CHRYSLER VOYAGER 2005 Service Manual

BOTTOM OF SEAT CUSHION
PAN PANEL-THIRD ROW -
FOLD-IN-FLOOR
REMOVAL
(1) Fold the third row seat with back down.
(2) Remove handle from cushion.
(3) Using a trim tool, remove bottom side of the
cushion pan panel (Fig. 105).
INSTALLATION
(1) Place bottom side of the cushion pan panel into
position (Fig. 106).
(2) Press on back of cushion pan panel to seat the
fasteners.
(3) Install handle on cushion.
(4) Place seat in the up right position.
HEADREST SLEEVE - THIRD
ROW - FOLD-IN-FLOOR
REMOVAL
(1) Remove headrest (Fig. 107).
(2) Using a trim tool remove sleeve by prying
sleeve away from the seat back frame to unlock it
(Fig. 108)
(3) Pull headrest sleeve upward and out the top of
the seat back frame and remove from seat.
Fig. 105 THIRD ROW CUSHION PAN & COVER
Fig. 106 THIRD ROW CUSHION PAN & COVER
Fig. 107 HEADREST
1 - HEADREST
2 - DEPRESS TAB
Fig. 108 REMOVING HEADREST SLEEVES
1 - HEADREST SLEEVES
2 - TRIM TOOL
23 - 152 SEATSRS

INSTALLATION
(1) Place headrest sleeve into position and push
downward until sleeve locks into position (Fig. 109).
(2) Install headrest (Fig. 107).
SEAT - THIRD ROW - FOLD-IN-
FLOOR
REMOVAL
(1) Fold third row seat into floor well.
(2) Using a trim stick, unclip anchor molding (Fig.
110).
(3) Remove third row seat attaching bolts (Fig.
111).
(4) Raise seats to the upright position.
(5) Remove the rear seat lower trim cover (Fig.
112).
(6) Remove rear attaching bolts (Fig. 113).
(7) Remove rear seat from vehicle.
Fig. 109 HEADREST SLEEVES
1 - SLEEVES
Fig. 110 ANCHOR MOLDING
1 - 2-WAY CLIPS INTO SEAT FRAME
2 - 4-WAY LOCATING PINS (2)
3 - FRONT SEAT ANCHOR MOLDING
Fig. 111 THIRD ROW SEATS
1 - ATTACHING BOLTS
RSSEATS23 - 153
HEADREST SLEEVE - THIRD ROW - FOLD-IN-FLOOR (Continued)

INSTALLATION
(1) Place rear seat into position (Fig. 114).
(2) Install rear attaching bolts to seat (Fig. 115).
Tighten bolts to 54 N´m (40 ft. lbs.) torque and follow
tightening sequence.
Fig. 112 REAR SEAT TRIM COVER
1 - PLASTIC NUTS ON WELD STUDS
2 - LOWER TRIM COVER
Fig. 113 THIRD ROW SEAT
1 - ATTACHING BOLTS
Fig. 114 THIRD ROW SEAT INSTALLED
1 - ALIGN SEAT BRACKETS WITH REAR EDGE OF TUB
Fig. 115 THIRD ROW SEAT
1 - ATTACHING BOLTS
23 - 154 SEATSRS
SEAT - THIRD ROW - FOLD-IN-FLOOR (Continued)

(3) Fold the rear seat into the floor well.
(4) Install attaching bolts (Fig. 116). Tighten bolts
to 54 N´m (40 ft. lbs.) torque.
(5) Place the rear seat lower trim cover into posi-
tion and press clips into the lock position (Fig. 117).
(6) Raise third row seat into upright position.
(7) Install lower trim cover with plastic nuts and
tighten them in sequence (Fig. 118).
SEAT BACK COVER/FOAM -
THIRD ROW - FOLD-IN-FLOOR
REMOVAL
(1) Remove seat back panel.
(2) Disengage J-straps (Fig. 119).
(3) Remove seat cover and foam from seat back
frame (Fig. 120).
(4) Separate cover and foam.
Fig. 116 THIRD ROW SEATS
1 - ATTACHING BOLTS
Fig. 117 ANCHOR MOLDING
1 - 2-WAY CLIPS INTO SEAT FRAME
2 - 4-WAY LOCATING PINS (2)
3 - FRONT SEAT ANCHOR MOLDING
Fig. 118 REAR SEAT TRIM COVER
1 - PLASTIC NUTS ON WELD STUDS
2 - LOWER TRIM COVER
Fig. 119 THIRD ROW SEAT BACK
1 - J-STRAPS
RSSEATS23 - 155
SEAT - THIRD ROW - FOLD-IN-FLOOR (Continued)

INSTALLATION
(1) Place seat back foam into cover.
(2) Install seat cover and foam onto seat back
frame (Fig. 121).
(3) Engage J-straps (Fig. 122).
(4) Install seat back panel. (Refer to 23 - BODY/
SEATS/SEAT BACK - INSTALLATION).
SEAT BACK FRAME - THIRD
ROW - FOLD-IN-FLOOR
REMOVAL
(1) Remove seat back cover and foam. (Refer to 23
- BODY/SEATS/SEAT BACK COVER/FOAM -
REMOVAL).
(2) Remove strap at top of frame (Fig. 123).
(3) Remove two bolts on each side of frame.
(4) Remove seat back frame from seat.
Fig. 120 THIRD ROW SEAT BACK COVER & FOAM
1 - SEAT BACK COVER
2 - FOAM
3 - SEAT BACK FRAME
Fig. 121 THIRD ROW SEAT BACK COVER & FOAM
1 - SEAT BACK COVER
2 - FOAM
3 - SEAT BACK FRAME
Fig. 122 THIRD ROW SEAT BACK
1 - J-STRAPS
Fig. 123 THIRD ROW SEAT BACK COVER & FOAM
1 - SEAT BACK COVER
2 - FOAM
3 - SEAT BACK FRAME
23 - 156 SEATSRS
SEAT BACK COVER/FOAM - THIRD ROW - FOLD-IN-FLOOR (Continued)

INSTALLATION
(1) Place seat back frame into position.
(2) Install two bolts on each side of seat back
frame.
(3) Install strap at top of frame (Fig. 123).
(4) Install seat back cover and foam. (Refer to 23 -
BODY/SEATS/SEAT BACK COVER - INSTALLA-
TION).
SEAT BELT CENTER LAP BELT
- FOLD-IN-FLOOR
REMOVAL
(1) Set third row seat in the upright position.
(2) Remove the third row cushion back cover (Fig.
124).
(3) Fold the third row seat into floor well.
(4) Remove seat cushion pan carpet to floor panel
using a trim tool (Fig. 125).
(5) Using a trim tool, remove seat cushion pan bot-
tom side panel (Fig. 126).
(6) Remove handle from cushion.
(7) Remove seat cushion cover and foam from
cushion pan. (Refer to 23 - BODY/SEATS/SEAT
CUSHION COVER/FOAM - REMOVAL).(8) Remove nut attaching center tip half and
buckle together.
(9) Remove center tip half and buckle from seat
(Fig. 127).
INSTALLATION
(1) Place seat with seat cushion in the upright
position.
(2) Place center tip half and buckle into position.
(3) Install nut attaching center tip and buckle
(Fig. 127).
Fig. 124 THIRD ROW SEAT BACK COVER
1 - ATTACHING SCREW
Fig. 125 SEAT CUSHION CARPETING
1 - CARPET FROM SEAT TO FLOOR
2 - SEAT CUSHION PAN COVER
Fig. 126 THIRD ROW CUSHION PAN COVER
RSSEATS23 - 157
SEAT BACK FRAME - THIRD ROW - FOLD-IN-FLOOR (Continued)

(4) Install seat cushion cover and foam. (Refer to
23 - BODY/SEATS/SEAT CUSHION COVER/FOAM -
INSTALLATION).
(5) Install handle to cushion.
(6) Install seat cushion pan bottom side panel (Fig.
126).
(7) Fold the third row seat into floor well.
(8) Place seat cushion pan carpet to floor panel
into position and push on panel to seat push pin fas-
teners (Fig. 125).
(9) Third row seat in the upright position.
(10) Install the third row cushion back cover (Fig.
124).
SEAT BACK PANEL - THIRD
ROW -FOLD-IN-FLOOR
REMOVAL
(1) Third row seat in the upright position.
(2) Using a trim tool, remove seat back panel (Fig.
128).
INSTALLATION
(1) Place seat back panel into position (Fig. 128).
(2) Push on seat back panel to seat push pin fas-
teners.
SEAT BACKSTOW STRAP -
THIRD ROW - FOLD-IN-FLOOR
REMOVAL
(1) Third row seat in the upright position.
(2) Remove seat back cover and foam as necessary
to access stow strap
(3) Slide stow strap from frame loop (Fig. 129).
INSTALLATION
(1) Slide stow strap onto frame loop (Fig. 129).
(2) Install seat back cover and foam. (Refer to 23 -
BODY/SEATS/SEAT CUSHION COVER/FOAM -
INSTALLATION).
Fig. 127 CENTER TIP AND BUCKLE - THIRD ROW -
FOLD-IN-FLOOR
1 - CENTER TIP HALF AND BUCKLE
2 - SEAT BELT BUCKLE
Fig. 128 SEAT BACK PANEL
1 - TRIM STICK
Fig. 129 THIRD ROW SEAT BACK UP STOW STRAP
1- STOW STRAP
23 - 158 SEATSRS
SEAT BELT CENTER LAP BELT - FOLD-IN-FLOOR (Continued)

SEAT CUSHION COVER/FOAM -
THIRD ROW - FOLD-IN-FLOOR
REMOVAL
(1) Third row seat in the upright position.
(2) Remove the third row cushion side shield (Fig.
130).
(3) Fold the third row seat into floor well.
(4) Remove seat cushion pan carpet to floor panel
using a trim tool (Fig. 131).(5) Using a trim tool, remove seat cushion pan bot-
tom side panel (Fig. 132).
(6) Remove handle from cushion.
(7) Place seat with the seat back down position.
(8) Disengage seat cushion cover J-straps from
cushion pan (Fig. 133).
(9) Remove cover and foam from cushion pan.
(10) Separate the cover and foam.
INSTALLATION
(1) Place the seat cushion cover and foam together.
(2) Install seat cushion cover and foam onto cush-
ion pan.
(3) Engage seat cushion cover J-straps to cushion
pan (Fig. 133).
(4) Install handle on cushion.
Fig. 130 THIRD ROW SEAT BACK COVER
1 - ATTACHING SCREW
Fig. 131 SEAT CUSHION CARPETING
1 - CARPET FROM SEAT TO FLOOR
2 - SEAT CUSHION PAN COVER
Fig. 132 THIRD ROW CUSHION PAN COVER
Fig. 133 THIRD ROW CUSHION PAN
RSSEATS23 - 159

(5) Fold seat into floor well.
(6) Install seat cushion pan bottom side panel (Fig.
132).
(7) Install seat cushion pan carpet to floor panel
(Fig. 131).
(8) Install the third row cushion side shield (Fig.
130).
(9) Place third row seat in the upright position.
SIDE SHIELD CUP HOLDER -
FOLD-IN-FLOOR
REMOVAL
(1) Open cup holder door.
(2) Remove two screws attaching cup holder to
side shield (Fig. 134).
INSTALLATION
(1) Place cup holder into position (Fig. 134).
(2) Install the two cup holder attaching screws.
SEAT RECLINER/FOLD
FORWARD MECHANISM
-THIRD ROW -FOLD-IN-FLOOR
REMOVAL
(1) Remove seat back frame. (Refer to 23 - BODY/
SEATS/SEAT BACK FRAME - REMOVAL).
(2) Remove the side shields from seat cushion.
(3) Remove two recliner/fold forward mechanism
bolts on each side from cushion pan.
(4) Remove the recliner/fold forward mechanism
from seat cushion pan.
INSTALLATION
(1) Place recliner/fold forward mechanism on seat
cushion pan.
(2) Install two recliner/fold forward mechanism
bolts on each side to cushion pan.
(3) Install the side shields to seat cushion.
(4) Install seat back frame. (Refer to 23 - BODY/
SEATS/SEAT BACK FRAME - INSTALLATION).
Fig. 134 SECOND ROW SEAT CUP HOLDER
1 - ATTACHING SCREWS
23 - 160 SEATSRS
SEAT CUSHION COVER/FOAM - THIRD ROW - FOLD-IN-FLOOR (Continued)

STATIONARY GLASS
TABLE OF CONTENTS
page page
WINDSHIELD
DESCRIPTION........................161
WARNING
WINDSHIELD SAFETY PRECAUTIONS....161
REMOVAL............................161
INSTALLATION........................162
SLIDING DOOR GLASS
REMOVAL............................163INSTALLATION........................163
QUARTER WINDOW
REMOVAL............................164
INSTALLATION........................164
LIFTGATE GLASS
REMOVAL............................164
INSTALLATION........................164
WINDSHIELD
DESCRIPTION
The windshield is attached to the window frame
with urethane adhesive. The urethane adhesive is
applied cold and seals the surface area between the
window opening and the glass. The primer adheres
the urethane adhesive to the windshield.
It is difficult to salvage a windshield during the
removal operation. The windshield is part of the
structural support for the roof. The urethane bonding
used to secure the windshield to the fence is difficult
to cut or clean from any surface. If the moldings are
set in urethane, it would also be unlikely they could
be salvaged. Before removing the windshield, check
the availability of the windshield and moldings from
the parts supplier.
WARNING
WINDSHIELD SAFETY PRECAUTIONS
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANE
ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
AN ACCIDENT.
URETHANE ADHESIVES ARE APPLIED AS A SYS-
TEM. USE GLASS CLEANER, GLASS PREP SOL-
VENT, GLASS PRIMER, PVC (VINYL) PRIMER AND
PINCH WELD (FENCE) PRIMER PROVIDED BY THE
ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL
INTEGRITY COULD BE COMPROMISED.
DAIMLERCHRYSLER DOES NOT RECOMMEND
GLASS ADHESIVE BY BRAND. TECHNICIANS
SHOULD REVIEW PRODUCT LABELS AND TECHNI-
CAL DATA SHEETS, AND USE ONLY ADHESIVESTHAT THEIR MANUFACTURES WARRANT WILL
RESTORE A VEHICLE TO THE REQUIREMENTS OF
FMVSS 212. TECHNICIANS SHOULD ALSO INSURE
THAT PRIMERS AND CLEANERS ARE COMPATIBLE
WITH THE PARTICULAR ADHESIVE USED.
BE SURE TO REFER TO THE URETHANE MANU-
FACTURER'S DIRECTIONS FOR CURING TIME
SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.
VAPORS THAT ARE EMITTED FROM THE URE-
THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
LATED AREA.
SKIN CONTACT WITH URETHANE ADHESIVE
SHOULD BE AVOIDED. PERSONAL INJURY MAY
RESULT.
ALWAYS WEAR EYE AND HAND PROTECTION
WHEN WORKING WITH GLASS.
CAUTION: Protect all painted and trimmed surfaces
from coming in contact with urethane or primers.
Be careful not to damage painted surfaces when
removing moldings or cutting urethane around
windshield.
REMOVAL
WINDSHIELD REMOVAL ± EXTERIOR METHOD
The urethane adhesive holding the windshield to
the opening pinch weld (fence) can be cut using a
sharp cold knife from the exterior of the vehicle.
Using the cold knife method is effective if the wind-
shield is already broken. If the glass must be sal-
vaged, cutting the urethane adhesive from the
interior of the vehicle using a reciprocating or oscil-
lating power knife is recommended.
(1) Remove inside rear view mirror.
(2) Remove windshield wiper arms.
(3) Remove cowl cover.
RSSTATIONARY GLASS23 - 161