transaxles have a common transmission
and differential sump. Filling the transaxle accom-
modates the differential as well.
TRANSMISSION FLUID
MopartATF+4 (Automatic Transmission Fluid) is
required in the 41TE automatic and T850 manual
transaxles. Substitute fluids can induce transmission
problems and/or failure.
MopartATF+4 (Automatic Transmission Fluid)
when new is red in color. The ATF is dyed red so it
can be identified from other fluids used in the vehicle
such as engine oil or antifreeze. The red color is not
permanent and is not an indicator of fluid condition.
As the vehicle is driven, the ATF will begin to look
darker in color and may eventually become brown.
This is normal.ATF+4 also has a unique odor that
may change with age. Consequently,odor and color
cannot be used to indicate the fluid condition
or the need for a fluid change.
FLUID ADDITIVES
DaimlerChrysler strongly recommends against the
addition of any fluids to the transmission, other than
those automatic transmission fluids listed above.
Exceptions to this policy are the use of special dyes
to aid in detecting fluid leaks.
Various ªspecialº additives and supplements exist
that claim to improve shift feel and/or quality. These
additives and others also claim to improve converter
clutch operation and inhibit overheating, oxidation,
varnish, and sludge. These claims have not been sup-
ported to the satisfaction of DaimlerChrysler and
these additivesmust not be used.The use of trans-
mission ªsealersº should also be avoided, since they
may adversely affect the integrity of transmission
seals.
DESCRIPTION - FUEL REQUIREMENTS
Your engine is designed to meet all emissions reg-
ulations and provide excellent fuel economy and per-
formance when using high quality unleaded gasoline
having an octane rating of 87. The use of premium
gasoline is not recommended. The use of premium
gasoline will provide no benefit over high quality reg-
ular gasoline, and in some circumstances may result
in poorer performance.
Light spark knock at low engine speeds is not
harmful to your engine. However, continued heavy
spark knock at high speeds can cause damage and
immediate service is required. Engine damage result-
ing from operation with a heavy spark knock may
not be covered by the new vehicle warranty.
Poor quality gasoline can cause problems such as
hard starting, stalling and hesitations. If you experi-
0 - 4 LUBRICATION & MAINTENANCERS
FLUID TYPES (Continued)

NOTE: Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
DESCRIPTION - FUEL REQUIREMENTS -
DIESEL ENGINE
WARNING: DO NOT USE ALCOHOL OR GASOLINE
AS A FUEL BLENDING AGENT. THEY CAN BE
UNSTABLE UNDER CERTAIN CONDITIONS AND
HAZARDOUS OR EXPLOSIVE WHEN MIXED WITH
DIESEL FUEL.
Use good quality diesel fuel from a reputable sup-
plier. For most year-round service, number 2 diesel
fuel meeting DIN EN 590 (Class0-4)will provide
good performance. If the vehicle is exposed to
extreme cold (below -18ÉC/0ÉF) or is required to oper-
ate at colder than normal conditions for prolonged
periods, use climatize No. 2 diesel fuel or dilute the
No. 2 diesel fuel with 50% No. 1 diesel fuel as long as
it meets ASTM D 975: 1D and 2D and the quality of
lubrication behavior is in accordance with DIN EN
590. This will provide better protection from fuel gel-
ling or wax plugging of the fuel filters.
Diesel fuel is seldom completely free of water. To
prevent fuel system trouble, including fuel line freez-
ing in winter, drain the accumulated water from the
fuel/water separator using the fuel/water separator
drain provided. If you buy good quality fuel and fol-
low the cold weather advice above, fuel conditioners
should not be required in your vehicle. If available in
your area, a high cetane ªpremiumº diesel fuel may
offer improved cold starting and warm up perfor-
mance.
DESCRIPTION - ENGINE OIL - DIESEL
ENGINES
Use only Diesel Engine Oil meeting standardMIL-
2104Cor API ClassificationCD or higherorCCML
D4, D5.
SAE VISCOSITY GRADE
CAUTION: Low viscosity oils must have the proper
API quality or the CCMC G5 designation.
To assure of properly formulated engine oils, it is
recommended that SAE Grade 10W-40 engine oils
that meet Chrysler material standard MS-6395, be
used in accordance to ACEA B3, B4 specification.
European Grade 10W-40 oils are also acceptable.
Oils of the SAE 5W-40 grade number are preferred
when minimum temperatures consistently fall below
-15ÉC.
DESCRIPTION - AWD REAR DRIVELINE
MODULE FLUIDS
The AWD Rear Driveline Module Assembly consists
of two subassemblies, the Overrunning Clutch Hous-
ing (front) and the Differential Carrier (rear).
The recommended lubricant for the Overrunning
Clutch Housing is MopartATF+4. The recommended
lubricant for the Differential Carrier is Mopart
80W-90 Gear and Axle Lubricant.
DESCRIPTION - AWD POWER TRANSFER UNIT
FLUID
The recommended lubricant for the AWD Power
Transfer Unit is MopartGear and Axle Lubricant
80W-90.
FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES
DESCRIPTION SPECIFICATION
Fuel Tank (Gas) 75 L (20 gal.)
Fuel Tank (Diesel) 75 L (20 gal.)
Engine Oil* - 2.4 L 4.7 L (5.0 qts.)
Engine Oil* - 3.3/3.8 L 4.7 L (5.0 qts.)
Engine Oil* - 2.5 L (Diesel) 6.0 L (6.3 qts.)
Cooling System** - 2.4 L 10.7 L (11.4 qts.)
Cooling System** - 2.5 L
Turbo Diesel with Auxiliary
Heater13.8 L (14.6 qts.)
Cooling System** - 3.3/3.8
L without Auxiliary Heater12.6 L (13.4 qts.)
Cooling System** - 3.3/3.8
L with Auxiliary Heater15.4 L (16.3 qts.)
Automatic Transaxle -
Service Fill3.8 L (4.0 qts.)
Automatic Transaxle -
41TE Overhaul Fill9.2 L (9.7 qts.)
Manual Transaxle (T850
5-Speed)2.4-2.7 L (2.5-2.9 qts.)
AWD Power Transfer Unit 1.15 L (2.4 pts.)
Power Steering 1.2 L (2.5 pts.)
AWD Bi-directional
Overrunning Clutch0.575 L (1.22 pts.)
AWD Rear Carrier 0.7 L (1.48 pts.)
* (includes oil filter)
** (includes heater and recovery/reserve bottle)
0 - 6 LUBRICATION & MAINTENANCERS
FLUID TYPES (Continued)

Use only brake fluid that was stored in a tightly-
sealed container.
DO NOTuse petroleum-based fluid because seal
damage will result. Petroleum based fluids would be
items such as engine oil, transmission fluid, power
steering fluid etc.
SPECIFICATIONS
BRAKE FLUID
The brake fluid used in this vehicle must conform
to DOT 3 specifications (DOT 4 and DOT 4+ are
acceptable) and SAE J1703 standards. No other type
of brake fluid is recommended or approved for usage
in the vehicle brake system. Use only MopartBrake
Fluid or equivalent from a tightly sealed container.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container of brake fluid will absorb moisture
from the air and contaminate the fluid.
CAUTION: Never use any type of a petroleum-based
fluid in the brake hydraulic system. Use of such
type fluids will result in seal damage of the vehicle
brake hydraulic system causing a failure of the
vehicle brake system. Petroleum based fluids would
be items such as engine oil, transmission fluid,
power steering fluid, etc.
JUNCTION BLOCK
DESCRIPTION - NON-ABS JUNCTION BLOCK
A junction block is used on vehicles that are not
equipped with antilock brakes (ABS). The junction
block mounts in the same location as the integrated
control unit (ICU) does on vehicles equipped with
ABS. This allows for use of the same brake tube con-
figuration on all vehicles. The junction block is
located on the driver's side of the front suspension
cradle/crossmember below the master cylinder (Fig.
45).
It has six threaded ports to which the brake tubes
connect. Two are for the primary and secondary
brake tubes coming from the master cylinder. The
remaining four are for the chassis brake tubes going
to each brake assembly.
OPERATION - NON-ABS JUNCTION BLOCK
The junction block distributes the brake fluid com-
ing from the master cylinder primary and secondary
ports to the four chassis brake tubes leading to the
brakes at each wheel. Since the junction blockmounts in the same location as the ABS integrated
control unit (ICU), it allows for the common use of
brake tubes going to the brakes whether the vehicle
is equipped with or without ABS.
NOTE: Although the brake tubes coming from the
master cylinder to the junction block or ABS ICU
may appear to be the same, they are not. They are
unique to each brake system application.
REMOVAL - NON-ABS JUNCTION BLOCK
(1) Using a brake pedal depressor, move and lock
the brake pedal to a position past its first 1 inch of
travel. This will prevent brake fluid from draining
out of the master cylinder when the brake tubes are
removed from the junction block.
(2) Disconnect the battery negative cable.
(3) If the vehicle is equipped with speed control,
perform the following:
(a) Disconnect the battery positive cable.
(b) Remove the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - REMOVAL).
(c) Disconnect the vacuum hose connector at the
tank built into the battery tray.
(d) Remove the screw securing the coolant filler
neck to the battery tray.
(e) Remove the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - REMOVAL).
(f) Remove the fasteners and move the speed
control servo off to the side, out of the way.
CAUTION: Before removing the brake tubes from
the junction block, the junction block and the brake
tubes must be thoroughly cleaned. This is required
to prevent contamination from entering the brake
hydraulic system.
(4) Remove the four chassis brake tubes from the
top of the junction block (Fig. 45).
(5) Remove the primary and secondary brake
tubes from the top of the junction block.
(6) Remove the bolts attaching the junction block
mounting bracket to the front suspension crossmem-
ber (Fig. 45), then remove the junction block.
INSTALLATION - NON-ABS JUNCTION BLOCK
(1) Install the junction block and mounting bracket
on the front suspension crossmember (Fig. 45).
Install the mounting bolts and tighten to a torque of
28 N´m (250 in. lbs.).
(2) Install the primary and secondary brake tubes
from the master cylinder in their ports. Tighten tube
nuts to a torque of 17 N´m (145 in. lbs.).Take care
not to twist tubes when tightening tube nuts.
They must be properly positioned to allow free
RSBRAKES - BASE5-33
FLUID (Continued)

Use only brake fluid that was stored in a tightly-
sealed container. DO NOT use petroleum-based fluid because seal
damage will result. Petroleum based fluids would be
items such as engine oil, transmission fluid, power
steering fluid etc.
SPECIFICATIONS
BRAKE FLUID
The brake fluid used in this vehicle must conform
to DOT 3 specifications (DOT 4 and DOT 4+ are
acceptable) and SAE J1703 standards. No other type
of brake fluid is recommended or approved for usage
in the vehicle brake system. Use only Mopar tBrake
Fluid or equivalent from a tightly sealed container.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container of brake fluid will absorb moisture
from the air and contaminate the fluid.
CAUTION: Never use any type of a petroleum-based
fluid in the brake hydraulic system. Use of such
type fluids will result in seal damage of the vehicle
brake hydraulic system causing a failure of the
vehicle brake system. Petroleum based fluids would
be items such as engine oil, transmission fluid,
power steering fluid, etc.
JUNCTION BLOCK
DESCRIPTION - NON-ABS JUNCTION BLOCK
A junction block is used on vehicles that are not
equipped with antilock brakes (ABS). The junction
block mounts in the same location as the integrated
control unit (ICU) does on vehicles equipped with
ABS. This allows for use of the same brake tube con-
figuration on all vehicles. The junction block is located
on the driver's side of the front suspension cradle/
crossmember below the master cylinder (Fig. 44).
It has six threaded ports to which the brake tubes
connect. Two are for the primary and secondary
brake tubes coming from the master cylinder. The
remaining four are for the chassis brake tubes going
to each brake assembly.
OPERATION - NON-ABS JUNCTION BLOCK
The junction block distributes the brake fluid com-
ing from the master cylinder primary and secondary
ports to the four chassis brake tubes leading to the
brakes at each wheel. Since the junction block
mounts in the same location as the ABS integrated control unit (ICU), it allows for the common use of
brake tubes going to the brakes whether the vehicle
is equipped with or without ABS.
NOTE: Although the brake tubes coming from the
master cylinder to the junction block or ABS ICU
may appear to be the same, they are not. They are
unique to each brake system application.
REMOVAL - NON-ABS JUNCTION BLOCK
(1) Using a brake pedal depressor, move and lock
the brake pedal to a position past its first 1 inch of
travel. This will prevent brake fluid from draining
out of the master cylinder when the brake tubes are
removed from the junction block. (2) Disconnect the battery negative cable.
(3) If the vehicle is equipped with speed control,
perform the following: (a) Disconnect the battery positive cable.
(b) Remove the battery (Refer t o 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - REMOVAL). (c) Disconnect the vacuum hose connector at the
tank built into the battery tray. (d) Remove the screw securing the coolant filler
neck to the battery tray. (e) Remove the battery tray (Refer t o 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - REMOVAL). (f) Remove the fasteners and move the speed
control servo off to the side, out of the way.
CAUTION: Before removing the brake tubes from
the junction block, the junction block and the brake
tubes must be thoroughly cleaned. This is required
to prevent contamination from entering the brake
hydraulic system. (4) Remove the four chassis brake tubes from the
top of the junction block (Fig. 44). (5) Remove the primary and secondary brake
tubes from the top of the junction block. (6) Remove the bolts attaching the junction block
mounting bracket to the front suspension crossmem-
ber (Fig. 44), then remove the junction block.
INSTALLATION - NON-ABS JUNCTION BLOCK
(1) Install the junction block and mounting bracket
on the front suspension crossmember (Fig. 44).
Install the mounting bolts and tighten to a torque of
28 N´m (250 in. lbs.). (2) Install the primary and secondary brake tubes
from the master cylinder in their ports. Tighten tube
nuts to a torque of 17 N´m (145 in. lbs.). Take care
not to twist tubes when tightening tube nuts.
They must be properly positioned to allow free
movement with rubber isolated suspension
crossmember.
5s - 32 BRAKESRS
FLUID (Continued)

WARNING: THE WARNING WORDS ªDO NOT OPEN
HOTº ON THE RADIATOR PRESSURE CAP IS A
SAFETY PRECAUTION. WHEN HOT, PRESSURE
BUILDS UP IN COOLING SYSTEM. TO PREVENT
SCALDING OR INJURY, THE RADIATOR CAP
SHOULD NOT BE REMOVED WHILE THE SYSTEM
IS HOT OR UNDER PRESSURE.
There is no need to remove the radiator cap at any
timeexceptfor the following purposes:
(1) Check and adjust coolant freeze point.
(2) Refill system with new coolant.
(3) Conducting service procedures.
(4) Checking for vacuum leaks.
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY,
WAIT 15 MINUTES BEFORE REMOVING CAP. THEN
PLACE A SHOP TOWEL OVER THE CAP AND WITH-
OUT PUSHING DOWN ROTATE COUNTERCLOCK-
WISE TO THE FIRST STOP. ALLOW FLUIDS TO
ESCAPE THROUGH THE OVERFLOW TUBE AND
WHEN THE SYSTEM STOPS PUSHING COOLANT
AND STEAM INTO THE CRS TANK AND PRESSURE
DROPS PUSH DOWN AND REMOVE THE CAP COM-
PLETELY. SQUEEZING THE RADIATOR INLET HOSE
WITH A SHOP TOWEL (TO CHECK PRESSURE)
BEFORE AND AFTER TURNING TO THE FIRST
STOP IS RECOMMENDED.
CLEANING
Use only a mild soap to clean the pressure cap.
INSPECTION
Hold the cap in your hand,top side up(Fig. 20).
The vent valve at the bottom of the cap should open.
If the rubber gasket has swollen, preventing the
valve from opening, replace the cap.Hold the cleaned cap in your hand,upside down.
If any light can be seen between vent valve and the
rubber gasket, replace the cap.Do not use a
replacement cap that has a spring to hold the
vent shut.
A replacement cap must be of the type designed for
coolant reserve systems. This design ensures coolant
return to the radiator.
RADIATOR FAN
DESCRIPTION
The dual radiator fans are mounted to the back
side of the radiator (Fig. 21). The radiator fan consist
of the fan blade, electric motor and a support shroud
which are all serviced as an assembly.
Fig. 20 Cooling System Pressure Cap
1 - OVERFLOW NIPPLE
2 - MAIN SPRING
3 - GASKET RETAINER
4 - STAINLESS-STEEL SWIVEL TOP
5 - RUBBER SEALS
6 - VENT VALVE
7 - RADIATOR
8 - FILLER NECK
7 - 28 ENGINERS
RADIATOR PRESSURE CAP (Continued)

OPERATION
The power steering pump is a constant displace-
ment vane type pump. The 2.4L pump has an inte-
gral fluid reservoir and there is a secondary remote
non-flow reservoir which acts only as a fluid fill and
check point. The 3.3L/3.8L pump houses very little
fluid and is therefore supplied by a remote flow
through reservoir.
WARNING
WARNING: POWER STEERING FLUID, ENGINE
PARTS AND EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH THE ENGINE OFF TO PREVENT PERSONAL
INJURY FROM MOVING PARTS.
CAUTION
CAUTION: When the system is open, cap all open
ends of the hoses, power steering pump fittings or
power steering gear ports to prevent entry of for-
eign material into the components.
STANDARD PROCEDURE - POWER STEERING
PUMP INITIAL OPERATION
WARNING: FLUID LEVEL SHOULD BE CHECKED
AND ADJUSTED WITH ENGINE OFF TO PREVENT
INJURY FROM MOVING ENGINE COMPONENTS.
CAUTION: Use only MoparTAutomatic Transmis-
sion Fluid (MS-9602) in power steering system. Use
of other MoparTpower steering fluids (MS5931 and
MS9933) should be avoided to ensure peak perfor-
mance of the power steering system under all oper-
ating conditions. Do not overfill.
Read the fluid level through the side of the power
steering fluid reservoir. The fluid level should indi-
cateªFILL RANGEºwhen the fluid is at a temper-
ature of approximately 21ÉC to 27ÉC (70ÉF to 80ÉF).
(1) Wipe the filler cap and area clean, then remove
the cap.
(2) Fill the fluid reservoir to the proper level and
let the fluid settle for at least two (2) minutes.
(3) Start the engine and let run for a few seconds,
then turn the engine off.
(4) Add fluid if necessary. Repeat the above steps
until the fluid level remains constant after running
the engine.
(5) Raise the front wheels off the ground.
(6) Start the engine.
(7) Slowly turn the steering wheel right and left,
lightly contacting the wheel stops.
(8) Add fluid if necessary.
(9) Lower the vehicle, then turn the steering wheel
slowly from lock-to-lock.
(10) Stop the engine. Check the fluid level and
refill as required.
(11) If the fluid is extremely foamy, allow the vehi-
cle to stabilize a few minutes, then repeat the above
procedure.
Fig. 1 POWER STEERING PUMP (2.4L)
1 - PULLEY
2 - BRACKET
3 - PRESSURE FITTING
4 - RETURN FITTING
5 - SUPPLY FITTING
Fig. 2 POWER STEERING PUMP (3.3L/3.8L)
1 - SUPPLY FITTING
2 - PRESSURE FITTING
3 - PULLEY
RSPUMP19-37
PUMP (Continued)

FLUID
STANDARD PROCEDURE - POWER STEERING
FLUID LEVEL CHECKING
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH THE ENGINE OFF TO PREVENT INJURY
FROM MOVING PARTS AND TO ENSURE ACCU-
RATE FLUID LEVEL READING.
The fluid level can be read on the exterior of the
power steering fluid reservoir. The fluid level should
be within the ªFILL RANGEº when the fluid is at
normal ambient temperature, approximately 21ÉC to
27ÉC (70ÉF to 80ÉF) (Fig. 17).
Before removing the power steering filler cap, wipe
the reservoir filler cap free of dirt and debris. Do not
overfill the power steering system.Use only
MopartATF+4 Automatic Transmission Fluid
(MS-9602) in the power steering system.For
additional information on Automatic Transmission
Fluid, (Refer to LUBRICATION & MAINTENANCE/
FLUID TYPES - DESCRIPTION).
CAUTION: Use only MoparTATF+4 Automatic Trans-
mission Fluid (MS-9602). Use of other MoparT
power steering fluids (MS5931 and MS9933) should
be avoided to ensure peak performance of the
power steering system under all operating condi-
tions.
FLUID COOLER
DESCRIPTION
All models (except 2.5L Diesel) are equipped with a
cooler for the power steering system fluid. The power
steering fluid cooler is located on the front suspen-sion cradle crossmember reinforcement (Fig. 18).
There are two different size coolers depending on
model and options. There is a standard 6-inch and an
8-inch.
OPERATION
The purpose of the power steering fluid cooler is to
keep the temperature of the power steering system
fluid from rising to a level that would affect the per-
formance of the power steering system.
The cooler used on this vehicle is referred to as a
fluid-to-air type cooler. This means that the air flow
across the tubes (and fines surrounding them) of the
cooler is used to extract the heat from the cooler
which it has absorbed from the power steering fluid
flowing through it. The cooler is placed in the power
steering fluid return line, between the steering gear
and the power steering fluid reservoir.
REMOVAL
(1) Using a siphon pump, remove as much fluid as
possible from the power steering fluid reservoir.
(2) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(3) Remove the hose clamps at the cooler and
remove the hoses from the cooler inlet and outlet
tubes.
(4) Remove the 2 bolts attaching the power steer-
ing cooler cradle crossmember reinforcement (Fig.
18). Remove the cooler.
Fig. 17 Power Steering Fluid Reservoir
Fig. 18 Power Steering Cooler
1 - CRADLE CROSSMEMBER REINFORCEMENT
2 - POWER STEERING COOLER
19 - 44 PUMPRS

DIFFERENTIAL CARRIER SEAL
REMOVAL
The Power Transfer Unit must be removed from
the vehicle to replace this seal.
(1) Remove P.T.U. from vehicle.
(2) Use a pry bar to remove seal from retainer
plate (Fig. 16). Be careful not to damage seal journal
when removing seal.
INSTALLATION
The Power Transfer Unit must be removed from
the vehicle to replace this seal.
(1) Using a large socket, carefully install new seal.
The spring side of the seal must face the transaxle
differential.
(2) Reinstall the P.T.U. into the vehicle.
(3) Check and fill fluids as required.
END COVER BALL BEARING
REMOVAL
The end cover ball bearing can be removed and
installed without removing the Power Transfer Unit
from the vehicle. When replacing the bearing the out-
put seal must be removed to gain access to the bear-
ing.
(1) Raise vehicle on hoist.
(2) Remove right front half shaft from vehicle.
(3) Remove output seal with a hammer and chisel
(Fig. 17).
Fig. 17 Output Seal Removal
1 - HAMMER
2 - CHISEL
3 - SEAL
4 - POWER TRANSFER UNIT
MD998334 Seal Installer
MD998346 Bearing Puller
Fig. 16 Transaxle Differential Carrier Seal
1 - TRANSAXLE CASE
2 - DIFFERENTIAL CARRIER SEAL
3 - RETAINER PLATE
RSPOWER TRANSFER UNIT21-9
POWER TRANSFER UNIT (Continued)

(4) Remove bearing retaining snap ring (Fig. 18).
(5) Use bearing puller MD998346 to remove bear-
ing (Fig. 19).
INSTALLATION
The end cover ball bearing can be removed and
installed without removing the Power Transfer Unit
from the vehicle. When replacing the bearing the out-
put seal must be removed to gain access to the bear-
ing.
CAUTION: When installing bearing, position the
bearing in place by hand square to the bore. Other-
wise, bearing and/or housing damage may occur
upon installation.(1) Use installer MD998200 and driver handle
C-4171 to install bearing (Fig. 20) into the housing.
(2) Install bearing retaining snap ring.
CAUTION: When installing bearing retaining snap
ring, be sure to index the snap ring so that the
snap ring does not cover bearing oil passage.
(3) Install new outer half shaft seal using
MD998334 seal installer (Fig. 21).Do not reuse the
old seal.
(4) Reinstall right front half shaft.
(5) Check and fill fluids as required.
Fig. 18 Bearing Snap Ring
1 - BEARING
2 - SNAP RING PLIERS
3 - BEARING SNAP RING
Fig. 19 Bearing Removal
1 - P.T.U. END COVER
2 - SPECIAL TOOL
MD998346
Fig. 20 Bearing Installation
1 - SPECIAL TOOL MD998200
2 - SPECIAL C-4171
Fig. 21 Installing New Seal
1 - P.T.U. END COVER
2 - HAMMER
3 - SPECIAL TOOL
MD998334
21 - 10 POWER TRANSFER UNITRS
END COVER BALL BEARING (Continued)