ABS CHRYSLER VOYAGER 2005 Service Manual

(8) Remove the steering wheel using a standard
wheel puller (Fig. 5).
(9) Remove the knee blocker/steering column open-
ing cover (Refer to 23 - BODY/INSTRUMENT PAN-
EL/STEERING COLUMN OPENING COVER -
REMOVAL).(10) Remove the parking brake release handle
link.
(11) Remove the knee blocker/steering column
cover plate (Refer to 23 - BODY/INSTRUMENT PAN-
EL/KNEE BLOCKER - REMOVAL).
(12) Remove the upper shroud mounting screws
(Fig. 6). Using hands on each side of the column,
gently press inward at seams between the two
shrouds at points of contact to disengage inner lock-
ing tabs, then remove upper shroud. If the vehicle is
equipped with traction control, the lower shroud will
need to be removed once the upper shroud is unfas-
tened in order to disconnect the traction control wir-
Fig. 3 Driver Airbag Wiring Connections
1 - DRIVER AIRBAG
2 - SQUIB CONNECTORS
3 - SPEED CONTROL/HORN WIRING CONNECTOR
4 - CLOCKSPRING
Fig. 4 Steering Wheel Mounting
1 - STEERING WHEEL
2 - REMOTE AUDIO CONTROL WIRING CONNECTOR (IF
EQUIPPED)
3 - RETAINING BOLT
4 - DAMPER
Fig. 5 Steering Wheel Removal
1 - STEERING WHEEL
2 - PULLER
Fig. 6 Upper Shroud Mounting
1 - UPPER SHROUD
2 - LOWER SHROUD
3 - MOUNTING SCREWS
19 - 12 COLUMNRS
COLUMN (Continued)

(19) Position the lower shroud on the column (Fig.
8). Install the lower shroud mounting screw. Tighten
the screw to 2 N´m (17 in. lbs.) torque.
(20) If equipped with adjustable pedals, Connect
the wiring connector for the switch (Fig. 7) to the col-
umn wiring harness.
(21) Position the upper shroud on top of the lower
shroud and snap it into place. Install the upper
shroud mounting screws (Fig. 6). Tighten the screws
to 2 N´m (17 in. lbs.) torque.
(22) Inspect shroud mating surfaces for excessive
gaps and correct as necessary.
(23) Install the cluster trim bezel (Refer to 23 -
BODY/INSTRUMENT PANEL/CLUSTER BEZEL -
INSTALLATION).
(24) Install the knee blocker/steering column cover
plate. (Refer to 23 - BODY/INSTRUMENT PANEL/
KNEE BLOCKER - INSTALLATION)
(25) Install the parking brake handle link.
(26) Install the knee blocker/steering column open-
ing cover. (Refer to 23 - BODY/INSTRUMENT PAN-
EL/STEERING COLUMN OPENING COVER -
INSTALLATION)
(27) Align the splines and install the steering
wheel on the steering column shaft(Refer to 19 -
STEERING/COLUMN/STEERING WHEEL -
INSTALLATION).
(28) Install the damper over the steering column
shaft (Fig. 4).
(29) Install the steering wheel retaining bolt (Fig.
4). Tighten the bolt to 61 N´m (45 ft. lbs.) torque.
(30) If the steering wheel is equipped with remote
audio controls, connect the wiring connector to the
clockspring (Fig. 4).
(31) Connect the two squib connectors to the
driver airbag (Fig. 3). The connectors are color coded
to avoid connector mix-up.
(32) Connect the speed control and horn connector
to the clockspring (Fig. 3).
(33) Install the airbag to the steering wheel.
Install the driver airbag mounting screws (Fig. 2).
Tighten screws to 10 N´m (90 in. lbs.) torque.
(34) Connect the battery negative (ground) cable to
battery post following special Diagnosis And Testing
procedure. (Refer to 8 - ELECTRICAL/RESTRAINTS
- DIAGNOSIS AND TESTING)
(35) Check operation of all steering column
mounted components.
(36) Road test vehicle to ensure proper operation
of steering.SPECIFICATIONS
COLUMN FASTENER TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Driver Airbag Mounting Screws 10 Ð 90
Multi-Function Switch Mounting
Housing Set-Screw14 Ð 124
Shroud Attaching Screws - Fixed 3 Ð 23
Shroud Attaching Screws -
Lower/Upper2Ð17
SKIM Attaching Screw 4 Ð 30
Steering Column Coupling Pinch
Bolt28 Ð 250
Steering Column Mounting Nuts 12 Ð 105
Steering Wheel Retaining Bolt 61 45 Ð
IGNITION SWITCH
REMOVAL
The ignition switch attaches to the lock cylinder
housing on the end opposite the lock cylinder (Fig.
20). For ignition switch terminal and circuit identifi-
cation, refer to the appropriate wiring information.
The wiring information includes wiring diagrams,
proper wire and connector repair procedures, further
details on wire harness routing and retention, as well
as pin-out and location views for the various wire
harness connectors, splices and grounds.
(1) Disconnect negative cable from battery.
Fig. 20 Ignition SwitchÐViewed From Below
Column
1 - IGNITION SWITCH
2 - LOCK CYLINDER HOUSING
3 - RETAINING TABS
RSCOLUMN19-17
COLUMN (Continued)

(6) Remove ignition switch mounting screw (Fig.
25) with a #10 Torxttamper proof bit.
(7) Depress retaining tab (Fig. 21) or (Fig. 26) and
gently pry ignition switch from steering column (Fig.
27).
(8) Disconnect electrical connectors from ignition
switch and remove switch (Fig. 28).
INSTALLATION
The ignition switch attaches to the lock cylinder
housing on the end opposite the lock cylinder (Fig.
20). For ignition switch terminal and circuit identifi-
cation, refer to the Wiring Diagrams section.
(1) Ensure the ignition switch is in the RUN posi-
tion and the actuator shaft in the lock housing is in
the RUN position.(2) Install electrical connectors to ignition switch.
(3) Carefully install the ignition switch. The
switch will snap over the retaining tabs (Fig. 29).
Install mounting screw (Fig. 25).
(4) Install upper and lower shrouds.
(5) Install key cylinder (cylinder retaining tab will
depress only in the RUN position).
Fig. 25 Ignition Switch Mounting Screw
1 - MOUNTING SCREW
2 - IGNITION SWITCH
Fig. 26 Ignition Switch Retaining Tab
1 - IGNITION SWITCH
2 - RETAINING TAB
Fig. 27 Removing Ignition Switch
1 - IGNITION SWITCH
2 - RETAINING TAB
Fig. 28 Ignition Switch Connectors
1 - KEY IN SWITCH
2 - PRNDL SWITCH
3 - IGNITION SWITCH
RSCOLUMN19-19
IGNITION SWITCH (Continued)

(6) Connect negative cable to battery.
(7) Check for proper operation of ignition switch
and key-in warning switch.
KEY/LOCK CYLINDER
DESCRIPTION
The lock cylinder is inserted in the end of the
housing opposite the ignition switch.
OPERATION
The ignition key rotates the cylinder to 5 different
detents (Fig. 30) :
²Accessory
²Off (lock)
²Unlock
²On/Run
²Start
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove steering column cover retaining
screws.
(3) Remove screws holding steering column
shrouds and remove lower shroud.
(4) Place key cylinder in RUN position. Depress
lock cylinder retaining tab on the bottom of the lock
housing and remove key cylinder.
INSTALLATION
(1) Install key in lock cylinder. Turn key to run
position (retaining tab on lock cylinder can be
depressed).(2) The shaft at the end of the lock cylinder aligns
with the socket in the end of the housing. To align
the socket with the lock cylinder, ensure the socket is
in the Run position (Fig. 31).
(3) Align the lock cylinder with the grooves in the
housing. Slide the lock cylinder into the housing
until the tab sticks through the opening in the hous-
ing.
(4) Turn the key to the Off position. Remove the
key.
(5) Install lower steering column shroud.
(6) Install steering column cover.
(7) Connect negative cable to battery.
Fig. 29 Ignition Switch Installation
1 - IGNITION SWITCH
2 - ACTUATOR SHAFT
3 - RETAINING TABS
Fig. 30 Ignition Lock Cylinder Detents
Fig. 31 Socket in Lock Cylinder Housing
1 - LOCK CYLINDER HOUSING
2 - SOCKET
19 - 20 COLUMNRS
IGNITION SWITCH (Continued)

SHROUD - LOWER
REMOVAL
(1) Remove the two shroud-to-shroud mounting
screws fastening the upper to lower shrouds (Fig.
32).
(2) Using hands on each side of the column, gently
press inward at seams between the two shrouds at
points of contact to disengage inner locking tabs.(3) Remove the lower shroud-to-column mounting
screw (Fig. 33).
(4) If equipped with adjustable pedals, disconnect
the wiring connector for the switch (Fig. 34).
(5) Remove the lower shroud from the steering col-
umn.
(6) If equipped with adjustable pedals, depress the
retaining tabs on the switch and remove the switch
from the lower shroud (Fig. 34).
INSTALLATION
(1) If the vehicle is equipped with adjustable ped-
als:
(a) Pass the wiring through the mounting hole
and install the switch into the lower shroud (Fig.
34), snapping it into place.
(b) Connect the switch wiring connector to the
column wiring harness.
(2) Position the lower shroud under the steering
column and install the lower shroud-to-column
mounting screw (Fig. 33). Tighten the screw to 2 N´m
(17 in. lbs.) torque.
(3) Align the upper shroud with the lower, then
snap shrouds together at locking tab locations on
both sides of column.
(4) Install the two shroud-to-shroud mounting
screws (Fig. 32). Tighten the screws to 2 N´m (17 in.
lbs.) torque.
(5) Inspect shroud mating surfaces for excessive
gaps and correct as necessary.
(6) Check operation of any previously disconnected
switches.
Fig. 32 Upper Shroud Mounting
1 - UPPER SHROUD
2 - LOWER SHROUD
3 - MOUNTING SCREWS
Fig. 33 Lower Shroud Mounting
1 - STEERING COLUMN
2 - LOWER SHROUD
3 - MOUNTING SCREW
Fig. 34 Adjustable Pedals Switch Mounting
1 - LOWER SHROUD
2 - ADJUSTABLE PEDALS SWITCH
3 - WIRING CONNECTOR
RSCOLUMN19-21

SHROUD - UPPER
REMOVAL
(1) Remove the two shroud-to-shroud mounting
screws fastening the upper to lower shrouds (Fig.
35).
(2) Using hands on each side of the column, gently
press inward at seams between the two shrouds at
points of contact to disengage inner locking tabs.(3) If the vehicle is equipped with traction control,
remove the lower shroud-to-column mounting screw
(Fig. 36).
(4) If the vehicle is equipped with traction control,
disconnect the switch wiring connector from the col-
umn wiring harness (Fig. 37).
(5) If the vehicle is equipped with power foldaway
mirrors (Export), disconnect wiring connector at mir-
ror switch pig tail.
(6) Remove the upper shroud from the steering col-
umn.
(7) If the vehicle is equipped with traction control,
remove the switch wiring from the routing clip
attached to the upper shroud (Fig. 38).
(8) If the vehicle is equipped with traction control,
remove the traction control switch from the upper
shroud (Fig. 39).
(9) If the vehicle is equipped with power foldaway
mirrors (Export), remove power foldaway switch from
upper shroud.
INSTALLATION
(1) If the vehicle is equipped with power foldaway
mirrors (Export), install the power foldaway switch
in the upper shroud.
(2) If vehicle is equipped with traction control,
install the traction control switch in the upper
shroud (Fig. 39).
(3) If the vehicle is equipped with traction control,
attach the switch wiring to the routing clip attached
to the upper shroud (Fig. 38).
Fig. 35 Upper Shroud Mounting
1 - UPPER SHROUD
2 - LOWER SHROUD
3 - MOUNTING SCREWS
Fig. 36 Lower Shroud Mounting
1 - STEERING COLUMN
2 - LOWER SHROUD
3 - MOUNTING SCREW
Fig. 37 Traction Control And Autostick Wiring
Connections
1 - TRACTION CONTROL WIRING CONNECTOR
2 - ROUTING CLIP
3 - AUTOSTICK WIRING CONNECTOR
4 - COLUMN WIRING HARNESS
19 - 22 COLUMNRS

(11) Remove both tie rod ends from steering
knuckles using Puller, Special Tool C-3894±A (Fig. 5).
Fig. 7 Hoses To Power Steering Gear - 3.3L/3.8L Engine
1 - RETURN HOSE (TO RESERVOIR)
2 - PRESSURE HOSE (FROM PUMP)
3 - CRADLE CROSSMEMBER
4 - PRESSURE HOSE ROUTING CLAMP
5 - RETURN HOSE ROUTING CLAMP
6 - PRESSURE HOSE TUBE NUT7 - POWER STEERING GEAR
8 - ABS BRACKET
9 - ROUTING CLIP
10 - LEAK DETECTION PUMP FILTER
11 - RETURN HOSE TUBE NUT
12 - ROUTING CLIP
Fig. 8 Steering Gear Mounting To Suspension Cradle
1 - POWER STEERING GEAR
2 - MOUNTING BOLTS (12 MM)
3 - MOUNTING BOLT (14 MM)
4 - FRONT SUSPENSION CRADLE CROSSMEMBER
Fig. 9 Removing Roll Pin From Intermediate Coupler
1 - INTERMEDIATE COUPLER
2 - KNURLED NUT
3 - SUSPENSION CRADLE
4 - REMOVER SPECIAL TOOL 6831A
5 - STEERING GEAR
6 - NUT
7 - ROLL PIN
8 - THREADED ROD
19 - 30 GEARRS
GEAR (Continued)

FLUID COOLER
DESCRIPTION
Trailer Tow equipped vehicles are supplied 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).
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.
19). Remove the cooler.
INSTALLATION
(1) Install the power steering fluid cooler on the
cradle crossmember reinforcement (Fig. 19). Install
the mounting bolts and tighten to 11 N´m (100 in.
lbs.).
(2) Install power steering fluid hoses on the cooler.
Be sure hose clamps are installed on hose past
the upset bead on the power steering cooler
tubes.
(3) Lower the vehicle to a point where front tires
are just off the ground.
(4) Perform Power Steering Pump Initial Opera-
tion procedure. (Refer to 19 - STEERING/PUMP -
STANDARD PROCEDURE)
Fig. 18 Power Steering Cooler
1 - CRADLE CROSSMEMBER REINFORCEMENT
2 - POWER STEERING COOLER
Fig. 19 Power Steering Cooler
1 - CRADLE CROSSMEMBER REINFORCEMENT
2 - POWER STEERING COOLER
RSPUMP19-45

(8) Remove pressure hose routing bracket bolt at
engine (Fig. 22). Bolt can be accessed through hole in
cradle crossmember (Fig. 23).
(9) Disconnect pressure hose tube nut at power
steering pump (Fig. 22).
(10) Remove power steering fluid pressure hose
from vehicle.
INSTALLATION
INSTALLATION - 2.4L ENGINE
(1) Remove any used O-rings from ends of power
steering hose.
(2) Using a lint free towel, wipe clean hose ends,
power steering pump pressure outlet fitting and
steering gear port.
(3) Install new O-rings on ends of power steering
fluid pressure hose. Lubricate O-rings using clean
power steering fluid.CAUTION: Use care not to bend tube ends of power
steering hoses when installing. Leaks and restric-
tions may occur.
CAUTION: Power steering fluid hoses must remain
away from exhaust system and must not come in
contact with any unfriendly surfaces on vehicle.
(4) Route hose up through cradle crossmember
toward power steering pump avoiding tight bends or
kinking.
(5) Install power steering pressure hose end into
pump pressure outlet fitting (Fig. 20). Thread tube
nut into outlet fitting, but do not tighten at this time.
(6) Route hose behind cradle crossmember and
start hose end into gear port. Do not tighten hose
tube nut at this time.
(7) Install hose into right routing clamp (Fig. 20),
then install mounting bolt into cradle crossmember.
Tighten bolt to 23 N´m (200 in. lbs.) torque.
Fig. 21 HOSES TO POWER STEERING GEAR - 3.3L/3.8L ENGINE
1 - RETURN HOSE (TO RESERVOIR)
2 - PRESSURE HOSE (FROM PUMP)
3 - CRADLE CROSSMEMBER
4 - PRESSURE HOSE ROUTING CLAMP
5 - RETURN HOSE ROUTING CLAMP
6 - PRESSURE HOSE TUBE NUT7 - POWER STEERING GEAR
8 - ABS BRACKET
9 - ROUTING CLIP
10 - LEAK DETECTION PUMP FILTER
11 - RETURN HOSE TUBE NUT
12 - ROUTING CLIP
RSPUMP19-47
HOSE - POWER STEERING PRESSURE (Continued)

(3) Install new O-rings on ends of power steering
fluid pressure hose. Lubricate O-rings using clean
power steering fluid.
CAUTION: Use care not to bend tube ends of the
power steering hoses when installing. Leaks and
restrictions may occur.
CAUTION: Power steering fluid hoses must remain
away from the exhaust system and must not come
in contact with any unfriendly surfaces on the vehi-
cle.
(4) Route hose up behind engine toward pump
avoiding tight bends or kinking.
(5) Install power steering pressure hose end into
pump pressure outlet fitting (Fig. 22). Thread tube
nut into outlet fitting, but do not tighten at this time.
(6) Attach pressure hose routing bracket to engine
(Fig. 22). Tighten bolt to 23 N´m (200 in. lbs.) torque.
(7) Tighten hose tube nut at pump outlet fitting to
31 N´m (275 in. lbs.) torque.
(8) Route hose behind cradle crossmember and
start hose end into gear port. Do not tighten hose
tube nut at this time.
(9) Attach hose to suspension cradle crossmember
and steel reinforcement using two routing clamps
and bolts (Fig. 21). Tighten clamp bolt at steel rein-
forcement to 11 N´m (100 in. lbs.) torque. Tighten
clamp bolt at cradle crossmember to 23 N´m (200 in.
lbs.) torque.
(10) Tighten hose tube nut at power steering gear
port to 31 N´m (275 in. lbs.) torque.
(11) Install front emissions vapor canister. (Refer
to 25 - EMISSIONS CONTROL/EVAPORATIVE
EMISSIONS/VAPOR CANISTER - INSTALLATION)
(12) Lower vehicle.
(13) Fill and bleed the power steering system
using the Power Steering Pump Initial Operation
Procedure. (Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE)
(14) Inspect system for leaks.
HOSE - POWER STEERING
RETURN
REMOVAL
REMOVAL - 2.4L ENGINE
NOTE: Before proceeding, review all WARNINGS
and CAUTIONS. (Refer to 19 - STEERING/PUMP -
WARNING)(Refer to 19 - STEERING/PUMP - CAU-
TION)(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from power steering fluid
reservoir.
(3) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(4) Remove front emissions vapor canister. (Refer
to 25 - EMISSIONS CONTROL/EVAPORATIVE
EMISSIONS/VAPOR CANISTER - REMOVAL)
(5) Place an oil drain pan under vehicle to catch
power steering fluid.
(6) Cut tie-strap securing insulating heat sleeve to
power steering fluid return hose near power steering
pump. Pull back heat sleeve to expose hose clamp.
(7) Remove clamp, then return hose from power
steering pump (Fig. 20).
(8) Remove 2 bolts attaching power steering cooler
to cradle crossmember reinforcement (Fig. 24).
(9) Remove bolts attaching routing clamps to front
suspension cradle crossmember (Fig. 20). Remove
return hose from clamps.
(10) Back out return hose tube nut at power steer-
ing gear and remove hose (Fig. 20).
REMOVAL - 3.3L/3.8L ENGINE
NOTE: Before proceeding, review all WARNINGS
and CAUTIONS. (Refer to 19 - STEERING/PUMP -
WARNING)(Refer to 19 - STEERING/PUMP - CAU-
TION)
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from power steering fluid
reservoir.
(3) Place an oil drain pan under vehicle to catch
any draining power steering fluid.
(4) Remove clamp attaching return hose to power
steering fluid reservoir. Disconnect hose from reser-
voir (Fig. 22).
(5) Follow return hose downward and open
retainer at ABS bracket (Fig. 21). Remove hose tube
from retainer.
(6) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(7) Remove front emissions vapor canister. (Refer
to 25 - EMISSIONS CONTROL/EVAPORATIVE
EMISSIONS/VAPOR CANISTER - REMOVAL)
(8) Remove bolt securing return hose routing
clamp to suspension cradle crossmember (Fig. 21).
RSPUMP19-49
HOSE - POWER STEERING PRESSURE (Continued)